Aral . ZA HONDAHOW TO USE THIS MANUAL This service manual estes the sonic procades for the TRXZEO Sie wen the strdars set by he Cattraa Aw Resouose Board GENERAL INFORMATION FRaMEBODY Pancisexnausteverem — EM | MAINTENANCE LUBRICATION SYSTEM oeyecaeetaiyaace |g | Fuck system ese es nem | § mon E or a puma Z | evLNDERHEADNALVE ——_ a Nee et en craiavac sate Tesasmetnme | 2 | CYLINDERIPISTONICAM ae a Ls ee fougewor te wes ne mae oe» Set se | FT CLUTCHIGEARSHIFT LINKAGE = > ——— 3 ALTERNATORISTARTER CLUTCH CRANKCASETRANSMISSION/CRANKSHAFT REI Seren eee FRONT WHEEL/SUSPENSIONSTEERING me @ | REAR WHEELISUSPENSION a amt atm) |8 ae Sie comes nrette | | a | sraxesveres REE a SE [REAR DRIVING MECHANISM A ser BATTERYICHARGING SYSTEM " 2 are —— regen tw see | | TeRTON sere incon iri i oy ao 7° | PBR Acumattanann petincrimacseutapeonseys | 4) LIGHTSMETERSISwTCHES RES eee ee a eee SSHRC ivy PROGRAM |” WIRING DIAGRAMS ‘TROUBLESHOOTING a RIDE REDSYMBOLS The symbols used throughout this manual show specific sevice procedures. If supplementary information is required pertaining to these symbols, it would De explained specifically in the text without the use of the symbols. Replace the parts) with new one(s) before assembly Use recommended engine oll, unless otherwise specified Use molybenum oi! solution (mixture ofthe engine oll and molybdenum grease in @ ratio of 1:1) Use multi-purpose grease lithium based mul-purpose grease NLGI #2 or equivalent) Use molodenum disulfide grease (containing more than 3% molyadenum disulfide, NLGI #2 or equivalent) Example: Molykote® BR-2 Plus manufactured by Dow Corning, U.S.A. ‘Mult-purpose M-2 manufactured by Mitsubishi Ol, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent) Example: Molykote® G-n Paste manufactured by Dow Coming, US.A, Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. RRocol Paste manufactured by Surico Lubricant, Japan Use silicone grease, Apply a locking agent. Use a medium strength locking agent unless otherwise specified. Use sealant, Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified Use fork or suspension fluid ————)s RIDE RED1. GENERAL INFORMATION SERVICE RULES --- MODEL IDENTIFICATION---- GENERAL SPECIFICATIONS: LUBRICATION SYSTEM SPECIFICATIONS .------- 18 FUEL SYSTEM SPECIFICATIONS :--0--0-- 1-6 CYLINDER HEAD/CYLINDER/PISTON SPECIFICATIONS: CLUTCH SPECIFICATIONS «:essesnsnenrones 127, CRANKSHAFT/TRANSMISSION SPECIFICATIONS: FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS. : 18 REAR WHEEL/SUSPENSION SPECIFICATIONS. 18 BRAKE SYSTEM SPECIFICATIONS: REAR DRIVING MECHANISM SPECIFICATIONS: BATTERY/CHARGING SYSTEM SPECIFICATIONS: oo IGNITION SYSTEM SPECIFICATIONS -~ ELECTRIC STARTER SPECIFICATIONS -. LIGHTS/SWITCHES SPECIFICATIONS --~.-1-10 STANDARD TORQUE VALUES-~ ENGINE & FRAME TORQUE VALUES. LUBRICATION & SEAL POINTS» CABLE & HARNESS ROUTING «=. EMISSION CONTROL SYSTEMS -~ EMISSION CONTROL INFORMATION LABEL (U.S.A, only) 1-1 RIDE REDGENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's e design specifications may cause damage to the vehicle, 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 3. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. - When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts 1g solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8, Route all electrical wires as shown in the Cable & Harness routing (page 1-19). MODEL IDENTIFICATION This manual covers 2 types of TRX250 models: e + TM Left foot operated gearshift + TE Electric shit program (ESP) Be sure to refer to the procedure that pertains to the appropriate version of the TRX250. TRKQSOTE shown: ‘he Mol ldertienton Labels oat onthe lt i frame down WopEL DENTIFGATION LABEL eGENERAL INFORMATION ‘The vehicle identification number (VIN) is stamped on the front side of, the frame, © ‘The engine serial number is stamped on the right side of the < crankcase. The color label is attached on the left frame pipe under the seat. When ordering color-coded