Basic Information Identification Make: Honda Model: TRX 400EX Model Code: TRX400EX Sub Model: Sportrax Codes Year Code: Various codes based on specific model year (e.g., X for 2005, 6 for 2006, etc.) Vin Code: Last digit of VIN indicates model year Introduction Market Position Market Position: The Honda TRX 400EX is positioned as a capable and versatile sport ATV, known for its reliable engine and sporty handling, popular for recreational trail riding and intermediate-level motocross. Competitive Analysis Competitive Analysis: Competes with models like the Yamaha YFZ 450, Suzuki LT-R450, and Kawasaki KFX450R, offering a balance of performance and ease of maintenance. Key Features Key Features: Proven 400cc air-cooled engine, 5-speed manual transmission with reverse, electric start, independent front suspension, single rear shock, hydraulic disc brakes. Manual Details Coverage Areas Coverage Years: 2005, 2006, 2007, 2008, 2009 Page Count Page Count: Estimated 300-500 pages (typical for a comprehensive service manual) Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine: Complete engine overhaul, troubleshooting, tuning, lubrication system, cooling system, internal components. Transmission: Clutch system, gearbox, shifting mechanisms, fluid maintenance, troubleshooting. Fuel System: Carburetor (specific model likely Keihin), fuel pump, fuel lines, fuel tank, air filter. Ignition System: CDI unit, spark plugs, ignition coils, wiring, timing. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting, ignition switch, wiring diagrams. Suspension: Front and rear suspension components, shocks, springs, linkages, adjustment procedures, troubleshooting. Brakes: Hydraulic brake systems (front and rear), brake pads, rotors, calipers, master cylinders, brake lines, bleeding procedures. Steering: Handlebars, steering shaft, tie rods, knuckle components, lubrication, troubleshooting. Chassis Frame: Frame inspection, component mounting, sub-frame maintenance. Bodywork Plastics: Fender removal and installation, seat, fuel tank cover, paneling. Wheels Tires: Tire pressure, removal and installation, wheel bearings, balancing. Cooling System: Radiator, coolant, fan, hoses, thermostat. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, valve adjustments, chain adjustments, brake system service. Troubleshooting: Diagnostic charts for common problems, electrical issues, engine performance, starting problems. Repair: Step-by-step instructions for engine rebuilds, transmission repair, suspension overhaul, electrical component replacement. Disassembly Assembly: Detailed procedures for removing and reassembling all major components. Wiring Diagrams: Comprehensive and clear wiring schematics for all electrical systems. Torque Specifications: Precise torque values for all critical fasteners. Special Tools: Identification and usage instructions for specialized tools required for certain repairs. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and component-level repair. Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution, suitable for professional printing, with clear diagrams and text. Binding Type Binding Type: Digital Download (printable pages) Paper Type Paper Type: N/A (Digital) Searchability Searchability: Likely text-searchable PDF for quick information retrieval. Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, air-cooled, 4-valve, single-cylinder Displacement: 397cc Bore X Stroke: 85.0 mm x 70.0 mm Compression Ratio: 9.4:1 Carburetor: Keihin 38mm flat-slide carburetor (likely with a throttle position sensor on later models) Performance Horsepower: Approximately 35-40 HP (estimated, not officially published by Honda for this model) Torque: Approximately 25-28 lb-ft (estimated) Fuel System Fuel Capacity: 2.5 gallons (9.5 L) Fuel Type: Unleaded gasoline, 86 octane or higher Lubrication Oil Type: API SG, SAE 10W-40 or SAE 20W-50 (depending on ambient temperature) Oil Capacity With Filter: 2.0 US qt (1.9 L) Ignition Spark Plug Type: NGK CR7EH-9 or Denso IX24EH-9 Spark Plug Gap: 0.032 in (0.8 mm) Cooling Cooling System Type: Air-cooled with a fan-assisted oil cooler Transmission Standard Transmission Type: 5-speed manual with Reverse Optional Optional Transmission: N/A Features Clutch Type: Wet, multi-plate Final Drive: O-ring-sealed chain, 520 size Fluid Specifications Transmission Oil Type: SAE 10W-40 API SG motorcycle oil Fluid Capacities Transmission Oil Capacity: 0.58 US qt (0.55 L) Dimensions Exterior Length: 72.0 inches (1828 mm) Width: 47.8 inches (1214 mm) Height: 42.7 inches (1085 mm) Wheelbase: 50.0 inches (1270 mm) Ground Clearance: 4.1 inches (104 mm) Weights Dry Weight: 377 lbs (171 kg) Curb Weight: Approximately 400 lbs (181 kg) (estimated with fluids) Towing Capacity: N/A (ATVs are generally not designed for towing) Safety Features Ratings Safety Ratings: ATVs are not typically subjected to standardized crash test ratings like automobiles. Safety is dependent on operator skill and adherence to safe riding practices. Active Features Active Safety: Hydraulic disc brakes (front and rear), handlebar grips, thumb throttle with return spring. Passive Features Passive Safety: Durable frame, plastic body panels, footpegs. Technology Features Infotainment Infotainment Features: N/A (Basic sport ATV with no digital infotainment systems) Driver Assistance Driver Assistance Features: N/A (No advanced driver-assistance systems) Connectivity Connectivity Features: N/A Maintenance Service Intervals Engine Oil Change: Every 3000 km (1864 miles) or 6 months, whichever comes first. Consult manual for specific conditions. Air Filter Cleaning: Inspect every 500 km (310 miles) or monthly. Clean as needed, replace if damaged. Spark Plug Replacement:...