2003 Honda 400ex Manual
Clymer Honda Atv service and repair manuals are written with model specific coverage for your Honda Atv. Honda TRX400EX FourTrax and TRX400EX Sportrax manual. Clymer Manuals Honda TRX400 Foreman 1995-2003 M459-3. Honda TRX400EX Sportrax. Honda TRX400EX. The Honda TRX 400X is a sport style ATV with an. The engine is paired with a 5-Speed manual transmission and total.
I have a 2003 LTZ 400 that i bought a few days ago. The quad was running fine until last night. I let my brother ride it down the street and back and i didnt notice anything etong with bike. Then my neighbors friend came over and said 'can i ride it?'
I said 'sure' so he ripped it down the road all fine and when he got back it died right in front of us. My brother said it was dieing on him also. He also said that he wasnt using the clutch to shift. I told him he was an idiot. Im throwing that in there incase that caused a problem as well. But today i go to check it to make sure its getting fuel which it is and replaced the spark plug incase it wasnt getting spark but it is. So i started it and it was having a problem starting then i got started and was reving at idle high.
So i took it around the block and it died on me a little bit down, so i try to restart it and it started so i kicked it into 1st and it kinda launched on me and started going with the clutch all the way in. Then it died right after and wasnt running right during that process and was idleing all over the place and just died and now i cant get it started it again. Before it would start without the choke or priming it.
It would start real quick now i cant figure if it needs to be rejetted or something else. Air filter looks clean also.
But any help would be gratelly appreciated!
If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding.
IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items:. 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510). Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items:.
2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511). Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet, Welding Manual, Welding Template Box, or Frame Weld Inspection Chart, you may order them at no cost from DDS at (440) 572-0725.
For your reference, a brief repair procedure overview is provided below. Evidence of a small oil leak located where the Bank 1 cylinder head, engine block, and timing cover meet. Use the following repair procedure to address this condition. 2003 – 2007 model year 4Runner vehicles equipped with the 1GR-FE engine and produced BEFORE the Production Change Effective VINs shown below. MODEL PLANT DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN 2WD JTEZU17R#68064608 Hino 2WD JTEZU14R#78076191 4Runner Hino 4WD JTEBU14R#78078323 4Runner 4WD JTEBU14R#78090468 Tahara 2WD JTEZU14R#70091230 Tahara 4WD JTEBU14R#70117349 OP CODE DESCRIPTION TIME OFP T1 T2 EG7036 Reseal FrontTiming Cover with FIPG 2WD7.6 1548 EG7036 Reseal Front Timing Cover with FIPG 4WD8.5 11310-0P030 65 48 Applicable Warranty.: This repair is covered under the Toyota Powertrain Warranty.
This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle’s in-service date.Warranty application is limited to correction of a problem based upon a customer’s specific complaint. There is no punch mark on the VIN plate as specified in this Service Bulletin, proceed to the REPAIR PROCEDURE section of this Service Bulletin. IMPORTANT: Due to the complexity of this campaign it is imperative that you check iN and your Dealer Responsibility Report before you begin repairs. If iN or your Dealer Responsibility Report indicate the Safety Recall has been performed, but you confirm the unit is not punched and the repair has actually been done (by inspecting the weld), please contact the Warranty HelpLine at (800) 421-1900, option 7. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items:. 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) Frame Weld Inspection Chart (S0516) You MUST provide your TIG welder with the following items: 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) 2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) Welding Template Box (S0512) All of the above items were shipped to you with Service Bulletin GL1800 #14. If you need additional copies of these materials, you may order them from Resolve at (440) 572-0725.
