2003-2005 Rincon 650 TRX650 Service & Repair Manual

A Few Wo rds Abo ut Safe ty Service Info rm ation The service and repair in/OIlTIation contained in th~ manual is intended for use by qualilied, professional tecllnicians, Anempling service 0< repairs withol.llthe prQger training, tools, and equipmenl could C$use injury to 1'00 or others, II could also damage tile vellide or Cleate an unsafe condition, This manual describes tile proper methods and procedures for perfooning service, maintenance, and repairs, Some ptocedures require t!)e use of specialty designed toots and (!edicatoo eo;r..oipmeol. AllY person WilD inlends to use a replacemeot pan, service procedure or a looIlIlal is not recommended by Honda, must determine Ihe risks to t!)eir personal safety and the sale operation 01 the v~lcle, If you need to replace a pari, l>Se genuine Honda pans w~h tM correct pan Ilumber or all equ;val,mt part, We strongty recommend that you do 001 usc replaoemont P<'rtl> 01 inferiOr quality, For Your Customer's Safety Proper seNice and maintenance are essential to the customer's saJety and the reliabitity 01 the vehicle. AffoJ error or oversight while servicing a vehicle can fe5uH in faulty operation, damage to the vehicle. or injury to others. For Your Safety Because this maoual is iolended lor the professional service tecllnician, m do not provide wami ngs about many basiC shO!) sal oty practices (e.9., Hot parts-wear gloll1)s) . II you have not received shO!) salety treining or do nol leet confidant about your knowledge of safe sCIVicing practice, we recommended that you do not at1empt to perform the procedures described irlthis manual. Some of the O1"IO$t important general service safety precautions are giWln below. However, we cannot warn you of eVlilry conceivable hazard thaI can arise in porforming service and repllir prooedur6S. Only you can decide whether or not you shoUld perform a givlm task. can cause you to be seriously hurt or k ;I!&d. Important Safety Pre cautions AWARNING Improper service or repairs can create an unsafe condition Ihat can cause your customer or others to be seriously lIurt or killed. Follow the procedures and pr&C3ubons in t!1is manual and otller service materials carefully. AWARNING Failure to property lollow instructions and precautions can cause you 10 be seriousty hurt or killed. Follow the procedures and preeautions In t!1;s manual carefulty. Make sure you have a clear understanding 01 all basic shop safely practices aod that you are wearing appropriate clothing and using safety equipment. When performing any service taSk. be especially careful 01 the following: • Read all 01 the instl1lClions belo(8 you begin, and make sure you have the 100ls, IhO replacemCl'11 or repair parts, and the skills required to perform the tasks safely and oompletely. • Proted your eyes by using preper salety glasses, goggles or face Shields any time you hammer. drill, grind, pry or work around pressurized air 01 liquids, and springs or otllel stored-energy components. II there is affoJ doubt, put on eye protection. • Use othel pfotecli~e wear when necessary, lor example gloves or safety shoes. Handling flo{ or sllarp parts carl cause severe burns or cuts. Before you grab something that 1000 like it can hurl you. stop and put on gloves. • Protect yourself and Olhers whenevor you have the vehiCle up in the eir. Ally lime you lilt the vehicle, either with a hoiSt or a jack. make sure that rt is always securety support&d. Use Jad<: stands. Make sure the engine Is off before you begin any servicing procedures, unless the instruc1ion tells you to do otherwise. This will help eliminate severat potential hazardS: ' • Carbon monoxide poisoning from engine exhaust. Sa sure there is adequate ventilation whenever you run Ihe eng,ne. • Bums from hoi part<; or coolan1. Let the engine and exhaust system cool before working if) Ihose areas • Injury lrom moving parts. If tile instl\lCliontells you to filii the engine, be sure your hands, fingers and cklthing are out of the way . Ga&Oline vapors and lIydrogen gases trom batteries are explosive. To reduce tile posSibility of a fire or expfosion, be carelul wilen working around gasdine or batteries. • US& onty a non1Tsmmabie $Owent, f)()t gaser,nc. to clean parts. • Never drain or slor o gasoline in an open conlainef. • Keep all cigarettes, sparks and llames away from Ihe battery and a ll fuel·related pans.