parts, always specify the designated color code. © ‘The carburator identification number is stamped on the left side of the carburetor body. © © CARBURETOR IDENTIFICATION NUMBERGENERAL INFORMATION GENERAL SPECIFICATIONS Tem ‘Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight DIMENSIONS Curb weight Maximum weight capacity FRAME Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Fear tire sizo Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity ENGINE Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve ‘opens closes Exhaust valve opens closes Lubrication system il pump type Cooling system Air fitration Engine dry weight CARBURETOR Throttle bore ___ SPECIFICATIONS: 1,905 mm (75.0 in} 4,035 mm (40.7 in} 1,065 mm (41.9 in) 1,130 mm (44.5 in} 785 mrn (30:8 in} 780 mm (30.7 in} 795 mm (31.3 in) 320 mm (126 in} 4150 mm (5.9 in) TM: 190 kg (419 Ibs) ‘TE: 193 kg (425 Ibs) TM: 197 kg (434 Ibs) ‘TE: 201 kg (243 Ibs) 175 kg (386 Ibs) Double cradia Double wish-bone 130 mm (5.1 in} Double tube Swingarm 125 mm (4.9 in) Double tube AT22 x 7-11 AT22 10-0 1x55 AT 9x80AT TRACKER HP (Goodyear) ‘TRACKER HP (Goodyear) Hydraulic drum brake Mechanical drum brake By 42 mm (1-678 in) one 9.1 liters (2.40 US gal, 2.00 Imp gal) [2.4 liters (0.63 US gal, 0.53 Imp gal) ‘Single oylinder, longitudinally installed 68.5 x 62.2 mm (2.70 x 2.45 in} 229.2 em’ (14.0 cu-in) 92:1 OHV 5° BTDC (at 1 mm lift) 31° ABDC (at 1 mm lift) 30° BBDC (at 1 mm lift) 3° ATDC (at 1 mm lif) Forced pressure and wet sump Trochoid Air cooled (with oil cooler) Oiled double urethane foam TM: 38.9 kg (79.1 Ibs) TE: 374 kg (82.5 Ibs) Piston valve 20mm (08 in)eC e@ ce DRIVE TRAIN | ELECTRICAL TEM Clutch systom Clutch operation system Transmission Primary reduction Final reduction Gear ratio ast 2nd 3rd ath sth Reverse Gears! pattern Ignition system Staring system Charging system Rogulatorirectifior Lighting system GENERAL INFORMATION ‘SPECIFICATIONS Centrifugal and multi-plate, wet Automatic Constant mesh, 5-speed with reverse 3.086 (71/23) 3.692 (48/13) 3.231 (42/13) 2.167 (39/18) 11.667 (36:21) 1.280 (32/25) 41042 (25/24) 5.550 (39/20 x 37/13) R-N-1-2-3-4-5 TM: Left foot operated return system TE: Electr shift (left hand operated) return system AC-CDI Electric starter motor and emergency recoil starter Single phase output alternator SCR shorted, tiple phase full wave rectification BatteryGENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS TEN | Engine off ‘STANDARD. 15 Miers (T6US af, 1.3 Imp ad) 19 Titers (2.0 US at, 1.7 Imp at) Pro Honda GN4 4-stroke oil or equiva- ‘engine oil lent motor oil APl service classification, 6 or Higher - ASO T 803 stand Viscosity: SAE 10W-30 ‘Oipump | Tip clearance 0.15 (0.006) 0:20 (0.008) Body clearance 0.15 - 0.21 (0.006 0.008) 0:25 (0.010), ‘Side clearance (0.05 = 0.13 (6.002 = 0.008) 0.15 (0.006) FUEL SYSTEM SPECIFICATIONS 7 TEM ‘SPECIFICATIONS Carburetor identification number POCIF Main jet ‘Standard 8 FRigh attitude #92 Slow jet 38 Pilot serew Ti turns out Final opening 5/8 turn out [CRigh attitude setting 77a turns out from seated 4 Fioat evel 14 mm (0.55 in) idle speed 7,400 + 100 rpm 7 ‘Throttle lever freeplay 38mm (V8 8/16 Tn) ew OOOGENERAL INFORMATION CYLINDER HEAD/CYLINDER/PISTON SPECIFICATIONS < Unit: mm fin) TEM __ STANDARD ‘SERVICE LIMIT Cylinder compression at 800 rom 1.278 KPa (13.0 katem?, 185 psi) Valve clearance INEX |0113 0.005) - Valve, valve Valve stem 0.0. 