Honda TRX400, TRX400EX Fourtrax, Sportrax ATV Repair Manual 1999-2007

This chapter describes service procedures for the following components and electrical systems:

1. Left crankcase cover.



2. Stator.



3. Flywheel.



4. Starter clutch.



5. Starter motor.



6. Starting system switches.



7. Handlebar switch unit.



8. Ignition system.



9. Charging system.



10. Lights.

Refer to Chapter Three for spark plug service and gapping, and battery replacement and charging. Refer to Chapter Two for performance problems and possible causes related to the electrical system.


BASIC ELECTRICAL SYSTEM OPERATION

A permanent magnet alternator is located on the left end of the crankshaft, and is the source of power for the ignition system and for recharging the battery.

When testing the electrical system, first identify whether the problem is related to the ignition system or the charging system.

Then refer to the appropriate section in this chapter to methodically test the components of that system.

Engine power is transferred to the driven sprocket by an endless, O-ring chain. This type of chain is internally lubricated and sealed by O-rings (Figure 53).

The chain requires regular cleaning, lubrication and adjustment for long life, as described in Chapter Three. Measurement of the chain, to determine its wear, is also performed in Chapter Three.

If the chain needs to be replaced, remove the chain by one of the methods described in this section. Refer to Table 1 for chain specifications.

• General Information
• Troubleshooting
• Lubrication, Maintenance and Tune-Up
• Engine Top End
• Engine Lower End
• Clutch, Gearshift Linkage and Lubrication System
• Transmission and Internal Shift Mechanism
• Fuel and Exhaust Systems
• Electrical System
• Front Suspension and Steering
• Rear Suspension
• Brakes
• Body
• Supplement: 2005-On Model Service Information
• Color Wiring Diagrams