Honda TRX400EX FOURTRAX 1999, Service Manual

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FRONT
Slide the boot off the throttle cable adjuster
Loosen the cable adjuster.
Bend down the lock washer tab and remove the pivot
nut, lock washer, throttle arm and return spring, then
the throttle lever with the plastic washer.
Disconnect the throttle cable from the throttle arm.
Remove the dust seal from the housing bottom.
ASSEMBLY
Apply grease to the lever pivot in the hous-
ing.
Coat a new dust seal lip with grease and install it into
the housing until it is fully seated.
Connect the cable to the throttle arm.
Insert the throttle lever with the washer into the
housing and install the throttle arm with the spring
over the throttle lever pivot by aligning the flat sur-
faces.
Install a new lock washer and the pivot nut.
Tighten the pivot nut and bend up the washer tab
against the nut.
Install the housing cover with a new gasket and tighten
the three screws.
TORQUE: 4 10.4 2.9
Adjust the throttle lever free play (page
FRONT WHEEL AND HUB
WHEEL REMOVAL
Loosen the wheel nuts
Place the support block under the frame to raise the
front wheel off the ground.
Remove the nuts and wheel.
HUB DISASSEMBLY
CAUTION:
Support the caliper so that it does not hang from the
brake hose.
Do
not or bend the brake hose.
Remove the following:
mounting bolts and brake caliper
-
brake hose from the clamp
-
bolt and disc guard
CALIPER
12-6