1N 5.475 — §.490 (0.2156 — 0.2761) 5.45 (0.215) guide EX 5.455 = 6.470 (0.2148 - 0.2154) 5.43 (0214) Valve guide 10. INEX | 5500-6512 (0.2165 - 0.2170) 5.52 0217), Yu Stemto-quide clearance IN 0.010037 (0.0004 0.0018) 0:12 (0.005) Ex 10.030 — 0.057 (0.0012 - 0.0022) 0.14 (0.006) ‘Valve seat width IWEX | 4.2 (0.05) 1510.06) Valve spring Free length inner | 42a (167) 41.1 (1.82) Outer 4421178) 251683) Rocker arm Arm.D: iNEX |12.000 = 12078 10724-04731) 12.05 (0.44) Shalt 0. INEX | 11966-11984 (0.4711 - 0.4718) 1132 (0.468) Ye ‘Arm-to-shal clearance INEX | 0016 ~ 0.052 (0.0006 0.0020) 0,08 (0-003) Camshaft, Cam lobe height IN) 36.2616 35.4276 (19882 - 13945] | 35.2 (1.38) cam follower Ex__/ 36.0020 36 1620 (13780-13843) | 35.0(1.38) TamTollower 0. INEX | 22.467 ~ 22.482 (0.8845 - 0.8857) 22.46 (0.684) Follower bore 1 INEX | 22.610 = 22.626 (0.8862 - 0.8868) 22.54 (0.887) ___| Followarto-bore clearance" INEX | 0.028 0089 0.00 - 0.0023) ‘0.07 (0.003) ‘Cylinder head warpage = 0.100.004), Gylindor 1D. 68.500 68.510 (2 6968 - 7.6972) 168,60 (2700) Outotround = 0.10 (0.004), Taper | 0.10 (0.004) Warpage c 0.10 (0.004) Piston, piston | Piston O.D. at 18 (0.6) from bottom | 68.462 68.482 (2.6953 - 26961) 8.40 (2.693) pin, piston Piston pin hole 1.0. 15.002 ~ 15.008 (0.5906 - 0.5909) 15.04 (0.592) ting Piston pin 0.D. 14,994 — 15.000 (0.590: 5906) 14.96 ) Piston-to-piston pin clearance — 0.002 ~ 0.014 (0.0001 - 0.0006) 0.02 (0.001) < Piston ring end gap Top | 0200.35 (0.008 - 0.018) 05 (002) See 40-055 0.016- 0.022) 07 (009) it (side 0200.70 (0.008-0.028) - ral) "Piston ring-to-ring groove Top 0.015 — 0.046 (0.0006 — 0.0078) 0.09 (0.004) socom See 0015-0046 0.0008 0.0018) 4409 (0.004) Cylindarte-piston clearance 0.078= 0.088 (0.0007 - 0.0019} 0:10 0.004) Connecting rod small end 1D. 15.010 - 15.028 (05909-08917) | 18.08 (0593) Connecting rod:to-piston pin clearance 0.010 0.038 (0.0008 - 0.0013) 0.10 0.004) CLUTCH SPECIFICATIONS © Unit mn in Tem STANDARD SERVICE LIMIT ‘Change clutch | Spring free length ™ 3521139) 345 (1.36) Te 370 1.46) 36.3 (143) Disc thickness: — 29-30 (0.10.12) 12.6 (0.10) Plate warpage = 0.20 (0.008) | Outer 1.D. 28.000 ~ 28.021 (1.1024 — 1.1032) 28.04 (1.104) © Outer guide OD. 27989 21980 (11007 01s) | 2792 1089) Centrifugal sim | 116.00 - 116.20 (4 567 - 4875) 16.5 14.58) clutch Weight lining thickness 2.0 (0.08), 4.20.05) _ Clutch spring height 301012) 2.85 (0.112) Clutch weight spring free length 3075 (127) 316 (124) Deum bushing LD. 24,000 - 24,021 (0.949 0.9457) | 24.05 (0.947) 23.959 - 23.980 (09433-09441) | 23.95(0.842) < Crankshaft O.D. at drive gear 1-7GENERAL INFORMATION CRANKSHAFT/TRANSMISSION SPECIFICATIONS Trem Shift fork 1D. Claw thickness Shaft OD. Transmission | Gear LD. ma Ms. 1, C2, €3, CR Roverse idle Gearbushing OD. |Ma MS 1, C2, €3, CR | Gearto-bushing | clearance | Gear bushing LD. Mainshatt 00. | countershatt 0. averse idle shaft 0.0. Bushingte-shatt | Ma, C3 clearance MS averse idle goarto-shaft clearance Crankshaft | Runout Front Rear Big end side clearance Big end radial clearance ‘STANDARD 73,000 13.018 (0.5118 05128)_ 4.83 ~ 5100 (0.194 - 0.197) 12.966 ~ 12.984 (0.5105 - 0.5112) 23.000 ~ 23.021 (0.9055 — 0.9063) 48.000 - 18.018 (0.7087 - 0.7034) — 125.000 ~ 25.021 (0.9843 - 0.9851) 73,000 - 13.018 (0.6118 - 0.5125) 22.959 - 22.979 (0.9039 - 0.9047) 117959 = 17980 (0.7070 - 0.7078) 24,969 ~ 24.980 (0.9826 - 0.9835) (0.021 - 0.062 (0.0008 - 0.0024) 10.020 = 0.062 (0.0008 - 0.0024) ~ | 20.000 - 20.021 (0.7874 - 0.7882) 45.000 = 16.018 (0.5906 - 0.5913), 22.000 - 22.021 (0.8661 - 0.8670) 19.959 — 19.980 (0.7858 - 0.7866) 14.966 ~ 14.984 (0.5892 - 0.5899) 27,959 - 21.980 (0.8645 - 0.8654) — 112.966 — 12.984 (0.5108 0.5112), 10.020 ~ 0.062 (0.0008 - 0.0024) (0.016 - 0.052 (0.0006 - 0.0020) (0.016 - 0.082 (0.0006 - 0.0020) (0.05 =0'50 (0.002 = 0.020) — (0.004 0.072 (0.0002 — 0.0006) 2a Unit: mm (in) SERVICE LIMIT 13.04 (0.513) 45 (018) 12.96 (0.510) 73.08 (0907) 18.04 (0.710) 25.08 (0.986) 1306 (0513) 22.96 (0.903) 1734 (0.706) 982) 104) 0:10(0.004) 20.04 (0.789) 15:04 (0.592) 72.08 (0.868) 49.93 (0.785), 1496 (0.588) 93 (0.863) 12.94 (0.509) 0.10 (0.004) 0:70 (0.004) 0:10/0.004) 0106 (0.002), 0.03(0.001) 080 (0.031 0105 (0.002), FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Minirnurn tire ti Cold tre pressu [Maximum With cargo ‘Tie-rod distance between the ball joints Too ‘STANDARD Standard 20 KPa (0.20 Kgler", 2.9 pi Minimum 17 kPa (0.17 kgfiem 25 psi 23 kPa (0.23 kgficm”, 3.3 psi) 20 kPa (0.20 katicm’, 2.9 psi 323. 