Honda Recon TRX250 2005-2007 Factory Service & Work Shop Manual

HOW TO USE THIS MANUAL Thla IfIIVICO!! manu,,1 c\e$CrJbes the MNIOe ~dur" lor the TRX250 TMfTE (Recon) Folow !he Malnlenance Schedule (Seclooo 3) rec:onvnenaabOllS lei _that !he Whode .. If! peM OP8f81"IiJ conduoon and emoSSlOllievell .,. wllI'llll !he 5tandllfOil set by the Cahfornla Iur RelOUfC815 Board (CARB) PWIomwIg the lira! KheOuIed mBlOtenaoce IS vety rrnpoftant It ~I8S lor the Iflcllll_r \hilt occtJf'I dunng Itle bteak·1n penod s..::t.on. 1 and 3 II~ to the ~ ve/"oIcIe SedIOI'I 2 lluWaleS pl'QClldures lor remov,V'fI!Ilaliabon of eomponen~ tnat may be requlllld to perlonn WI'tICe descnhed '" tile (oHoW'"1I MICtIOn! Sed>onl -4 through 20 (Iesaibe partl oIlhe vehickl. grouped 80C0(dl~ ''',,'''''' FincI the MdIon you want 0Il1h1S pege then tum 10 !he table 01 contents on me first page or tne taCtIon Most MClIOt'IS start Wlth an 8ssembty Of system llluslra~n. HNiee informellOO snd lI'OUOiesIIootong lor the IIICbOO The BUbsequel1l pages g_ deglled proc:edlJ'U 11 you don' """"" the soun:;e 01 !he trouble \10 10 Secbon 22 Troubleshooting Your salety ana tne !lalely of ~ "vety ~ To help you meke ..,Iormed daoIooni _ tIave pI'OIiIded safety messages and 0Ihef onfoomatoon Ihrougtooul mta mll/lUaI 01 COlnII, M iii 00\ pr&CtlC3l or possible 10 warn you aboulaU the hazards assoaClled wllh Mlf'VlClng till • .,.t"de Vou must uM your 0Wf0 g>ood judgement YOU wlM Iinl Important safety llllorTntItJon in a VII!>&ty of Iormt - • Sefe!y Labels - on the vehicle • Safety Meuages - preceded by • safely ale" symbol .i wid one oIlhrge IoIgnal words, DANGER, WARNING. or CAUTION These siglllli wonK mean" W¥MMil ~~RT~I~:n,~=~OUSlY You CAN bot KILLED or SERIOUSLY HURT ID'e''±'i t t' '' t''''' " you donl follow instructlOnll You CAN be HURT " you don'l 'oIIow GIf4I""I£' nslruCllon. • II'IIIn.IctIornI - t>ow 10 1I8I'VICtI1tu .... htde cornoctIy aIld aalely N you lead IIlIS manual. you WIll lind Inlonnanon Ihal" Pfeoeded by a L!tOt'I([" symbol The purpose or this mft~ I. 10 help preIIltnl demage to you' YIIhIde. other property Of !he ItnYlfonment z ~ 0- W ~ 0: C C Z " W Z " Z W -' II ~ u W -' W GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVE CYLINDERJPISTON/CAM CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKCASEITRANSMISSION/CRANKSHAFT FRONT WHEEUSUSPENSION/STEERING REAR WHEE USUS PENSION BRAKE SYSTEM REAR DRIVING MECHANISM BATIERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES ELECTRIC SHIFT PROGRAM 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 telCt without the use of the symbols, ~ Replace the part(s) with new ooe(s) before assembly. , Use recommended engine oil, unless otherwise specified . 78 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1), • ..w;.. I Use multi-purpose grease (lithium based mutti-purpose grease NLGI #2 or equivalent). - I Use motytxJenum disulfide grease (oontaining more than 3% molybdenum disulfide, NLGI #2 or equivalent). ~ Example: Molykote4D BR-2 Plus manufaClured by Dow Corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan I Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NlGI #2 or equivalent). Example: Molykotee G-n Paste manufactured by Dow Corning. U.S.A. ~ Honda MOly 60 (U.S.A. only) Rocol ASP manufactured by Rocol limited. U.K. Rocot Paste manufactured by Sumico Luoocanl , Japan ,...riSi.i Use silicone grease. - 1m Apply a locking agent. Use a medium strength locking agent unless otherwise specified. ",' ftlll Use sealant. I Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. I , .. Use fOf1( or suspension fluid .

