Honda TRX400EX 2009 Service manual

Honda TRX400EX · 2009 · service manual · 345 pages

Honda TRX400EX
2009
Service manual
345 pages
ATV

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
6mm screw	9 N·m	0.9 kgf·m · 6.6 ft·lb	p. 16
12mm bolt and nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 16
Spark plug 1	18 N·m	1.8 kgf·m · 13 ft·lb	p. 16
Valve adjusting hole cap 4	15 N·m	1.5 kgf·m · 11 ft·lb	p. 16
Valve adjusting screw lock nut	24 N·m	2.4 kgf·m · 18 ft·lb	p. 16
Crankshaft hole cap	8 N·m	0.8 kgf·m · 5.9 ft·lb	p. 16
Timing hole cap	10 N·m	1 kgf·m · 7 ft·lb	p. 16
Engine oil drain bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 16
Cylinder head nut 4	44 N·m	4.5 kgf·m · 32 ft·lb	p. 16
Cam sprocket bolt 2	20 N·m	2 kgf·m · 15 ft·lb	p. 16
Intake sub-rocker arm shaft	27 N·m	2.8 kgf·m · 20 ft·lb	p. 16
Exhaust sub-rocker arm shaft	27 N·m	2.8 kgf·m · 20 ft·lb	p. 16
Cylinder head cover bolt	22 N·m	2.2 kgf·m · 16 ft·lb	p. 16
Cam tensioner lifter plug screw	4 N·m	0.4 kgf·m · 3 ft·lb	p. 16
Cylinder bolt	44 N·m	4.5 kgf·m · 32 ft·lb	p. 16
Gearshift stopper arm bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Flywheel bolt	128 N·m	13 kgf·m · 94 ft·lb	p. 17
Starter clutch outer bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 17
Left crankcase cover stud bolt i	10 N·m	1 kgf·m · 7 ft·lb	p. 17
Mainshaft bearing setting plate bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 17
Gearshift spindle return spring pin	24 N·m	2.4 kgf·m · 18 ft·lb	p. 17
Neutral switch	12 N·m	1.2 kgf·m · 9 ft·lb	p. 17
Footpeg bolt	42 N·m	4.3 kgf·m · 31 ft·lb	p. 18
Skid plate bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 18
Exhaust pipe joint nut	27 N·m	2.8 kgf·m · 20 ft·lb	p. 18
Muffler mounting bolt	32 N·m	3.3 kgf·m · 24 ft·lb	p. 18
Muffler band bolt Z	23 N·m	2.3 kgf·m · 17 ft·lb	p. 18
Rear frame upper mounting bolt	42 N·m	4.3 kgf·m · 31 ft·lb	p. 18
Engine oil drain bolt	20 N·m	2 kgf·m · 15 ft·lb	p. 18
Axle bearing holder pinch bolt	21 N·m	2.1 kgf·m · 15 ft·lb	p. 18
Front master cylinder reservoir cap screw	1.5 N·m	0.15 kgf·m · 1.1 ft·lb	p. 18
Parking brake arm lock nut	17.2 N·m	1.75 kgf·m · 13 ft·lb	p. 18
Rear master cylinder push rod lock nut	17.2 N·m	1.75 kgf·m · 13 ft·lb	p. 18
Tie-rod lock nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 18
Upper engine hanger nut	74 N·m	7.5 kgf·m · 55 ft·lb	p. 18
Front engine hanger plate bolt	26 N·m	2.7 kgf·m · 19 ft·lb	p. 18
Front engine hanger nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 18
Lower engine hanger nut	74 N·m	7.5 kgf·m · 55 ft·lb	p. 18
Throttle lever pivot nut 7 Yr	7 N·m	0.7 kgf·m · 5.2 ft·lb	p. 18
Throttle housing cover screw	3.4 N·m	0.35 kgf·m · 2.5 ft·lb	p. 18
Front wheel nut	64 N·m	6.5 kgf·m · 47 ft·lb	p. 18
Front wheel hub nut	69 N·m	7 kgf·m · 51 ft·lb	p. 18
Front brake disc bolt	42 N·m	4.3 kgf·m · 31 ft·lb	p. 18
Brake disc cover bolt 2	12 N·m	1.2 kgf·m · 9 ft·lb	p. 18
Shock absorber mounting nut	44 N·m	4.5 kgf·m · 32 ft·lb	p. 18
Upper and lower arm pivot nut	39 N·m	4 kgf·m · 29 ft·lb	p. 18
Tie-rod ball joint nut	44 N·m	4.5 kgf·m · 32 ft·lb	p. 18
Handlebar lower holder nut	39 N·m	4 kgf·m · 29 ft·lb	p. 18
Steering shaft end nut	69 N·m	7 kgf·m · 51 ft·lb	p. 18
Caliper bleed valve	5.4 N·m	0.55 kgf·m · 4 ft·lb	p. 19
Front brake caliper pad pin	17.2 N·m	1.75 kgf·m · 13 ft·lb	p. 19