1(12.73 0.04) Too-in: 8+ 15 (5/16 = i REAR WHEEL/SUSPENSION SPECIFICATIONS ITEM Minimum tre tread depth | Coldtire pressure Standard Minimum Maximum "With cargo ‘STANDARD 20 kPa (0.20 kafiem’, 2.9 psil 17 kPa (0.17 kaffer?, 25 psi 23 kPa (0.23 kgtiom’, 3.3 psi 20 kPa (0.20 kaficm”, 2.8 psi) Unit: mm (in) ‘SERVICE LIMIT 410.2) Unit: mm (ini SERVICE LIMIT 4102)GENERAL INFORMATION BRAKE SYSTEM SPECIFICATIONS trem Front Recommended brake fluid Drum 10, ‘Shoe lining thickness Brake panel warpage Brake panel seal lip wear ‘Master cylinder I. ‘Master piston O.D. Wheel cylinder LD. Wheel cylinder LD. Rear brake Drum 10. Shoe lining thickness ‘STANDARD DOT JerDOT 4 730.0 (5.12) 40 (0.16) 72.700 — 12.743 (0.5000 0.5017) 12.657 ~ 12.684 (0.4963 - 0.4994) 15.870 - 15.913 (0.6248 ~ 0.6265) 15,827 - 15.854 (0.6231 - 0.6242) 140.0651), 45 (0.18) REAR DRIVING MECHANISM SPECIFICATIONS rem ‘STANDARD ‘Axle runout 7 Rearfinel | Oilcapacity | Aferdraining | 80 em" (2.7 US o2, 28 Imp o2) drive ‘After disassembly | 100 om’ (3.4 US oz, 3.5 Imp oz) Recommended oil [Hyp (Gear backlash (0.05 ~ 0.25 (0.002 - 0.010) Backlash difference ing gearto-stop pin clearance (0:30-0:60 (0.012 - 0.024) gear oil SAE # 80, BATTERY/CHARGING SYSTEM SPECIFICATIONS ‘SPECIFICATIONS Needs charging eM Battery Capacity Current leakage Voltage (20°Ci68°F) | Fully charged Charging current Normal Quick Alternator | Capacity Charging coil resistance (20°C768" IGNITION SYSTEM SPECIFICATIONS rem ‘Spark plug | Standard For cold climate (below 5°C/41"F) For extended high speed riding Spark plug gap Ignition coil primary peak vonage Ignition pulse generator peak voltage Alternator exciter coil peak voltage Ignition timing F mark Full advance Unit: mm fin} SERVICE LIMIT ¥31.0(5.16) 10 (0.04) 0.4 (0.02) 0.5 (0.02), 12.755 (0.5022) 12,645 (0.4978), 46.925 (0.6270), 15.815 (0.6226) 1410 (5.55) To the indicator Unit: mm fin} SERVICE LIMIT 3.0 (0.12), 4 0.40 (0.016) 0.20 (0.008) 12V-10Ah mA max 130-132V Below 1ZAx5-10h 5OAx10h (0123 KWI5,000 rpm 01-100 ‘SPECIFICATIONS DPRAEA-9 (NGK), X24EPR-US (DENSO} 100 V minimurn {0.7 V minimum —100.V minimum 14° BTDC atidle SHE BTDC at 3,750 rpm 1-9GENERAL INFORMATION ELECTRIC STARTER SPECIFICATIONS Unit: mm fin} >» rem ‘STANDARD SERVICE LIMIT ‘Starter motor brush length 125 (0.49) 9.0 (0.35) LIGHTS/SWITCHES SPECIFICATIONS mem SPECIFICATIONS: ) Bulbs Headlight thigh/ow beam) 12V —26/25 Wx? Tailight LED x3 Neutral indicator wv-17W Roverse indicator 2V-17W Fuse Main fuse ™ 156A TE 5A. 30A ) RIDE RED& STANDARD TORQUE VALUES TORQUE FASTENER TYPE Nem (kgf-m, Ibfft) 5mm bolt and nut 5 (05, 37) ‘6mm bolt and nut 10(1.0, 7) ‘&mm bolt and nut 2212.2, 16) 10mm bolt and nut 3413.5, 25) 12mm bolt and nut 5418.5, 40) GENERAL FASTENER TYPE 5mm serew 6mm screw 6 mm flange bolt {8mm head, small flange} 6 mm flange bolt {8 mm head, large flange) 6 mm flange bolt (10 mm head) and nut ‘8mm flange bolt and nut 10 mm flange bolt and nut ENGINE & FRAME TORQUE VALUES + Torque specifications listed below are for important fasteners. ‘Others should be tightened to standard torque values listed above, INFORMATION TORQUE Nem (kaf-m, Ibf-ft) 4(0.4, 30) 9109.68) 10.1.0, 7), 12(12,9) 12(12,9) 26 (27,19) 394.0, 29) NOTE 1. Apply locking agent to the threads, 2. Apply engine oil to the threads and seating surface. 3. Apply grease to the threads and seating surface 4 Apply brake fluid to the threads. 