1997-2001 Honda TRX250 Fourtrax Recon ATV Repair Manual

IMPORTANT SAFETY NOTICE m.,* "o, Indicat". strong possibility of uvere persona' injury or da.th if instructions .,e not followed. CAUTION: Indicates. possibility of equipment chmage jf instructions IIr. not followfii . NOTE Gives helpful information. Detailed descriptions of standard workshop procedur es, safety principles and service operations afe not included. It is importa nt to note that this manual contains some warnings and ca utions against some specific service methods which CQu id cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in wh ich servi ce , whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anvone using service procedures or tools, whether or not recommended by Honda, must satisfy hi mself thoroughfythat ne ither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected. j

HOW TO USE THIS MANUAL This service manual describes the service procedu res for the TRX250 TM/TE (Recon), Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the California Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Sections 4 through 21 describe parts of the vehicle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting f or the section. The subsequent pages give detailed procedure. If you do not know the source of the trouble, go to section 22, Troubleshooting . z ;;: a: ~ ~ a: c c z « w z a z w .... 1'l a: t; w .... w CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/CYLINDER/PISTON CLUTCH GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKSHAFT/TRANSMISSION FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION BRAKE SYSTEM REAR DRIVING MECHANISM BATIERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/SWITCHES WIRING DIAGRAMS TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols . fI Replace the part(s) with new one(s) before assembl y. , Use recommended engine oi1. unless otherwise specified. , Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1). - ~ Use multi ·purpose grease (lithium based multi -purpose grease NLGI :;:: 2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI :t 2 or ~ equivalent). Example: Molykote e 8R-2 plus manufactured by Dow Corning, U.S.A. Multi-purpose M -2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI = 2 or equivalent). ~ Example: Molykote. BR·2 plus, manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.SA only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan ...-'iSit1 Use silicone grease. C) "" Apply a locking agent. Use a middle strength locking agent unless otherwise specified. ,",' WI Apply sealant. • Use DOT 3 or DOT 4 brake fluid . Use the recommended brake fluid unless otherwise specified . ... Use Fork or Suspension Fluid.

1. GENERAL INFORMATION GENERAL SAFETY 1·1 SERVICE RULES 1·2 MODEL IDENTIFICATION 1·3 SPECIFICATIONS 1· 4 TOROUE VALUES 1·13 TOOLS 1· 16 GENERAL SAFETY CARBON MONOXIDE If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause los$ of consciousness Bnd may lead to death. Aun the engine in an open area or with an exhaust evacuation system in an enclosed area. GASOLINE Work in a well venti lated area. Keep cigarettes, flames or sparks away from the wo rk areB or where gasoline is stored. '¥i";IIU,,,, Gasoline is extremely flammable Bnd is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS '''14'*''''' Engine Bnd exhaust s ystem parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts . LUBRICATION & SEAL POINTS 1·18 CABLE & HARNESS ROUTING 1·21 EMISSION CONTROL SYSTEMS 1·32 EMISSION CONTROL INFORMATION LABEL (CALIFORNIA TYPE ONLY) 1·33 USED ENGINE Oil Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is stiJI advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil . KEEP OUT OF REACH OF CHILDREN. BRAKE FLUID CAUTION: Spilling fluid on painted , plastic or rubber parts wiJI damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. Use an OSHA- approved vacuum cleaner or alternate method approved by OSHA, designed to minimi 2e the ha2ard caused by airborne asbestos fibers. ,ry4"d1iUQ Inhaled asbestos fibers have been found to cause respiratory disease and cancer. .. 1-1

GENERAL INFORMATION BATIERY HYDROGEN GAS & ELECTROLYTE • The battery gives off explosive g8$8S; keep sparks, flames and cigare ttes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (e lectrolyte). Contact with skin or eyes may cause severe burns. Wear protec- tive clothing and a face shield. - If electrolyte gets on your skin, flush with water. - If electrolyte gets in your eyes, flush with water for at least 15 minutes and ca ll II physician immediately. • Electrolyte is poisonous. - If swa llowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call 8 physician. KEEP OUT OF REACH OF CHILDREN. SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that do not meet HONDA's 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 t oo ls when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. 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 in cleaning solvent upon disassembly. lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all cable and harness routing as shown on pages 1-21 through 1 -31 Cable and Harness Routing. 1-2

MODEL IDENTIFICATION '97 SHOWN; AFTER '97 SIMILAR FRAME SERIAL NUMBER The frame serial number is stamped on the front of the frame. The carburetor identification numbers afe stamped on the right side of the carburetor body as shown. GENERAL INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the rear half of the lower crankcase, viewed from the right side. The color label is attached to the frame under the seat as shown. When ordering color·coded parts, always specify the designated color code. 1-3

