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2005-2009 TRX 400EX Service Repair Manual
2005-2009 TRX 400EX Service Repair Manual
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$16.99
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Vehicle data plateRef 38923
- Brand
- Honda
- Vehicle
- ATV
- Models covered
- Ameritron, TRX, TRX 400EX
- Years
- 2005, 2006, 2007, 2008, 2009
- Format
- PDF, searchable, print-ready
- Delivery
- Instant download after checkout
- Language
- English
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- Download link opens on the order page immediately
- The same link is emailed to you — re-download any time
- Open on phone, tablet or PC; print only the pages you need
- Not sure it covers your model year? Ask us before you buy
| 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: | Inspect every 3000 km (1864 miles) or 6 months. Replace if necessary. |
| Valve Clearance Adjustment: | Every 6000 km (3728 miles) or annually. |
| Chain Lubrication Adjustment: | Lubricate every 500 km (310 miles) or after washing/riding in wet conditions. Adjust tension every 1000 km (621 miles). |
| Fluid Specifications | |
| Brake Fluid: | DOT 4 hydraulic brake fluid |
| Coolant: | Honda M-7 Coolant or equivalent (50/50 mix of ethylene glycol and deionized water) |
| Known Issues | |
| Known Issues: | Some owners report issues with the starter bendix gear, carburetor jetting for altitude/modifications, and rear axle bearing wear. The electric start can sometimes be problematic if not properly maintained. Overheating can be an issue in extreme conditions due to the air-cooled nature. |
| Common Repairs | |
| Common Repairs: | Carburetor cleaning/rebuilding, chain and sprocket replacement, brake pad replacement, wheel bearing replacement, suspension linkage maintenance. |
| Vehicle History | |
| Brand Heritage | |
| Brand Heritage: | Honda is renowned for its reliable and high-performance engines, and a long history of innovation in powersports vehicles, including ATVs. |
| Model Evolution | |
| Model Evolution: | The TRX 400EX succeeded the popular TRX 300EX and TRX 400X, building on their legacy with a more powerful engine and updated chassis. It was a significant player in the sport ATV market during its production run. |
| Production | |
| Production Years: | 1999-2008 (as TRX400EX), though this manual covers the later models from 2005-2009 which saw minor updates. |
| Manufacturing Location: | Japan (primarily) |
| Awards & Recognition | |
| Recognitions | |
| Recognitions: | While specific awards for the 2005-2009 TRX 400EX are not widely publicized, it was consistently praised in enthusiast reviews for its reliability, performance, and value within the sport ATV segment during its production years. |
| Ratings | |
| Enthusiast Ratings: | Highly regarded by riders for its potent engine and balanced handling, making it a popular choice for both recreation and entry-level racing. |
| Certifications | |
| Certifications: | N/A (Not applicable to this type of vehicle) |
Delivery & file format
Delivery & file format
This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.
Check the model year and engine before you buy
Check the model year and engine before you buy
Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.
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2005-2009 TRX 400EX Service Repair Manual
Honda / Atv · PDF · Instant download
$16.99
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