5. ALOC bolt: replace with a new one, 6. Lock nut: replace with a new one. 7. Cestle nut: tighten to the specified torque and further tighten until its groove aligns with the cotter pin hole. 8 Stake. ENGINE FRAME/BODY PANELS/EXHAUST SYSTEM F THREAD TORQUE ren CTY DIA. (mm) Nem kgm, ttt) REMARKS Exhaust pipe stud bolt 2 8 610.6, 44) MAINTENANCE THRIB rem ary EAD ToRaue REMARKS DIA. (mm) Nem (kgf-m, IbF ft) Spark plug 1 12 22(2.2, 16) Valve adjusting screw lock nut 2 6 47 (17,13) NoTE 2 Valve adjusting hole cap 2 30 2012.0, 15) NOTE2 Timing hole cap 1 14 30110, 7) Engine oil drain boit 1 1225125, 18) LUBRICATION SYSTEM THREAD TORQUE eM QTY DIA. mm) Nem (kfm, tt) | REMARKS Pressure relief valve cap 1 4 19119, 14) | FUEL SYSTEM THREAD TORQUE et QTY DIA. fmm) Nem (kfm, tb ft) | REMARKS Carburetor insulator stud bolt 2 é y0110,7) |GENERAL INFORMATION CYLINDER HEAD/CYLINDER/PISTON item Cylinder Read nut Cam chain tensioner arm pivot bolt Cylinder stud bolt 4‘) |_Push rod end piece cLuTcH rem Change clutch center lock nut Change clutch spring bolt Centrifugal clutch lock nut GEARSHIFT LINKAGE rem Gearshift return spring pin Gearshift cam plate bolt Gearshift drum stopper arm pivot bolt Gearshift arm retaining bolt atv a 1 4 avy ary ALTERNATOR/STARTER CLUTCH rem Starter one-way clutch bolt Recoil starter driven pulley bolt Ignition pulse generator bolt ELECTRIC SHIFT PROGRAM (TE model) iTem ‘Angle sensor bolt Reverse shift switch 2 woe § avy THREAD TORQUE DIA. (mm) Nem (kgm, betty | REMARKS 3 "30 (3.1, 2) NOTE? 6 12 (12,9) NOTE? 8 1212.9) 6 13413, 10) THREAD TORQUE DIA. (mm) Nem (kgtm, tft) REMARKS 16 738.1, 58) 6 12(12,9) 18 88(90,65) | NOTE2,8 THREAD DIA. (mm) Nem (kgtsm, bet) “e222, 16) NOTE — 8 16(16, 12) NOTE1 6 12(12,9), NOTE1 6 1212.9) NOTE 1 THREAD TORQUE DIA. (mm)_|_Nim (kgtm, ett) REMARKS 6 16(16, 12) NOTET 10 74 (75, 55) NoTE2 5 5106 44) NOTE) THREAD TORQUE aie ~NOTET 10 1313, 10), 1-12 RIDE REDGENERAL INFORMATION FRAME FRAME/BODY PANELS/EXHAUST SYSTEM 7 THREAD TORQUE TEM CTY DIA. (mm) Nem (kgfm, tte) REMARKS ‘Genter mudguard bracket nut a 8 32 (3.3, 24) 4 Front carry pipe bolt 4 8 37 (38,27) Front carrer bolt 2 8 37 (38,27) Roar carrier bolt 6 8 37 (38,27) Muffler band bolt 1 8 2312317) Exhaust pipe protector bolt 3 6 2222, 16) MAINTENANCE | THREAD TORQUE eM OTY DIA. (mm) Nem tkgt-m, tl REMARKS Final gear case oll check bolt 7 8 12 (12,8) Final gear case ol filler cap 1 30 12112.9) Final gear case oil drain bolt 1 8 12(12,9) Tie-rod lock nut 4 2 54(5.5, 40) ENGINE REMOVAL/INSTALLATION = THREAD TORQUE cman] I Tes QTY DIA. (mm) Nem (kgm, betty REMARKS Lower engine mounting nut left and right) 2 io 54 (5.5, 40) Upper engine mounting bolt 1 8 22(3.3,24) Frame cross-member bolt 2 8 37 (38,27) (GEARSHIFT LINKAGE 7 THREAD TORQUE rem TY DIA. mm) __ Nem (kgm, rte) | REMARKS ‘Goarshifi pedal pinch Bak 7 6 20 (2.0, 15) Reverse stopper arm nut 1 6 740.7.5.1) FRONT WHEEL/SUSPENSION/STEERING CT 5 THREAD TORQUE Tem TV ptm) nm (igtm.tbesn) REMARKS Handlebar lower holder nut 2 10 39 (4.0, 29) NOTES Throttle housing cover screw 3 4 3.4 10.35, 2.5) Front whee! nut 8 10 6416.5, 47) Front whoo! hub nut 2 18 78 (8.0, 58) Note? ‘Shock absorber upper mounting nut 2 10 303.1, 22) NOTES Shock absorber lower mounting nut 2 10 49 (5.0, 36) NOTES Upper and lower arm pivot nut 8 0 30(3.1, 22), NOTE 6 Upper and lower arm bal joint nut 4 2 29,(3.0,21) NoTE 7 Brake hose clamp bolt {upper arm) 4 6 12(12,9) Brake hose clamp bolt (knuckle) 2 8 29(3.0,21) Tie-rod stud joint nut | 4 2 54 65, 40) NOTE 6 Steering shaft end nut 1 1 108 (11.0, 80) Steering shaft holder bolt 2 8 323.3, 24) REAR WHEEL/SUSPENSION -_ ‘THREAD TORQUE ess | e7v oiatonm | nimtigtm, tay REMARKS Rear wheal nai 8 10 64165, 471 Shock absorber upper mounting nut 1 10 44 (45, 32) Notes ‘Shock absorber lower mounting bolt 1 10 5415.5, 40) Swingarm pivot bolt (right) 1 20 1n2(114, 83) ‘Swingarm pivot bolt (left) 1 30 3.91040, 2.9) Swingarm left pivot lock nut 1 30 112114, 83),GENERAL INFORMATION GENERAL INFORMATION BRAKE SYSTEM irem Brake hose oil bolt ‘Wheol cylinder bleed valve Front master cylinder reservoir cap screw Front brake lever pivot bolt Front brake lever pivot nut Front master cylinder holder bolt Front brake wheel cylinder bolt Front brake adjuster mounting bolt Front brake panel bolt Roar axle nut Rear axle lock nut Rear wheel hub nut Rear brake arm pinch bolt Rear brake panel drain bolt Skid plate bolt Brake oil joint nut REAR DRIVING MECHANISM Tem Final gear case pinion bearing Tock nut Final gear case