HOW TO USE THIS MANUAL This """""" "'"""'" 00""-. "'" "''''"''' p"""","",. lor IJIe Tll X650FA 1'<0_ t'" Ma." .... """ -... (Sac!"" 3) _do tlon< to """.." , .. , tOo .... _ 10 In pota k """f31o.g oon<IItlon Md ",. ~ _ are WdrIin me _landa,,,,, .. I tI'r tile Coik>mia .&.Ir I1MOu1oes Board (CAHB) Perro.rr;"Il the r..- _oM<! ma",~ ~ ""'I' 1tnpo<IaroI. II ~I" lot ..... Itl illal-.r 'hat occurs o;klnng t .. br ... ..... .-;ad_ 5oc1io.. 1 IUld 3 apply to ,he __ dO. s..ction 2 iIIu.trlllOs Pf~'" !of """""allin' ta la t.", o! ~ tt>at may bo rnqo..ored ttl pe<lo<m .. ~ <Io$crlbed In "'" Iolloooing ~iono -.. ~ """'-'9h 24 """""'" parIS o! tho ""_. groupod occarn;ng to Ioca'"",_ Fond !he...ctIOO roo \OTdlI on 11'0. pag". then rum 10 the , oDI& ot """'crib on !he fi"" page 01 tOO ""'-on. ",..,.. W<'\IOnO ot M _ an ...-y 0< oyotom "' .. lra_. "'Moo 0010""",.,.., and _""""mg to. !t>e _. The ~ 1'0\)0'$ gMo OOIa i lO<l JX~r&, If roo ""'" know 11>0 """"0 01 "'" "auble, goo '" _ 27 T~log, y"", •• fety, and!he .. My oIOfl>Mo, if .. 'Y importan t. To help roo ma)ce inIoo'm<>d __ .... llaw por_ H ie\)' moSSoagO$ and 0 .... ' o-.tom> •• 1on II'IIOIJghooA !hie mao ...... Of OOO'fSO, ~ Ii; I'lOl prao1l~ Ot pooosil)le '0 "'am roo al>OuI "'I "'" ...... <do assotia'od ...;m -*Jng IM _. Yoo " .... , .... )'OUr """ IJOOd ~ You .,.. fir>:,! importan1 oaloty .. _ in a ... iel)l of Iorm. W>ckldi"ll • Sal...,. Lobols _ 00 tOO .... hiel • • S418~ ~ - P<~ b)' a ulery 016<1 .ymt>ol Lh aM <>nO 01 tI ... e.ogn.1 "",ro.. DANGEn, WMlNIIfG. or C"'UTIO~, ThtIU .ig .. I_,," me"": V "" WIU bo Kl l LEO Of SER I OU~Y G"" m-W ' HU~T ~ roo CIO(I ', loIIow ... ,,,,,,,,,",,, You CAN.,., Kl lLEIl or SER IOUSLY HURT mj" · 'W"I'tJ ~ you don~ toIkYwin .. tuC1ions. y"" C"N bo H URT ~ yoo don' ~ C' ·""'t'tl in.m.:tion •. kl)'Ou ,.,...ttois "'.......ai.)'O<l .... fn;j ;m",mation 11 .. it p.eoedO<I by . I N QIIC[] oymboI. The pu!pOU 01 lhio me>Mgf> i. 10 tlclp """,,,,,, da~ 10 YOU' • ...,ielo . ""'&f p<opMy. or me """""""""". w z a z w CONTENTS GENERAL INFORMATI ON MAINTENAN CE LUBRIC ATI ON SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVEfCAMSHAFT CYLINDERIPISTON ALTERNATOR/STARTER CLUTCH SUB·TRANSMISSIONJGEARSHIFT LINKAGE AUTOMATIC TRAN SM ISSION CRANKCASE/CRANKSHAFT/BALANCER FRONT WHEELJSUSPENSIONISTEERING REAR WHEE USUS PEN SION BRAKE SYSTEM FRONT DRIVING MECHANISM REAR DRIVING MECHANISM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER lI GHTSfMETERSlSWITC HES SE LECTABLE 4WD SYSTEM SYSTEM WIRING DIAGRAM TEC HNI CAL FEATURE TROUBLESHOOTING INDEX