For your reference, a brief repair procedure overview is provided below. DISASSEMBLY OVERVIEW You will be removing the following components from the vehicle as instructed in the Dealer Booklet: Handlebar weights Rear view mirrors Swingarm pivot covers Rider foot pegs Seat Side covers/Engine side covers Fairing pockets Fairing molding Meter panel Top shelter Battery Fuel tank Main wiring harness ground Front lower fairing Front exhaust pipe protector Muffler/exhaust pipe Antenna Whip(s) Coolant reserve tank Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: Before you send the motorcycle to the welder, you MUST check for lower crossmember frame weld cracks. If your inspection reveals no cracks in or on either the Left or Right lower cross- member frame welds, proceed to the REPAIR PROCEDURE OVERVIEW section of this Service Bulletin. If your inspection identifies a crack or cracks in or on either the Left or Right lower crossmember frame welds, perform the following procedure: Place the grinding template (S0512) on the crossmember. Using a suitable felt marker, draw a line on the weld with the crack, drawing the line along the entire edge of the the template (this line will be 89 mm long). If the crack falls within the length of this line (89 mm), prepare the motorcycle for welding per the Dealer Procedures and advise the welder to use the Cracked Weld Repair Manual (S0515).
After the bike has returned from the welder, prepare the frame and re-assemble the motorcycle per the Dealer Procedures. Then, proceed. This instruction on cam belt adjustment starts after you remove the fairing pieces. Plan on an hour to remove these.
Since you are performing your own service, buying Ducati belts may not be that expensive. There may be another belt source, but I have not confirmed this for the 996 engine of the 02-03 ST4s. Fig 1 – ST4s ready for belt adj./ repl. Fig 2 – Crank tool installed. 1) Ensure maximum of ½ tank of gas. Fuel will leak into the charcoal canister, then onto the floor if the tank is over half full and the tank is tilted up on its hinge.
So put the tank up on its hinge. 2) Remove spark plugs. Math lab manual 10th class. Cover sparkplug wells with boots or rags. This is a great time to toss out those Champions for a set of NGK DCPR8E’s. 3) Remove the front shield from the horizontal cylinder head. 4) Remove crankshaft cover on Riders LH side and insert crank tool. A crank tool can be made by following the drawing at the end of this document.
See Fig 2 above. The flat head screws used are kind of soft so beware on their removal. 5) Remove oil pressure sending unit cable and remove oil sending unit. No oil should pour out. 6) Remove battery and remove bolts fastening battery box to engine/frame. You can let the battery box dangle or partially support it via a bungee cord. Be careful of the cable on the ground of the ECU.
By dangling the battery box excess stress could be placed on this cables connector and you don’t want to troubleshoot an intermittent electrical issue. 7) Remove cam belt covers.
The two covers over the cams are real easy. The center piece is removed by pulling it down.
You may have to move some hoses and cables out Timing belt adj. Doc 1 of the way because it is a tight fit.
Removing the oil pressure sending unit gave clearance for the removal. Fig 1 shows bike ready to be worked on. On the Rider’s LH is a window on the case cover.
Using a flashlight to illuminate the area, marks can be rotated into view using the engine turning tool. There are two marks denoting the TDC of each of the cylinders. When a mark in the window aligns with the pointer, look at the crank driving pulley on the Rider’s RH of the engine. If the driving pulley’s mark is aligned with the pointer on the engine case, you are at TDC horizontal cylinder.
If the pulley mark and the pointer on the engine do not align, rotate the engine until the mark in the window on the Rider’s LH side case cover aligns as well as the pulley’s mark and the engine’s pointer. Fig 3 shows the engine pulley and pointer. You can check that the horizontal piston is at TDC by inserting a welding rod into the spark plug well and touch the top of the piston with it to sense its position. Timing marks on cam pulleys are clearly stamped on all four pulleys. When the crank driving pulley aligns with its corresponding pointer on the engine case and the marks on the pulleys align with their corresponding marks on both cylinders, you are in position for belt adjustment and replacement Incoming search terms:.
Disconnect battery. Mark location of timing plate in relation to inside of cam cover. This will give a starting point for timing on new module. Remove old ignition if applicable (see manual) Clymer, Haynes. If your bike is not equipped with timing rotor M/W# 53-528 OEM#32402-83 you must buy one (included in kit). Also a single fire coil is needed (included in kit) M/W# 53-632. Any single fire coil rated 2-4 ohms can be used.
2003 Honda 400ex Manual
NO SOLID CORE PLUG WIRES (copper, silver) they will damage the unit. Install module: helpful hints, early model nose cones, i.e. Shovel Heads, the hole for the wire may need to be drilled out. Align with previously scripted mark for timing. Use lockwashers for stand offs for correct clearance of cover plate.