cover bott, Final gear case mounting bolt OTHERS any ‘THREAD DIA. (mm) 10 32 22 10 ‘THREAD "TORQUE REMARKS Nem (kgm, bese) REMY 3413.5, 25) 5.4 (0.55, 4.0) 2(0.2, 15) 5.9 (0.60, 4.4) 5.9 (0.60, 44) 12(12, 9) 24(0.75, 55) 74 (0.75, 6.5) 28((3.0, 21) 394.0, 29) 127 (13.0, 93) 137 (140, 101) 1212, 9) 12(12, 9) 3218.3, 24) 1712.13) ‘TORQUE DIA. (mm) 10 0 THREAD DIA. (mm) 10 Nem (kgf-m, Ib ft) 98 (10.0, 72) 49 (5.0, 36) 25(25, 18) 5415.5, 40) NOTE 1 NOTE? NoTE 4 REMARKS NOTES NOTE 1 TORQUE) pny Nem (kgf-m, IbEft) 44 (45, 32) REMARKS NoTEs 1-14GENERAL INFORMATION LUBRICATION & SEAL POINTS eo ENGINE sexo _— — Valve stem (valve guide sliding surface) disulfide grease) Starter reduction gear shaft (entire surface) Valve adjusting hole cap threads Engine oll Rocker arm follower and adjusting serew tip Cam follower {entire surface) Cylinder head nut threads < Connecting rod small end inner surface Piston outer surface and piston pin hole Piston pin outer surface Piston ring entire surface Cylinder bore Primary drive gear teeth (change clutch outer} Change clutch disc linings Change clutch center lock nut threads Change clutch ball retainer b: Change clutch lifter lever spindle and roller Centrifugal clutch drum bushings Centrifugal clutch shoe lining Centrifugal clutch lock nut threads Gearshift drum stopper arm pivot Gearshift spindle journals © Gearshift master arm inner surtace ‘Sub-gearshift spindle arm roller Reverse stopper shaft journals Recoil starter driven pulley bolt threads | Starter one-way clutch sprag Starter driven gear teeth and one- area Starter reduction gear teeth Connecting rod big end area Transmission gear teeth and rotating surface ‘Mainshaft splines and journals Countershaft splines and journals Shift fork inner surface, quide pin and pawls Shift fork shaft entire surface Shift drum guide grooves | < Each bearing rotating area fay clutch contacting Each O-ring Centrifugal clutch drive plate O-ring groove Multi-purpose Each oil seal lips grease Electric shift reduction gear teeth and journals (front Unirex N2 grease ‘TE model only: Apply 3-5 @ crankcase cover) {EXXON)orTemplex | (shadowed area) Na grease (ESSO)GENERAL INFORMATION LOCATION “MATERIAL _| ‘REMARKS ‘Camshaft bearing retainer bolt threads Tocking agent Cam chain tensioner arm pivot bolt threads Cam chain tensioner adjuster bolt threads Centrifugal oil filter cover bolt threads Gearshift return spring pin threads Gearshift drum stopper arm pivot bolt threads Gearshift cam plate bolt threads ‘Starter one-way clutch bolt threads Ignition pulse generator bolt threads Rocoil starter mounting bolt throads Mainshaft bearing setting plate bolt threads Gear position switch bolt threads Angle sensor bolt threads ‘TE model only Alternatoriignition pulse generator wire grommet Sealant seating area Gear position switch wire grommet seating sres 1-16 RIDE RED© © FRAME LOCATION Throttle cable end Throttle cable threads (lever side) Throttle lever pivot and dust seal lip Rear brake lever pivot Parking lock arm pivot (screw) Steering shaft bushing inner surface Steering shaft dust seal lips ‘Swingarm pivot bearing ‘Swingarm pivot dust seal lips Front brake drum water proof seal lips Rear brake cam dust seal lips Rear brake cam spindle Rear brake anchor pin sliding surface Rear brake cam shoe sliding surfaces Rear brake panel axle dust seal lips Rear brake pedal pivot Rear brake pedal pivot dust seal ips Rear brake cable (peda nd parking brake cable ever) Final gear case oil seal lips (ring gear and drive shaft) Final gear case axle dust seal Swingarm axle housing dust seal Each O-ring Rear axle splines (lef, right and center) ‘Yoke joint splines Drive shaft splines MATERIAL Multi-purpose grease ‘Molybdenum disulfide grease GENERAL INFORMATION REMARKS 2-39 3g per each bearing 05-19 05-19 05-19 25-3 (side lip) 1-17GENERAL INFORMATION LOCATION | MATERIAL, REMARKS Rearbrake cam‘feltseal natn ol t Throtle inner cable Cable lubriant Choke inner cable