Front brake caliper pad pin plug	2.4 N·m	0.24 kgf·m · 1.8 ft·lb	p. 19
Rear brake caliper pad pin	17.2 N·m	1.75 kgf·m · 13 ft·lb	p. 19
Brake hose oil bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 19
Front brake lever pivot bolt	5.9 N·m	0.6 kgf·m · 4.4 ft·lb	p. 19
Front brake lever pivot nut	5.9 N·m	0.6 kgf·m · 4.4 ft·lb	p. 19
Front brake light switch screw	1.2 N·m	0.12 kgf·m · 0.9 ft·lb	p. 19
Rear brake reservoir hose joint screw	1.5 N·m	0.15 kgf·m · 1.1 ft·lb	p. 19
Rear master cylinder mounting bolt	13 N·m	1.3 kgf·m · 10 ft·lb	p. 19
Front brake caliper slide pin	22 N·m	2.2 kgf·m · 16 ft·lb	p. 19
Front brake caliper bracket pin	17.2 N·m	1.75 kgf·m · 13 ft·lb	p. 19
Front brake caliper mounting bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 19
Rear brake caliper slide pin	22 N·m	2.2 kgf·m · 16 ft·lb	p. 19
Rear brake caliper bracket pin	17.2 N·m	1.75 kgf·m · 13 ft·lb	p. 19
Rear brake caliper mounting bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 19
Parking brake base bolt	22 N·m	2.2 kgf·m · 16 ft·lb	p. 19
Brake pedal pivot bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 19
Front brake pipe joint nut	17 N·m	1.7 kgf·m · 13 ft·lb	p. 19
Fuel valve mounting bolt	9 N·m	0.9 kgf·m · 6.6 ft·lb	p. 19
Fuel valve lever screw	4 N·m	0.4 kgf·m · 3 ft·lb	p. 19
Reverse assist cable drum screw	0.7 N·m	0.07 kgf·m · 0.5 ft·lb	p. 19
Muffler band bolt	23 N·m	2.3 kgf·m · 17 ft·lb	p. 38
Muffler band bolts	23 N·m	2.3 kgf·m · 17 ft·lb	p. 45
Tie-rod lock nut	18 N·m	1.8 kgf·m · 13 ft·lb	p. 48
Tie-rod lock nut	15 N·m	1.5 kgf·m · 11 ft·lb	p. 48
Tie-rod lock nut	24 N·m	2.4 kgf·m · 18 ft·lb	p. 48
Pinch bolts	21 N·m	2.1 kgf·m · 15 ft·lb	p. 60
Cap screws	1.5 N·m	0.15 kgf·m · 1.1 ft·lb	p. 65
Oil pipe joint flare nut	20 N·m	2 kgf·m · 15 ft·lb	p. 75
Swingarm pivot nut	108 N·m	11 kgf·m · 80 ft·lb	p. 109
Gearshift pedal pinch bolt	20 N·m	2 kgf·m · 15 ft·lb	p. 109
Cylinder head nut	43.4 N·m	32 ft·lb	p. 119
Cam sprocket bolt	20 N·m	2 kgf·m · 15 ft·lb	p. 119
Washers	44 N·m	4.5 kgf·m · 32 ft·lb	p. 138
Clutch center lock nut	108 N·m	11 kgf·m · 80 ft·lb	p. 159
Primary drive gear nut	88 N·m	9 kgf·m · 65 ft·lb	p. 159
Gearshift spindle return spring pin	12 N·m	1.2 kgf·m · 9 ft·lb	p. 191
Pin hole	69 N·m	7 kgf·m · 51 ft·lb	p. 227
Bolts alternately	32 N·m	3.3 kgf·m · 24 ft·lb	p. 238
Brake caliper stay stopper pin bolt	64 N·m	6.5 kgf·m · 47 ft·lb	p. 243
Brake caliper stay stopper pin bolt	88 N·m	9 kgf·m · 65 ft·lb	p. 243
Brake caliper stay stopper pin bolt	128 N·m	13 kgf·m · 94 ft·lb	p. 243
Castle nut	29.8 N·m	22 ft·lb	p. 243
Castle nut	59 N·m	6 kgf·m · 44 ft·lb	p. 243
Castle nut	44 N·m	4.5 kgf·m · 32 ft·lb	p. 243
Pin hole	147 N·m	15 kgf·m · 108 ft·lb	p. 254
Clutch switch retainer bolt	4.1 N·m	3 ft·lb	p. 327
Reverse switch	12 N·m	1.2 kgf·m · 9 ft·lb	p. 327

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
DPR8Z	—		p. 14
DPR8Z	0.6–0.7 mm		p. 53

Service intervals

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Drive chain service	300 miles		p. 49

Get the document

The full file is delivered by the bot. Free owner guides for Honda are also available from the manufacturer.

Open in Telegram — the bot finds this document by its catalog id and sends the file.

Open in bot

Official free Honda owner's manuals

Parts catalogue

All manuals