TRX250x service manual repair 1987-1988 TRX250x

HOW TO USE THIS MANUAL Sections 1 throug h 3 apply to the whole FOU RTRAX, while sections 4 through 16 describe parts of the FOU RTR AX, grouped ac- co rdin g to location. Find the section you want on this page, then turn to t he t able of contents on page 1 of that section. Mos t secti ons start with an assembly or syst em ill ustration and alt the required specifi- ca ti ons, to rque values, general inst ru ctions, tools and troubleshooting for the section. The subsequent pages give detailed procedures. If you don't know what the source of a problem, refer to section 17 . TR OUBLE- SHOOTING . CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAUINSTALLATION CYliNDER HEAD/VALVES ~ ~============================ '" CYliNDER/PISTON ~ ~============================ CLUTCH/OIL PUMP/KICK STARTER ALTERNATOR/GEARSHIFT liNKAGE FRONT WHEEL/SUSPENSION/STEERING '" REAR WHEEU DRIVE MECHANISM Cii :============= = ~ REAR SUSPENSION n ~========================== HYDRAUliC BRAKES FENDERS /EXHAUST SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING INDEX

1. GENERAL INFORMATION GENERAL SAFETY SERVICE RULES MODELIOENTIFICATION SPECIFICATIONS T ORQUE VALU ES GENERAL SAFETY ; ii , ,-, ,-, ' -2 ' -3 ' -5 TOOLS CABLE & HARNESS ROUTING It ' -8 '-'0 If the engine must be running to do some ", ork, make sure that area Is well-ventilated. Never fIIn the engine in Q d osed area. Th e exhaust contains poisonous carbon monoxide gas that ma)' cause loss of consciousness and lead to death. Gasoline is utremely flammable and; s ex pl osive u ndu urtain conditions. Do "f!' smoke or 0/10 11' flames or sparks /n }'Our work area. SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that don 't meet HONDA 's design specifications may cause damage to the FOURT RAX . 2 . Use the special tools deSigned for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing this FOUATAAX . Metric bolts , nuts , and scr ews ara not i nterc hangeable with English fasteners. 4 , InstaU new gaskets. O-rings, co tt er pins, lo ck. plates. etc. when reassembling. 5. When tightening a se ries o f bolts or nuts, begin w ith the larger-diamete r or inn er bolt first. Then tighte n to the specified torq ue diagonally in 2 or 3 steps, unless a pa rt icular sequence is specified. 6. Clean parts in non-flammable or high flash point solvent upon disassembly. 7. Lubricate any sliding surfaces bef ore reassembly. 8. Afte r reassembly, check all parts for proper installation and operation. 1-1

GENERAL INFORMATION MODEl IDENTIFICATION The frame serial number is stamped on the fr ont frame. ~ CARBURETOR IDENTIFICATION NUMBER The carburetor identification number is on the carburetor body left side. 1-2 The engine se r ia l number is stamped on the upper right side of the crankcase.