GENERAL INFORMATION SPECIFICATIONS - GENERAL ITEM SPECIFICATIONS DIMENSIONS Overall length 1,794 mm (70.6 in) Overall width 1,034 mm (40.7 in) Overall height 1,054 mm (41 ,5 in) Wheelbase 1,131 mrn (44.5 in) Front tread 783 mm (30.8 in) Rear tread 780 mm (30.7 in) Seat height 777 mm (30.6 in) Footpeg height '97 - 2001: 298 mm ( 11 .7 in) After 2001 : TM: 29B mm (11.7 in) n-E: 306 mm (12.0 in) Ground clearance 152 mm (6. 0 in) Dry weight '97 - 2001: laO kg (397 I bsl After 2001: TM: 184 kg (406 IbsVTE: 188 kg (414 Ibsl Curb weight '97 - 2001: 188 kg (414Ibs) After 2001: TM : 191 kg (421 IbsVTE: 195 kg (430 Ibs) r, RAME Maximum weicht C808Citv 175 ka (386 Ibs) Frame type Double cradle Front suspension Double wish-bone Front wheel travel 130 mm (5. 1 in) Front damper Double tube Rear suspension Swingarm Rear wheel travel 125 mm (4.9 in) Rear damper Double tube Front tire size AT22 x 7·11 * Rear tire size AT22 X 10-9 * Front r im size '1 X 5.5 AT Rear rim size 9 X 8.0 AT Tire brand (Goodyear) FRIRR TRACKER HP Front brake Hydraulic drum brake Rear brake Mechanical drum brake To. Toe-in: 8 mm (5/16 in) Caster angle S" Camber angle 0.1 ° Trail length 42 mm (1 ·5/8 in) Fuel tank capacity 9.1 Q (2.40 US gal, 2.00 Imp gall !eNG INE Fuel tank reserve ca pa city 2.4' (0.63 US gal . 0.53 Imp ga(i Bore and stroke 68.5 X 62.2 mm (2.70 X 2.45 in) Displacement 229 cm' (14.0 cu-in) Compression ratio 9.0: , Valve train Overhead valve Intake valve opens 8° BTDC Intake valve closes 37 ° ABDC Exhaust valve opens 38 0 BeDC Exhaust valve closes 7° ATDC Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Air cooled Air filtration Oiled double urethane Crankshaft type Unit type, two main journals Engine dry weight '97 - 2001: 34.6 kg (76.3 IbsJ After 2001 : TM: 35.9 kg (79.1 Ibs) rrE: 37.4 kg (82.5IbsJ Cylinder arrangement Single cylinder lonQitudinally installed 1-4

GENERAL INFORMATION - GENERAL (Cont'd) ITEM SPECIFICATIONS CARBURETOR Carburetor type Piston valve Throttle bore 20 mm (0.8 in) DRIVE TRAIN Clutch system Centrifugal & mu lti-plate, wet Clutch operation system Automatic Transmission Constant mesh, 5-speed with reverse Primary reduction 3.086 (11 / 23) Final reduction 3.692 (48/13) Gear ratio '97 - 2001: ,,, 3.545 (39/ 11) 2nd 2.267(34/15) 3,d 1.B31 (31/19) 4th 1.273 (2Bj 22) 5th , .042 (25/24) Reverse 5.850 (39/ 20 X 33/11) After 2001: ,,, 3.231 (42/ 13) 2nd 2.167 (39/18) 3,d 1.667(35/ 21) 4th 1.280{32/25) 5th 1.042 (25/24) Reverse 5.550 (39!20 X 37 j13) Gearshift pattern left fool operated return system \'97 - 2001 /After 2001: TM) Electric shift (left hand operated) return system (After 2001: TE ) R N , 2 3 4 5 ELECTRICAL Ignition system AC-CDI Starting system Starter motor and emer gency recoil starter Charging system Single phase output alternator Regu lator/rect ifie r SCR shorted/ single phase full wave rectification Liohtino s stem Battery 1-5

GENERAL INFORMATION , LUBRICATION SYSTEM Unit' mm (in) ITEM SPECIFICATIONS SERVICE LIMIT Engine oil capacity At draining ' 97 2001 1.6 Q {l .7 US t 1.41m II After 2001 1.5 Q (1 .6 US CIt . 1.31mp CIt) At disassembly '97 2001 1.811 (1 .9 US qt 1.61mp qt) After 2001 1.911 (2 .0 US qt, 1.71m II Recommended engine oil HONDA GN4 4-stroke oil or equivalent motor oil API service classification Sf or SG - Oil pump rotor ~~ clearance 0. 15 (0.006) 0.20 (0.008) - Bodv clearance 0.15 0.21 0.006 0.008) 0.25 ( 0.010 ) Side clearance 0.05 0.13 (0. 002 0.005) 0.15 (0.006) , FUEL SYSTEM ITEM SPECIFICATIONS Carburetor '97 (exee t California type) PDCle identification number ' 97 California 98 2001 All " PDC 1C After 2001 PDC1 E Main 'at #95 - Slow ' at #38 Jet needle clip ' 97 3rd groove from top I position After ' 97 2nd groove from top Pilot Initial ' 97 {exee t California el 27/8 turns out screw opening ' 97 California e 2-3/4 turns out '98 2001 2-5/8 turns out After 2001 2 turns out H; h altitude settin 1/8 turns in from initial a enin Float level 14 mm (0.6 in) Idle speed 1 400 ± 100 rpm Throttle lever free I, 3 8 mm(1/8 5/ 16 in) 1-6

1997-2001 Honda TRX250 Fourtrax Recon ATV Repair Manual

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