1999 honda 400ex service manual

With proper care and routine maintenance, your ATV will provide many years of reliable use. When repairing an ATV, most home mechanics will find them easy to work with and repairs quick and trouble-free. Scheduled ATV maintenance should occur frequently at regular intervals. This routine maintenance should include changing the oil, inspecting the shift linkage — steering — suspension — coolant system — fuel system — drive belts — engine mounts, changing the spark plugs, and replacing the fuel and air filters.

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Sign in with Facebook. Sign in with Twitter. Sign in with Google. Sign in with Microsoft. Remove the bolts and springs. Remove the pressure plate and lifter piece. Remove the clutch discs and plates. Unstake the clutch center lock nut. Be carefulnor to damage the threads. Page Remove the lock washer, plain washer and clutch center. Remove the thrust washer, clutch outer and clutch outer guide.

The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the pressure plate. Replace the Check the plate warpage o n a surface plate using a clutchdiscsand Page Measure the mainshaft O.

Install the clutch outer and thrust washer. Install the clutch center and plain washer. Apply oil to the threads and seating surface of a new clutch center lock nut and install it onto the mainshaft. Hold the clutch center with the special tool and tighten the lock nut. Page Apply oil to the clutch lifter piece whole surface and lifter bearing. Install the clutch lifter piece and pressure plate.

Install the clutch springs and bolts. Tighten the bolts in a crisscross pattern in several steps. Install the right crankcase cover page Page Apply oil to the primary drive gear nut threads and seating surface. Install the washer and primary drive gear nut. Remove the oil pump page Install the clutch outer onto the mainshaft. Install the special tool between the primary drive and driven gears as shown and tighten the primary drive gear nut.

Page Flywheel bolt Apply locking agent to the threads. Remove the gasket and dowel pins. Remove the spacer, starter idle gear and shaft from the left crankcase cover. Remove the seatlrear fender page Disconnect the alternator connectors. Page Remove the nut, seven bolts and the left crankcase cover.

Remove the starter reduction gear shaft and gear. Remove the two ignition pulse generator bolts and wire clamp. Coat new O-ring with oil and install it into the starter motor groove.. Install the dowel pins and a new gasket Install the left crankcase cover, being careful not to pinch the neutral switch wire.

Page Route the alternator wire properly page Connect the alternator connectors. Install the seatlrear fender page Install the starter idle gear shaft, gear and spacer in the left crankcase cover. Install the dowel pins and new gasket. Install the starter idle gear cover and tighten the four bolts securely.

Page Starter Clutch Remove the flywheel using the special tool. Remove the starter driven gear while turning it coun- terclockwise. Check the starter clutch outer and sprag clutch for abnormal wear or damage. Check the starter driven gear teeth for wear or damage. Page Apply locking agent t o the starter clutch bolt threads.

Install the starter clutch assembly onto the flywheel and install the bolts. Hold the flywheel with the special tool and tighten the bolts. Page Apply oil to the flywheel bolt threads and seating sur- face, and install the special washer and bolt.

Hold the flywheel with the special tool and tighten the bolt. To service these parts, the engine must be removed from the frame section 6. Page Remove the gasket and dowel pins. Pull the gearshift plate away from the shift drum and remove the gearshift spindle. Measure the gear I. Page Check the gears for freedom of movement or rotation on the shaft. Engage the mainshaft and countershaft gears.

Apply oil to the countershaft oil seal lip. Install the mainshaft and countershaft assemblies as to install a set into the left crankcase. Install the shift fork shaft through the shift forks and into the left crankcase. Apply oil to the gearshift spindle oil seal lip Install the gearshift spindle by aligning the return spring ends with the spring pin bolt while pulling the gearshift plate. Page If the left crankshaft bearing is left on the crankshaft, remove it using the bearing puller with a suitable protector.

NOTE: Always replace the left crankshaft bearing with a new one when the crankshaft is removed. Drive the crankshaft bearing into the left crankcase with the marking side facing up. Page Bearing Remover, 15 Mm cob. Assemble the special tools onto the crankshah. Draw tne crankshatt into the bearing 'nner race. Page Apply oil to new bearings. Drive the mainshaft, crankshaft and balancer bear- ings in with the marking side facing up using the spe- cial tools.

Page Remove the mainshaft bearing using the special tools. Always wear insulated gloves when handling the crankcase after has been heated. Install the dowel pins and a new gasket. Page Install the cam chain drive sprocket onto the crank- shaft, b y aligning the wide groove w i t h the wide tooth. Install the cam chain onto the drive sprocket and through the crankcase.

Apply locking agent the cam chain tensioner bolt threads. Remove the handlebar cover attaching bolt, being careful not to let the bolt fall into the steering shaft. Remove the cover by releasing its ends off the han- dlebar carefully. Page Note Install the upper holders with the punch marks facing forward. Install the four bolts and tighten the forward bolts first, then tighten the rear bolts.

Wait 3 minutes and install the grip. Align the slit of the lever bracket with the punch mark on the handlebar, and tighten the upper bolt first, then the lower bolt. Connect the clutch switch to the connectors and install it into the clutch lever bracket. 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.

DUST Turn the inner race each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Install the distance collar with the large dia. Drive in a new outer bearing squarely with the mark- ing side facing up until is fully seated. NOTE: Do not interchange the left and right tires. Install the wheel nuts with the tapered side facing inward and tighten them.

Lube the bead area with water, pressing down on the tire sidewalllbead area in several places to allow the water to run into and around the bead. If your kit does not have instruc- tions, use the procedures provided here.

Check the tire for puncturing objects. Chalk mark the punctured area and remove the punc- turing object. Remove the lining from the patch and center it over the injury. Press the patch against the injury using a special NOTE: Allow cement to dry until tacky before applying patch. Press the spherical bearing out of the arm pivot. Tighten each nut to the specified torque and further tighten until its grooves align with the cotter pin hole.

Install the following: - tie-rod into knuckle page - wheel hub and front wheel page , Check the damper unit for leakage or other damage. Replace the shock absorber assembly if necessary. Install the throttle cable in the reverse order of removal.

Throttle Cable Inspection Check that the throttle lever move smoothly from full open to full close. If it does not move smoothly, lubricate the throttle cable. Removal 1 Remove the front fender.