Rear brake inner cable Reverse control inner cable ee _ Handlebar grip rubber inside Honda Bond A or Air cleaner case-to-connecting hose (carburetor and air Honda Handarip intake duct) mating area Cement (USA _ only) Front brake Teverio-masier piston contacting area Silicone grease Front brake lever pivot Brake panel shoe metal contacting areas Indicated by *" Brake shoe adjuster groove and wheel cylinder piston Indicated by {groove (shoe contacting grooves) Brake shoe adjuster screw threads and adjustor nut, spindle outer surface ‘Wheel cylinder body boot groove and piston boot groove Master cylinder piston and cups ‘Wheel cylinder piston and cup Brake oil pipe joint nut threads Rear final gear case cover mating surface brake fluid ‘Sealant 1-18 RIDE REDGENERAL INFORMATION CABLE & HARNESS ROUTING ‘THROTTLE CABLE REAR BRAKE CABLE Sz — FRONTBRAKE LIGHT Sw TCH WIRE REAR BRAKE LIGHT cearinoicaron / \ enonranaxe Gintinescane” 1 SwTCH WIRE REVERSE SELECTOR HOKE caste IGNITION CONTROL MODULE, HANDLESAR SWITCH WIRE ELECTRONIC CONTROL, INDICATOR WIRE UNIT {TE only) HEADLIGHT WIRE SHIFT CONTROL MOTOR CONNECTOR (TE only} FRONT BRAKE PIPE RIGHT FRONT BRAKE HOSE LEFT FRONT BRAKE HOSEGENERAL INFORMATION _ HANDLEBAR TARY CARE SWITCH WIRE GEAR INDICATOR 7 WIRE (TE only) FRONT BRAKE LIGHT. ‘SWITCH WIRE REAR BRAKE LIGHT SWITCH WIRE FRONT BRAKE HOSE CHOKE CABLE INDICATOR WIRE BREATHER HOSE CLAMP: THROTTLE CABLE ——— REAR BRAKE CABLE CHOKE CABLE IGNTION SWITCH WiRE cLaMe: CLAMP: MAIN WIRE HARNESS MAIN WIRE HARNESS. BRAKE LIGHT SWITCH WIRE IGNITION SWITCH WIRE HANDLEBAR SWITCH WIRE “INDICATOR WIRE HEADLIGHT WIRE 1-20GENERAL INFORMATION FRONT BRAKE HOSE THROTTLE CABLE REAR BRAKE CABLE CHOKE KNOB HANDLEBAR, SWITCH WIRE FRONT BRAKE LIGHT SWITCH WIRE FUEL TANK BREATHER HOSE FRONT BRAKE snore coe — SWITCH WIRE i a fh “ll pay I toe FRONTBRAKE LIGHT \/ - a, \ SWITCH WIRE oW, —) mean FRONT BRAKE HOSEGENERAL INFORMATION IGNITION CONTROL MODULE, GEARINDICATOR ‘WIRE (TE only) MAIN WIRE HARNESS THROTTLE CABLE REAR BRAKE CABLE IGNITION swiTcH wine (CHOKE GABLE INDICATOR WIRE HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS (TE only) HEADLIGHT WIRE MAIN WIRE HARNESS T- RIDE REDGENERAL INFORMATION ‘THROTTLE CABLE REAR BRAKE CABLE REVERSE SELECTOR CABLE CLAMP: “BRAKE LIGHT SWITCH WIRE HANDLEBAR SWITCH WIRE GEAR INDICATOR WIRE IGNITION SWITCH WIRE INDICATOR WIRE CHOKE CABLE IGNITION CONTROL MODULE CLAM: MAIN WIRE HARNESS IGNITION SWITCH WIRE INDICATOR WIRE GEAR INDICATOR 6P CONNECTOR (TE only) INDICATOR 4P R MAIN WIRE SONNECTON HARNESS (TE only) IGNITION'SWITCH IGNITION SWITCH 3PCONNECTOR CONNECTOR ELECTRONIC CONTROL MAIN WIRE HARNESS. UNIT (TE only) REVERSE SELECTOR CABLE SHIFT CONTROL MOTOR 2P CONNECTOR (TE only) WIRE BAND (TE only) MAIN WIRE HARNESS (for angle sensor) WIRE BAND {TE only) MAIN WIRE HARNESS (for angle sensor} SHIFT CONTROL MOTOR WIREGENERAL INFORMATION CLAMP: THROTTLE CABLE REAR BRAKE CABLE CARBURETOR CHOKE CABLE AIR VENT HOSE REAR BRAKE CABLE THROTTLE CABLE REAR BRAKE CABLE if = ft Gp SS, eC BRAKE LIGHT SWITCH 2P GREEN CONNECTOR REAR BRAKE VEHICLE SPEED LIGHT SWITCH SENSOR WIRE REAR BRAKE CABLE (LEVER SIDE) REAR BRAKE CABLE (PEDAL SIDE)GENERAL INFORMATION CARBURETOR ( REVERSE SELECTOR CABLE a VENTRCSE © Rake onUM BREATHER HOSE FINAL DRIVE GEAR, CHOKE CABLE « CASE BREATHER HOSE FUEL HOSE THROTTLE CABLE IGNITION COIL WIRE REAR BRAKE LIGHT SWITCH CONNECTOR REAR BRAKE LIGHT SWITCH CLAM: MAIN WIRE HARNESS “REVERSE SELECTOR CABLE “BATTERY GROUND CABLE GROUND CABLE BRAKE DRUM BREATHER HOSE - GEAR CASE BREATHER HOSE STARTER MOTOR BRAKE DRUM BREATHER HOSE GEAR POSITION ‘SWITCH WIRE FINAL DRIVE GEAR ‘CASE BREATHER HOSE VEHICLE SPEED SENSOR WIRE BATTERY GROUND CABLE ALTERNATOR WIRE GROUND CABLE 1-25 RIDE REDGENERAL INFORMATION BATTERY GROUND CABLE CLAMP: —— ‘MAIN WIRE HARNESS REVERSE SELECTOR CABLE BATTERY GROUND CABLE — GROUND CABLE BRAKE DRUM BREATHER HOSE GEAR CASE BREATHER HOSE GEAR POSITION REAR BRAKE CABLE SWITCH WIRE GROUND