Edelbrock Honda 99-LATER Owner's manual

INSTRUCTION SUPPLEMENT
99-LATER HONDA
TRX400EX
Removing Stock Carb and Cables
1.Remove seat/fender assembly and fuel
tank.
2.Remove throttle cables paying close
attention to routing.
3.Remove thumb throttle housing 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
keep 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
should resemble the one shown in Figure 1.
Re-assemble the air intake tube into air box
and install back 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.
Figure 2.
Twist Throttle
1.Install the pull (see figure 4 for cable
identification), cable end into the 8:00
position and the idle cable end into the
11:00 position on the cable wheel. See
Figure 3.
Figure 3.
Figure 4.
Pull Cable

2.Adjust the 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
discard, 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 occur!!!
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
proper
length. Install fuel line onto fuel valve
securing line with remaining pinch
clamp.
6. Turn on fuel and check for leaks.
7. Open throttle 3-5 times until fuel is
dispensed out of squirter. This will
ensure that 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 877-888-7504 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
modification 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