1. GENERAL INFORMATION SERVICE RULES .................. .......................... '-2 MODEL IDENTIFiCATION ······························ ' -2 GENERAL SPECiFiCATIONS························· ' -4 LUBRICATION SYSTEM SPECiFiCATIONS······ ·· ················· ··············· .. . ' -6 FUEL SYSTEM SPECiFiCATiONS ············ ····· '-6 CYLINDER HEAD/CYLINDER/PISTON SPECiFiCATIONS········································ ... '-7 CLUTCH SPECIFICATIONS ........................... ' -7 CRANKSHAFT/TRANSMISSION SPECiFiCATIONS ··· ·· ··································· ... '-8 FRONT WHEEL/SUSPENSION/STEERING SPECiFiCATIONS········································ ... '-8 REAR WHEEL/SUSPENSION SPECiFiCATIONS········································ ... '-8 BRAKE SYSTEM SPECiFiCATIONS ·············· '-9 REAR DRIVING MECHANISM SPECiFiCATIONS···························· ·· ·············· ' -9 BAITERY /CHARGING SYSTEM SPECiFiCATIONS············································'-9 IGNITION SYSTEM SPECIFICATIONS ·········· '-9 ELECTRIC STARTER SPECIFICATIONS ······ '-'0 LIGHTS/ SWITCHES SPECIFICATIONS ·······'-'0 STANDARD TORQUE VALUES··················· ,-" ENGINE & FRAME TORQUE VALUES ········ , -" LUBRICATION & SEAL POINTS ··················'-'5 CABLE & HARNESS ROUTING ··················· ' -'9 EMISSION CONTROL SYSTEMS ················ ' - 30 EMISSION CONTROL INFORMATION LABEL (U.S.A. only) ·····································'-32 .. 1-1

GENERAL INFORMATION 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 tools 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 electrical wires as shown in the Cable & Harness routing !page 1-19). MODEL IDENTIFICATION This manual covers 2 types of TRX250 models: • TM - Left foot operated gearshift • TE - Electric shift program (ESP) Be sure to refer to the procedure that pertains to the appropriate version of the TRX250. TRX250 TE shown: The Model Identification l abel is localed on the left side frame down r--:-:-:-:c::--::c::-==-::-:-=:-cc-c::-::------, pipe. MODEL IDENTIFICATION LABEL 1-2

The vehicle identification number ~VIN ) is stamped on the front side of the frame, GENERAL INFORMATION VIN o The engine serial number is stamped on the right side of the rear :=========",~o========::; crankcase. D ENGINE SERIAL NUMBER The color label is attached on the left frame pipe under the seat. When :==================~ ordering color - coded parts, always specify the designated color code. COLOR LABEL carburetor body. The carburetor ide ntification number is stamped on the left side of the r=::~~~~~~~~~~~~~=1 CARBURETOR IDENTIFICATION NUMBER 1-3

GENERAL INFORMATION GENERAL SPECIFICATIONS I DIMENSIONS ITEM Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight Cu rb weight 1,905 mm (75.0 in) 1,035 mm (40.7 in) 1,065 mm (4 1.9 in) 1,130 mm (44.5 in) 785 mm (30.9 in) 780 mm (30.7 in) 795 mm (3 1.3 in) 320 mm (12.6 in) 150 mm (5.9 in) SPEC IFI CA TI ONS TM: 190 kg (4 19Ibs) TE: 193 kg (425 Ibs) TM: 197 kg (434 Ibs) TE: 201 kg (443 Ibs) 1_",..,~ ______ -+-<M~.~'~im~"~mocwe"i,g~h~ t~ ,~e~p~.'~i~tY~ ______ -+-i '7 25~ kg~13~8~6~'~ b '~I~ __________________________ -+ r FRAME 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 rim size 11 x 5,5 AT Rear rim size 9 x 8.0 AT Front tire brand TRACKER HP (Goodyear) Rear tire brand TR AC KER HP (Goodyear) Front brake Hydraulic drum brake Rear brake Mechanical drum brake Caster angle 8 0 Trail length 42 mm (1-518 in) Camber angle 0.1 0 Fuel tank capacity 9.1 liters (2.40 US gal, 2.00 Imp gal) L """"c,o ______ -+-i Fuel tank reserve capacity 2.4 liters (0.63 US gal, 0.53 Imp gal) I ENGINE Cylinder arrangement Single cylinder, longitudinally ins~t~,'~le~d.------------1 Bore and stroke 68.5 x 62.2 mm (2.70 )( 2.45 in) Displacement 229.2 cm 3 (14.0 cu-in) Compression ratio 9.2: 1 Valve train OHV Intake valve opens 50 BTDC (at 1 mm lift) closes 31 0 ABDC (at 1 mm lift) Exhaust valve opens 30 0 BBDC (at 1 mm lift) closes 3 0 ATDC (at 1 mm lift) lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Air cooled (wi th oil cooler) Air filtration Oiled double urethane foam Engine dry weight TM: 35.9 kg (79.1 Ibs) __ -+-iE;: ng~iic;n:oe"d~ ", .w"'e" i !"gh c: I '---__________ ---1I--i T "E", :c37:::.4~k:g':",,82"'.,5,,'b""'- I ----------------------__1 CARBURETOR Carburetor type Piston valve Throt1le bore 20 mm (0.8 in) 1-4 I I ~ , I