CABLE VEHICLE SPEED ‘SENSOR WIRE CLAMP: REGULATOR’ TION coi. * MAIN WIRE HARNESS RECTIFIER JGNITION co» MAIN WIRE HARES ALTERNATOR 3P REVERSE SELECTOR CABLE RED CONNECTOR GEAR CASE BREATHER HOSE BRAKE DRUM BREATHER HOSE ‘VEHICLE SPEED SENSOR WIRE GEAR POSITION SWITCH WIRE ALTERNATOR WIRE VEHICLE SPEED SENSOR CONNECTOR GEAR POSITION SWITCH 6P CONNECTOR CLAMP: MAIN WIRE HARNESS REVERSE SELECTOR CABLE GEAR POSITION BATTERY GROUND CABLE ‘SWITCH CONNECTORS GROUND CABLE BRAKE DRUM BREATHER HOSE cuame: A | GEAR CASE BREATHER HOSE ‘STARTER MOTOR CABLE REVERSE SELECTOR CABLE ) BATTERY GROUND CABLE YLGENERAL INFORMATION BRAKEDRUM MAIN WIRE HARNESS CLAMP: BREATHER HOSE GROUND WIRE MAIN WIRE HARNESS: STARTER MOTOR CABLE SPARK PLUG WIRE BATTERY GROUND CABLE FINAL ORIVE GeaR > [C CASE BREATHER HOSE MAIN WIRE HARNESS REVERSE SELECTOR CABLE ALTERNATOR WIRE CLAM: MAIN WIRE HARNESS ALTERNATOR WIRE BRAKE/TAIL LIGHT REVERSE SELECTOR CABLE CONNECTOR GEAR CASE BREATHER HOSE BRAKE DRUM BREATHER HOSE ‘VEHICLE SPEED SENSOR WIRE GEAR POSITION SWITCH WIRE CLAMP: MAIN WIRE HARNESS STARTER MOTOR CABLE BATTERY GROUND CABLE BRAKE DRUM AME BREATHER HOSE MAIN WIRE HARNESS. REVERSE SELECTOR CABLE BATTERY GROUND CABLE GROUND CABLE BRAKE DRUM BREATHER HOSE GEAR CASE BREATHER HOSE FINAL DRIVE GEAR CASE BREATHER HOSE GROUND CABLE ALTERNATOR CLAMP: CONNECTOR: STARTER MOTOR CABLE IGNITION PULSE REVERSE SELECTOR CABLE BATTERY GROUND CABLE. GENERATOR CONNECTOR BRAKE/TAIL LIGHT ‘CONNECTOR BRAKE/TAIL LIGHT WIRE > @ MAIN WIRE HARNESS ~ BRAKE/TAIL LIGHT WIRE TOOLBOX LIDGENERAL INFORMATION REAR BRAKE LIGHT CLAMP: ‘SWITCH WIRE “MAIN WIRE HARNESS STARTER MOTOR CABLE BATTERY GROUND CABLE cLame: REAR BRAKE CABLE HS e BRAKE DRUM BREATHER HOSE finaLonve cean ~~ | REAR BRAKE LIGHT SWITCH ) | cASEBREATIENHSE | STARTER RELAY FUSE 1P CONNECTOR (TM) SWITCH 2P CONNECTOR FUSE 2P CONNECTOR (TE) FUSE 15.8 STARTER MOTOR CABLE FUSE 30 A (TE only) ~ sarreny o- ae arta eGENERAL INFORMATION ENGINE BATTERY GROUND CABLE u ———— sartery MAIN WIRE HARNESS GROUND TERMINAL REGULATORIRECTIFIER GROUND CABLE FRONT SIDE OF ENGINE (for TE) 6 s- GUIDE PLATE SHIFTCONTROL MOTOR ANGLE SENSOR REAR SIDE OF ENGINE: GROUND CABLE BATTERY GROUND CABLE VEHICLE SPEED SENSOR WIRE GEAR POSITION SWITCH WIRE REVERSE SELECTOR CABLE REVERSE SHIFT SWITCH [TE only] 1-29 RIDE REDGENERAL INFORMATION EMISSION CONTROL SYSTEMS ‘The US. Environmental Protection Agency (EPA) and the California Air Resources Board (CARB) require that ATV comply ‘with applicable exhaust emissions standards during Its useful life, when operated and maintained according to the instruc- tion provided: SOURCE OF EMISSIONS The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when sub- jected to sunlight. Carbon monoxide doos not react in the same way, but itis toxic, Honda Motor Co,, Ltd. utilizes appropriate carburetor settings as well as other systems, to reduce oxides of nitrogen, car bon monoxide and hydrocarbons. EXHAUST EMISSION CONTROL SYSTEM ‘The exhaust emission control system is composed of an appropriate carburetor setting, and no adjustments should be ‘made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the ‘erankcase emission control systems CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere, Blow-by gas is returned to the combustion chamber through the air cleaner connecting tube and carburetor, AIR CLEANER, CARBURETOR CRANKCASE <== | FRESH AIR DRAIN HOSE BREATHER HOSE sowsy cas SERVICING THE HONDA USA. only Maintenance, replacement or repair of th establishment or individual using parts th PROHIBITED ACTIONS ‘The following prohibitions apply to everyone with respect to the engine’s emission control system, ‘You may not remove or disable any device or element of design that may affect an engine’s emission levels. This restric- tion applies before and after the engine is placad in service. mmission control devices and system may be performed by any ATV repair “certified” to EPA standards. 1-30 RIDE RED