Honda TRX400, TRX400FW Foreman ATV Repair Manual 1995-2003

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Item # M459-3  ISBN: 0892879262




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This repair manual covers Honda TRX400FW Foreman 1995-2003.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Safety first | Service hints | Torque specifications | Fasteners | Lubricants | Sealant, cements and cleaners | Threadlocking compound | Serial numbers | Precision measuring tools | Special tools | Mechanic's tips | Ball bearing replacement

CHAPTER TWO: TROUBLESHOOTING
Troubleshooting instruments | Starting the engine | Starting difficulty | Poor idle speed performance | Poor medium and high speed performance | Electric starting system | Charging system | Ignition system | Lighting system | Oil temperature indicator | Combination meter | Fuel system | Engine overheating | Engine | Engine noises | Cylinder leakage test | Clutch | Transmission | Drive train troubleshooting | Handling | Frame noise

CHAPTER THREE: LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride check list | Maintenance schedule | Tires and wheels | Battery | Lubricants | Cleaning solvent | Periodic lubrication | Unscheduled lubrication | Periodic maintenance | Engine tune-up | Storage

CHAPTER FOUR: ENGINE TOP END
Engine principles | Cleanliness | Exhaust system | Cylinder head cover | Rocker arms, pushrods and cylinder head | Cylinder head | Valves and valve components | Cylinder | Piston and piston rings | Camshaft

CHAPTER FIVE: ENGINE LOWER END
Servicing engine in frame | Engine | Recoil starter | Driven pulley | Alternator cover | Rear crankcase cover | Flywheel and starter clutch | Gearshift linkage | Reverse shaft assembly | Lubrication system | Oil pump | Relief valve | Oil strainer screen | Crankcase and crankshaft | Transmission shifting check | Engine break-in

CHAPTER SIX: CLUTCH AND PRIMARY DRIVE GEAR
Clutch cover | Clutch lever assembly | Clutch assemblies | Centrifugal clutch and primary drive gear | Change clutch

CHAPTER SEVEN: TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission/reverse system identification | Transmission troubleshooting | Transmission overhaul | Reverse idle gear assembly | Transmission inspection | Internal shift mechanism | Reverse selector cable replacement

CHAPTER EIGHT: FUEL SYSTEM
Carburetor | Carburetor float level adjustment | Carburetor adjustments | Throttle housing and cable | Fuel tank | Fuel valve | Air box | Choke cable replacement

CHAPTER NINE: ELECTRICAL SYSTEM
Charging system | Alternator | Ignition system | Electric starting system | Starter relay switch | Diode | Lighting system | Combination meter | Switches | Oil thermosensor | Cooling fan control unit | Speedometer sensor unit, 1997-on | Fuses | Wiring diagrams

CHAPTER TEN: FRONT SUSPENSION AND STEERING
Front wheel | Front hub | Shock absorbers | Tie rods | Steering knuckle | Control arms | Handlebar | Steering shaft | Tires and wheels

CHAPTER ELEVEN: FRONT DRIVE MECHANISM
Front drive axles | Propeller shaft | Front differential, 1995-2001 models | Front differential, 2002-2003 models

CHAPTER TWELVE: REAR AXLE, SUSPENSION AND FINAL DRIVE
Rear wheels | Tire changing and tire repairs | Rear axle | Final drive unit | Shock absorbers | Swing arm

CHAPTER THIRTEEN: BRAKES
Front brake assembly | Front brake drum | Front brake shoe replacement | Brake panel | Wheel cylinders | Front master cylinder | Brake fluid draining | Brake bleeding | Rear drum brake | Rear brake shoe replacement | Brake panel | Front brake hose replacement | Rear brake pedal and cable | Rear brake lever/parking brake cable

CHAPTER FOURTEEN: OIL COOLER AND COOLING FAN
Oil cooler | Cooling fan

CHAPTER FIFTEEN: BODY
Retaining clips | Seat | Right lower side cover | Side covers and fuel tank cover | Front carrier and front bumper | Front fender | Rear carrier | Rear fender | Handlebar cover

WIRING DIAGRAMS

Clymer ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Honda TRX400, TRX400FW Foreman ATV Repair Manual 1995-2003