Run wire loom. Connect wires, see wiring diagram. Tape unused wires, green or brown. 12v to tach (brown) will damage module. 1996 and later should not be timed 20˚ BTDC as the OEM module, but at 35˚ BTDC. Use this mark when using timing light.
If VOESswitch is not used you must ground VOES wire (green) while timing. Refer to manual for correct identification of timing marks. At start up and timing, set spark advance in middle position. FUNCTION SWITCHES LED timing indicator light: When out, shows TDC. When ignition is on, LED will light up. When engine is cranking LED will blink.
Electric Start/Kickstart: Set accordingly. VOES/Race mode: VOES switch lets the motor run smoother and improves gas mileage. If you don’t use it or add one tape up green wire and switch to race. VOES switch to use, M/W# 53-652. Spark advance: High compression motors should use race mode and 93 octane or better gas. Changing from VOES to race changes advance curves.
Agood rule of thumb is if the engine knocks when throttle is applied in high gear, turn back spark advance curve until it stops engine knock. RPMlimiter: Set at desired RPM to cut engine power. Rear Cylinder: This is for racing and should be set at a dyno. Rear cylinder timing is achieved through this adjuster. Most should dial to middle setting and leave alone. After all switches are set, install cover with supplied gasket and feel the increased performance of a solid state single fire ignition. Again, we remind you, if you don’t feel confident about installing this unit, let a qualified mechanic do it and be assured you are getting the best performance and gas mileage possible.
Incoming search terms:. Gauges & Indicators Lights when engine oil pressure is low enough to cause engine damage.
If the indicator lights, pull safely to the side of the road. See page 162 for instructions and cautions. PGM-FI malfunction indicator lamp (red) low oil pressure indicator (red) Lights when there is any abnormality in the PGM-FI (Programmed Fuel Injection) system.
Should also light for a few seconds and then go off when the ignition switch is turned ON and the engine stop switch is at RUN. If the indicator comes on at any other time, reduce speed and take your motorcycle to a Honda dealer as soon as possible. Anti-lock brake system (ABS) indicator (red) ABS (ST 1300A) Lights when there is any abnormality in the anti-lock brake system (ABS). Normally, this indicator comes on when the ignition switch is turned ON, and goes off after you ride the motorcycle at a speed above 6 mph (10 km/h)If the indicator comes on while riding, stop the motorcycle in a safe place and turn off the engine. Refer to ABS indicator, page 61. For information about ABS, see page 60. LampCheck Use this button for the following purposes.
To adjust time To adjust display illumination Use this button for the following purposes. To adjust time To select and reset the fuel mileage meter To change the mileage units for the odometer/tripmeter and available driving distance Use this button for the following purposes. To adjust time To select and reset the tripmeter. Normal Engine Stop 1. Shift the transmission into neutral. Turn the fuel valve OFF. Lightly open the throttle (1) 2 – 3 times, and then close it.
Depress and hold the engine stop button (2) until the engine stops completely. Failure to close the fuel valve may cause the carburetor to overflow, result in hard starting.
Emergency Engine Stop To stop the engine in an emergency, press the engine stop button. Basic Operating Instructions 15 Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when:.piston is replaced.piston rings are replaced.cylinder is replaced.crankshaft or crank bearings are replaced Break-in Guidelines 16 Basic Operating Instructions Servicing Your Honda 17 Servicing Your Honda Keeping your CRF well maintained is absolutely essential to your safety. It’s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your CRF in good shape, this section includes a Maintenance Schedule for required servicing and step-by-step instructions for specific maintenance tasks.
You’ll also find important safety precautions, information on oils, and tips for keeping your Honda looking good. An ICM (Ignition Control Module) system is used on this motorcycle; consequently, routine ignition timing adjustment is unnecessary. If you want to check the ignition timing, refer to the Honda Service Manual (page 156).
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2000 Honda 400ex Manual
And since they’re all Honda approved you’llknowthat they’rejustastoughand well made as your Honda motorcycle. Please Note -All prices quoted are correct at time of printing and are subject to change without prior notice.