Honda TRX400EX FOURTRAX 1999, Service Manual

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GENERAL INFORMATION
TORQUE VALUES
-
STANDARD
FASTENER TYPE
5 bolt and nut
6
mm
bolt and nut
8 mm bolt and nut
10 bolt and nut
12 mm bolt and nut
TORQUE
5
(0.5, 3.6)
10
22 16)
34 (3.5,
54 (5.5, 40)
FASTENER TYPE
5 mm
screw
6 mm screw
6 flange bolt head, small flange)
6 flange bolt
mm
head, large flange)
6 flange bolt mm head) and nut
8 flange bolt and nut
10 mm flange bolt and nut
TORQUE
4 (0.4, 2.9)
9 6.5)
9 6.5)
12
12
26 (2.7.20)
39 (4.0. 29)
Torque specifications listed below are for important fasteners.
Others should be tightened to standard torque values listed above.
NOTES: 1. Apply locking agent to the threads.
2. Apply oil to the threads and seating surface.
3. Apply grease to the threads and seating surface.
4. ALOC bolt. replace with a new one.
5. Castle nut: tighten to the specified torque and further tighten until its grooves align with t h e cotter pin hole,
6. Stake.
ENGINE
ITEM
MAINTENANCE:
Spark plug
Valve adjusting hole cap
Valve adjusting lock nut
Crankshaft hole cap
Timing hole cap
Engine
oil
drain bolt (crankcase)
Engine oil drain bolt (oil tank)
Engine oil strainer screen ( a t oil tank)
Oil pipe joint flare nut
HEADIVALVE:
Cylinder head cover bolt
Rocker arm shaft
Intake sub-rocker arm shaft
Exhaust sub-rocker arm shaft
Cam sprocket bolt
Cam tensioner plug
Cylinder head nut
Cylinder bolt
Cylinder stud bolt
Clutch center lock nut
Primary drive gear nut
Gearshift drum stopper arm pivot bolt
Gearshift spindle return spring pin
Flywheel bolt
Starter clutch bolt
Left crankcase cover stud bolt
Gearshift Dinch bolt
LINKAGE:
CLUTCH:
1
4
1
1
1
1
1
2
1
2
2
2
2
1
4
4
4
1
1
1
1
1
6
1
1
4
THREAD
DIA.
12
36
7
30
14
12
10
27
16
8
14
14
12
7
6
10
10
18
18
6
8
12
8
6
6
TORQUE
18 (1.8, 13)
15
24 (2.4,
8 (0.8, 5.8)
10
25 (2.5, 18)
20
54 (5.5,
20
23 (2.3, 17)
27
27
27
20 (2.0, 14)
4 (0.4, 2.9)
44
44
20
108
88 65)
12
24 (2.4, 17)
127 (13.0. 94)
30
10
20 (2.0, 14)
REMARKS
NOTE 1
VOTE 1
NOTE 1
NOTE
1
2
NOTE 2
oage
VOTE 2,6
VOTE 2
VOTE 2
VOTE
1
1-1 1