ITEM DRIVE TRAIN I Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio ,,, 2nd 3,d 4,h 5th Reverse Gearshift pattern ELECTRICAL 19 nition system Starting system Charging system Reg u Iat orfrectifier lighting system GENERAL INFORMATION SPECIFICATIONS Centrifugal and multi-plate, wei Automatic Con slant mesh, 5-speed with reverse 3.086 (71123) 3.692 (48/13) 3.231 (42/13) 2.167 (39/18 ) 1.667 (35121) 1.280 (32/25) 1.042 (25/24) 5.550 (39/20 x 37113) R-N-1 -2-3-4-5 TM: Left foot operated return syst em _ __ -t---i;T;:E;-;: El ectric shift (left hand operated) return system AC-CDI Electric starter motor and emergency recoil starter Single phase output alternator I SeA shorted, triple phase full wave rectification Battery I 1-5

GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS FUEL SYSTEM SPECIFICATIONS il screw 1-6 lent motor oil API service Cl8ssification: SG or Higher JASO T 903 standa rd: MA /

GENERAL INFORMATION CYLINDER HEAD/CYLINDER/PISTON SPECIFICATIONS ITEM I ",800 'pm valve "em u.u. . Valve g,lde 1.0. I INI EX EX IN IN!EX looe' Unit: mm (ir , ,(13 '0 !~ 185 psi) - 1.13 0.005) - 5.455 - 5.470 . 5.43 0.21') - 5.500 - 5.5 1; :~~~~.' : ~'~n'<; 0.010 - 0.037. . ~ ) 2.4 (1. . 5;;~ -- r ~ 6(6) - ~ ;;Ro",e;;,:a~~'m~4~ '1 ~'; = mma~ft"~ O)"D;:":J~ )N~IEE ~ Xji 2.018 4 - Ws""==t jffuJ ~2bi[1.6k9)= INI EX . ;'O;~6_-0'~io':%i I2Df- Wa1.B~6~) "m followe, Cam lobe height -'" ~~:::;~~~= ~~~~: Tf3f Com OD j---iNjEX ~~ 1) - ;;~~;;; ~ '-, "boce I.D.· QN7EX _ 22.51O"22.526~. -' 225~:~J8F-::- I INI EX - O. - 0.059 (0.00" - i (0.003) _ 68.510 - o. Tape, _ ~:~ :~o", ""ton nn9 eno gap 68.462 : 68.482 ) 68.40 ~~~3 - -i4994 - 15.000 ~.~ r=::P. '4~' .. 9~60~.589!=) - 0:20 - 0.35 (o.o%%' - 0.014) 0.5 (0 ~ 0.40 - 0.55 (0.016 - 0.022) 0.7 (0.03) 0.20 - 0. 70 (0.008 - 0.028) CLUTCH SPECIFICATIONS Unit' mm (in) ITEM STANDARD SERVICE LIMIT ) Change clutch Spring free length TM - f- 35.2 (1.39) 34.5 (1.36) I--- Oisc thickness TE 37.0 (1.46) 36.3 (1.43) 2.9 - 3.0 (0.11 0.12) 2.6 (0.10) r- ;Iate warpage 0.20 (O.OOB) _ Outer 1.0. 28.000 28.021 (1.1024 1.1032) 28.04 (1.104) Outer guide 0.0. 27.959 27.980 (1.1007 1.1016) 27.92 (t099) Centrifugal ~~I.D. 11 6.00 "6. 20 (4.567 4.575) "6.5 (4.59) [ Weight lining thickness 2.0 (0.08) 1.2 (0.05) Clutch spring height 3.0 (0.12) 2.85 (0.112) Clutch weight spring free length 30.75 (1.211) 31.6 (1.24) I Drum bushing 1.0. 24.000 - 24.021 (0.9449 0.9457) 24.05 (0.947) Crankshaft 0 .0 . at drive gear , 23. 959 23.980 (0.9433 0.9441) 23.93 (0.942) 1-7

Honda Recon TRX250 2005-2007 Factory Service & Work Shop Manual

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