SYMBOLS The symbols \.ISed throughout this manual show specijic service procedures. If supplementary information is required pertain~9 to these symbols, it would be expllli"llo spedlie311y in !he le)(l without the use of the symbols. ~ Replace t he partes) with fleW one( s) before assembly. 'I Use the recommended engine oil, unless otherwise spWfied /Q Usc rnolybdef'lum oil $OluHon (mixlu1(~ of the engine oil and molybdenum grease in II ra~o of 1:1) .... am. Use mul!i-pu,po$e grease (lithium based mul1;·purpOSEl grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containi ng more Itlan 3"4 molybderlum oisullide. NLGI <r2 or equivalent) . ..... E><ample: Motykole$ SA-2 plus manufacturw by Dow Coming U.S.A, Multi-pur pose M·2 maJ'\l .. ~aclured by Mitsubishi Oil. Japan Use molybdenum disulfide paste (containing more ttlan 40% molybdenum disullide, NLGI 112 or equivalent). Example' MoIykoteC' G-o Paste manl,llacture(l by Oow Corning U.S.A- ~ Honda Moly 60 (U.S.A. only) Aocol ASP manufactured by Rocol Limited, UK Rocol Pasta manufactured by Sumico Lubficanl, Japan AiSio Use silioone gr9ase. "'11!1!1 Apptya locking agent Use a mooum slre;,gltllocking agel11 unless ottlerwise specified. AiSio Apply sealant I Use DDT 4 b ra k;e fiui<!_ Use the recommended brake Iluicluniess olherwi se speCified. GI Usa fork or suspension Hui tl.

1. GENERAL INFORMATION SERVICE RULES ................................... ........ ' -2 MODEL IDENTIFiCATION····················· ........ 1-2 GENERAL SPECiFiCATIONS················ ..... ... 1-5 LUBRICATION SYSTEM SPECIFICATIONS · ' -7 FUEL SYSTEM SPECIFICATIONS ················ ' -7 COOLING SYSTEM SPECIFICATIONS ······· ·· ' -7 CYLINDER HEADIVALVE/CAMSHAFT SPECIFICATIONS .......................................... ' -8 CYLINDER/PISTON SPECIFICATIONS 1-8 AL TERNATORI ST ARTER CLUTCH SPECIFICATIONS ········································· 1-8 SUB·TRANSMISSION/GEARSHIFT LINKAGE SPECiFiCATIONS····· .................... 1-9 AUTOMATIC TRANSMISSION SPECIFICA· liON S ····················································· .. ·· .. ·· 1-9 CRANKCASE/CRANKSHAFT/BALANCER SPECiFiCATIONS····················· .. ···· ·.... ··········· 1-9 FRONT WHEELI SUSPENSION /STEERING SPECiFiCATIONS········· ····················· 1-9 REAR WHEEl/SUSPEN SION SPECiFiCATIONS··································· ........ 1-9 BRAKE SYSTEM SPECIFICATIONS ············ '-10 FRONT DRIVING MECHANISM SPECiFiCATIONS····· .. ·· ······················ ·········· 1· 10 REAR DRIVING MECHANISM SPECiFiCATIONS········································,,'-10 BATI ERY /C HARGING SYSTEM SPECIFICATIONS ........ ... ·····························' -10 IGNITION SYSTEM SPECIFICATIONS ·······' - 11 ELECTRIC STARTER SPECIFICATIONS .... ·· 1- 11 LIGHTS/M ETERS /SWITCHES SPECiFiCATIONS····· ....................... ············ '· 11 STANDARD TORQUE VALUES····· ··············1· 12 ENGINE & FRAME TORQUE VALUES ...... ·· 1-1 2 TOOLS ·· .......... ·········· .... ······················ .. ········· 1-16 LUBRICATION & SEAL POINTS ............ ·· .... 1-18 CAB LE & HARNESS ROUTING ··········· .. · .. ··· 1·21 EMISSION CONTROL SYSTEMS ···············1·35 EMISSION CONTROL INFORMATION LABEL (U.S.A. only) .... .. ........... .......... .. ······· 1-36 1·1

GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their eQu ivalents. Parts that do not meet Honda's dosign specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metr ic bo lts. nuts and screws are not interchangeable w ith English fastelle,s. 4. Illsta!! new gaskets, O-rings, cotler pins. and lock plates whell reassembling. 5. When tightening boits or nuts . begin wi th tho la. ger diameter or ir lil er bolt first. Then tig hten to the specified torque diagonally in incremental steps unless a part icu lar seque rl ce is specified 6 Clean parts in cleaning solvent upon disassembly. lu bricate any aliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as show in the Cable arid Hamess Routi 'l g lpage 1·21). MODEL IDENTIFICA nON 1-2

GENERAL INFORMATION The model identification label is located on the frame down tube. U.S.A.: Carlada: The frame serial number is stamped on the fro" t side of the frame. The angine serial number is Stamped on the right side of the ,-- -------c- C----- -- , cranKcase. /"l~2'--<' ENGINE SERIAL NUMBER !~t~ /, "",,4. /'- ;rc; '< /.>._,J". ~v 1-3

