Edelbrock TRX400EX user manual

INSTRUCTION SUPPLEMENT

99-LATER HONDA

TRX400EX

Removing Stock Carb and Cables

1.Remove seat/fender assembly a nd fuel

tank.

2.Remove throttle cables paying close attention to routing.

3.Remove thumb throttle housin g if you are installing a twist throttle.

4.Remove air box and air box intake tube.

5.Remove stock carburetor.

6.Stuff a clean rag into intake manifold to

kee p debris from entering engine.

Preparing machine for carburetor

installation

1. Route the provided throttle cables per

manufacturer’s recommended procedure, routing them the same as the stock cables.

2.Remove the rubber alignment tabs from the manifold using a razor blade or cutters.

Be very careful not to damage the intake manifold!

3.Remove air box intake tube from the air box and use a hacksaw to cut approx. 1½” off of the air box intake tube. Your tube sho uld resemble the one shown in Figure 1. Re-assemble the air intake tube in to air box and install b ack onto bike. Don’t forget to

tighten clamp around intake tube and re-

insert crank vent into the air boot.

Figure 1.

Thumb Throttle

Attach cable into cable wheel with the cable end at the 8 :00 position of the cable wheel, then into bracket. Secure by replacing the cable bracket end and phillips screw. See

Figure 2.

Twist Throttle

1.Install the pull (see figure 4 for cable

identification), ca ble end into the 8:00 position and the idle cable end into the 11:00 position on the cable wh eel. See

Figure 3.

Figure 4.

Pull Cable

2.Adjust th e pull cable to achieve wide- open throttle. Adjust the idle cable to take up the slack. When cables are properly

adjusted, there should be approx. 1/8” of free-play in the throttle.

Edelbrock Carburetor Installation

1. Using an 11mm or 7/16” wrench, remove hex plug from carburetor cap. Do not disc ard, as it may be reinstalled after all adjustments are made.

2. Install supplied metering adjustment tool into cap. Do not over-tighten as damage may oc cur!!!

3. Install supplied fuel line onto carburetor

fuel inlet and secure with supplied clamp.

4. Install carb into manifold and align as close to vertical as possible and tighten manifold clamp.

NOTE: After throttle cables have been installed, the handlebars should be rotated from one stop to the other, making sure they operate smoothly throughout the motion. If the throttle is not smooth check the cable adjustment, throttle housing and cable routing.

With the carb and airbox in place, the intake tube should clear the throttle cable as shown in Figure 5.

Figure 5.

5. Install fuel tank and cut fuel line to prop er

length. Install fuel line onto fuel valve securing line with remaining pinch clamp.

6. Turn on fuel and check for leaks.

7. Op en throttle 3-5 times until fuel is dispensed out of squirter. This will ensure tha t the accelerator pump is primed and operational. Once fuel is

dispensed, DO NOT continue to pump throttle as this will flood the engine!

8. Attach air boot to front of carb and secure with clamp.

NOTE: If flooding occurs, open throttle wide open while turning over engine until the engine starts.

If you have any questions concerning installation or tuning please call our toll free tech line at 877-888-750 4 ext 2.. M-F 8:00am-12: 30pm, 1:30pm-5:00pm PST

SPECIAL NOTE: For thumb throttle

applications, it will be necessary to grind away some of the throttle housing to obtain full throttle. See supplied throttle modificatio n sheet.

Edelbrock #3004 and #3105

Carburetor Specifications

Bore Size:34mm wide X 38mm tall oval bore

Needle: 15E @ 12 clicks

Alternate Needles: 13E, 17E

Pump Setting: 21/4 turns out

Replacement Cables: Thumb-#3013 Twist- #9337

Edelbrock #3027 and #3156 Doug

Eichner Signature Series Carburetor

Specifications

Bore Size: 38mm round bore

Needle: 23E @ 21 clicks

Alternate Needles: 21E, 25E

Pump Setting: 21/4 turns out

Replacement Cables: Thumb-#3013 Twist- #9337