|
1999-2008 Honda TRX 400EX
Exhaust Installation
q Remove the stock exhaust system
q Install the Sparks head pipe.
q The head pipe should be centered between the engine cases and frame.
q The clutch cable runs in front of the exhaust headers instead of the stock route. Just bend the cable guide to make it fit.
q Tighten the exhaust stud nuts up to 17 ft/lbs
q Slide the rear section onto the head pipe
q Replace the stock bolts into the rear section and tighten
q If there are any clearance issues, simply loosen the exhaust stud nuts slightly and rotate the head pipe until everything clears properly.
Jetting recommendations
q To access the carburetor, take the seat and fuel tank off.
q Be sure to turn the fuel petcock off before taking the tank off.
q Take the carburetor off of the motor and pull it up into the open.
q Take off the float bowl to access the main and pilot jets.
q Install the recommended main and pilot jets.
q Reinstall the carburetor making certain that everything is together correctly and tight.
q These recommendations are with the Sparks Exhausts, Air filter, the Air box lid off, at sea level.
|
|
Main jet |
|
Needle jet / clip position |
Pilot (slow jet) |
Fuel screw (from closed) |
|
99-08TRX 400EX |
155 |
|
stock / stock |
45 |
2 |
|
|
|
|
|
|
|
|
Air filter installation & maintenance
q Remove all of the stock air filter and its components.
q Thoroughly clean the air box and air boot. Dirt is your motors number 1 enemy.
q Slide the air supercharger ring into the air boot, small diameter goes first.
q Oil your clean air filter with a good pour on type oil, we recommend DT-1, Moose or UNI air filter oil.
q Pour a liberal amount of oil all over foam and massage the oil into filter and squeeze out any extra oil.
q Slide the filter over the air supercharger until it butts up against the front of the air box.
q Tighten the clamp and you are ready to go.
q It is important to clean and oil the filter whenever it gets dirty.
q To clean it, we recommend using filter cleaner like Moose. Other options would be kerosene or mineral spirits and then a good degreaser like Simple Green, 409, even a good dishwashing soap.
q The goal is to get all of the old oil and dirt out of the filter. Rinse well and dry before re-applying the oil.
q DO NOT use gasoline to clean your filter. It can significantly shorten the life of the foam and loosen the glue.
|