GENERAL INFORMATION The clIrburetor identifiC"tion numb(' '' ;$ stamped on Ihe lett side of tho earburet or body. The color label; $ altachod 011 1 1'10 ri ght sido 01 the frame under the scat. ,----~--c=-__:---------_, Whon ord ering color coded pans, always specify the designated col or ;Y,f'~ code . ~~M~ 1-4

GENERAllNFORMATIQN GENERAL SPECIFICATIONS ITEM - SPECI FI CA TIONS DIMENSIONS Overalllen~~n 2, 125 riim (83.7 in) Overall widlh 1.171 mm (46.1 in) Overall height 1, 207 m m (47.!> in ) Wheelbase 1.289 mm (50.7 in) Front IJea el 915 mm 1 3&.0 in) Rear tread 945 mm (37.2 in) Seat height 875 mm (34.4 in ) Footpeg height 34 1 mm (13. 4 in) Ground clearance 254 m m (10.0 in ) Dr y weight 273 kg (600 Ibs) Curb weig ht 286 kg (63 1 Ibs) Maximum weight I:apaci ty 220 kg (485 Ibs) FRAM E Frame type Double Grad e Front suspension Double wish-bone Front wheel travel 175 mm (6.9 in) Front damper Double tu be Rear suspension Double wish-bo ne Rear wheel travel 203 mm (8.0 in) Rear damper Single tube Fr ont lire size AT25 x SR 12 Rca r tire size AT25 x 10R12 Front rim size 12 x 6.0AT ** Rea r rim size 12 x 7.5 AT * * Front tire brand H-TRAK UR10l IOHTSU) Rear tire brand H-TRAK UR301 IOH TS U) Front brake Hydraulic drum brake (Dual leading) Rear brake Hydrauli cl mechanil:sl disl: brake Caster angle 1.6 " Tr ail length 2.1 mmIO.08i n) Camber angle (p Fuel lank capacity 17 liters (4.5 US g81, 3.7 Imp gal) Fuallank reserve capacity 3.1 liters (0.82 US gal, 0.68 I mp ga l) ENG INE Cylinder arrangeme nt Single cylinder, longi tudinal ly installed Bore and stroke 100 )( 82.6 mm (3.9 x 3.25 in) Oisplal:ement 649 cm'139.6 cu-in) Compression ra t io 9.2 : 1 Va lve train OHV Intake valve opens at 1 mm (0.04 in l lift 8" BTDC Intake valve closes at 1 mm (0.04 in) lift 35 ABDC E)( haust valve ope ros at 1 mm (0.04 in) lift 40" BB DC E)(hauS I valve doses at 1 mm (0.04 in ) li ft 5° ATDe Lubrication system Forced pressure (dry sump) Oil pump type Trochoid Cooling system Liquid cooled Ai r filtration Oiled urethane foam Engine dry w eig hl 59 .8 k (131 .8Ibs) CARBURETOR Carburetor type Constant Vacu lJ m (V E type) Throttle bore 40 mm (1. 6 in) ~ - 1~5

GENERAL INFORMATION DR I VE TRA IN ITEM Transmission Shift clutch (1st, 2nd and 3rd clutchesl Primary reduct io " Socondary reduction Final reduction Transmission ratio Gearshift pattern - EL- ECCT"RmIC~AITL---I-====~-- F Ignition system 1-6 Starting system Charging system Regula t or/ rectifier Lighting system Forward Reverse Front Rear '" ,", 3" Reverse Sub-transmission o (Driv.,) R (Reverse) ~ SPECIFICATIONS I AutomatIC (Torque converter + 3 speed drrve system and reverse) I Multi plate, wet (hydraulIc clutch wIth eleetnc controlled) 1.333 (64/48) 2.000 (38119) 2.375138116) 3.230142/13) 3. 153141/13) 2.053 (39119) 1. 375 (33/24) 0.933(28130) 2.1 38 (39/19 x 25124) 0 - N - R 2-modfl; 3-spfled Automatic and Manual (ESP; 3 speeds) 1-mode Ifixed l ow ratio) ________ ---j DC-CDI Electric staller motor and emergency recoil staller Triple phase output alternator FET shorted, tr ip le phase full wave rect ifi cation Batlery

2003-2005 Rincon 650 TRX650 Service & Repair Manual

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