GENERAL INFORMATION SPECIFICATIONS OIMENSIONS Overall length 1,750 mm (68.9 in) Overall width 1,110 mm (43.7 in) Overall height 1 ,075 mm (42.3 in) Wheelbase 1,150 mm 145.3 in) Seat height 780 mm (30.7 in) Footpeg height 330 mm (13.0 in) Ground clearance 125 mm ( 4.9 in) Dry weight 159 kg (351 fbi Weight distribution Front 77 kg (1 70 fb i Rear 82 kg (181 fbi Weight distribution Front 104 kg (229 fbi (At loaded weight) Rear 141 kg(311Ib) FRAME Type Double cradle Front suspension, travel Double wish-bone, 170 mm (6.7 in) Rear suspension, travel Swingarm, 200 mm 17.9 in) Rim size Front 10 x 5.5 Rear 9 x 8.0 AT Tire size Front AT 22.0 x 7.00 - 10 . * Rear AT 22.0 x 10.00- 9. Tira pressure Front 4.4 psi (0.30 kg/ cm 2 , 30 kPa) Rear 2.9 psi (0.20 kg/ cm 2 , 20 kPa) Front brake, lining swept area Single disc x 2, 535.3 cm 1 (83.0 sq-in) Rear brake, lining swept area Single disc, 354.4 cm 1 (54.9 sq-in) Fuel capacity 8.5' 12.3 U.S. gal., 1.9 Imp. gal.) Fuel reserve capacity 1.8 f (0.5 U. S. gal., 0.4 Imp. gaL) Toe-in 10 ± 10 mm (0.4 ± 0.4 in) Caster angle 8" Camber 0" Trail length 35 mm 11.4 in) Tread Front 850 mm (33 .5 in) Rear 850 mm (33.5 in ) ENGINE Type Gasoline, air-cooled 4· slroke Cylinder arragement Single cylinder inclined 20 0 Bore x stroke 74 x 57.3 mm (2.91 x 2. 26 in) Displacement 246.4 cc (15.03 cu-in) Compression ratio 9.4 ± 0.2 : 1 Va lve Irain Overhead camshaft chain drive Maximum horsepower 21 .1 BHP/7 ,500 rpm (SAE j245) Maximum torgue 2.25 kg·m/6, OOO rpm Oil capacity 2.0 IiI (2. 11 U .S. qt ., 1. 76 Imp. qt.) after disassembly 1 .6 IiI (1.69 U.S. qt ., 1.41 Imp. qt.) after draining lubrication system Forced pressure and wet sump Cylinder compression 1370 kPa (13.7 kg l cm 2 , 195 psi) Intake valve Opens 10 0 BTDC Closes 35 0 ABDC Exhaust valve Opens 7 0 BBDC Closes 38 0 ATDC Va lve clearance Intake 0.10 mm (0.004 in) (Cold) Exhaust 0.10 mm (0.004 in) CARBURETOR Type Dual valve Venturi dia. 29 mm 11.1 in) Main jet #125 Pilot screw opening 2-1/2 turns out Jet needle 3rd groove Float level 18.5 mm (0.73 in) Idle speed 1 ,400 ± 100 rpm 1-3

GENERAL INFORMATION DRIVE TRAIN Clutch Wet multi-plate Transmission 5-speed and reverse constant mesh Primary reduction 2.833 (68124) Gear rat io , 3.692 (48/13) II 2.529143/17) "' 1.857139/21) 'V 1.458 (35/2 4) V , . 178 (33/ 28) Reverse 5.415 (33/13 x 32/15) Final reduction 2.923 (38/13) Gearshift pattern R > N- 2-3-4-5 1 Drive chain sizellinks 520 /86 links ELECTRICAL Ignition system CO, Initial ignition timing 10 0 BTDC at idle Full advance 33° BTDC at 3,000 j: 200 rpm Alternator 0.' 35 Kw/5,OOO rpm Spark plug DRBES-l (NGK) X24ESR-U INO) Spark plug gap 0.6 - 0.7 mm Headlight 12 V- SOW/ 55 W Taillight 12 V - 5W 1·4

GENERAL INFORMATION TORQUE VALUES ENGINE Thread dia Torque Item ( mm) N·m kg -m ft-lb Oil drain plug 12 20 - 30 2.0- 3.0 14 - 22 Oil pump mounting bolt 6 10 - 14 1.9- 1.4 7- 10 Fuel valve lock nut 18 20 - 25 2.0 - 2.5 15 - 18 Fuel strainer cup 24 3- 5 0.3-0 .5 2. 2-3.6 Valve adjuster lock nut 6 15 - 18 1.5- 1.8 11 - 1 3 Cyl inder head nut 10 35 - 45 3.5- 4.5 25 - 33 Cylinder head bolt 10 35-45 3.5-4.5 25-33 Cam sprocket bolt 7 17- 23 , .7 - 2.3 12 - 1 7 Oil pipe bolt 8 12 - 16 1.2 - 1.6 9- 12 Spark plug 12 15 - 20 1.5- 2.0 11 - 1 5 Cam chain tensioner lifter sealing bolt 6 8- 12 0.8 - 1.2 6- 9 Cam chain tensioner lifter attach ing bolt 6 SH 8- 12 0.8 - 1.2 6- 9 Cylinder head cove r bolt 6 SH 8- 12 0.8 - 1.2 6- 9 6 flange 10 - 14 1.0 - 1.4 7- 10 Cylinder mounting bolt 6 8- 12 0.8- 1.2 6- 9 Oil bolt (oil pass pipe) 8 , 2 - 16 1.2 - 1.6 9- 12 Kick starter rachet guide bolt 6 10 - 14 1.0 - 1.4 7- 10 Clutch lock nut 18 100 - 120 10.0 - 12.0 72 - 87 Clutch l ifter plate bolt 6 10- 14 1.0- 1.4 7- 10 Primary drive gear lock nut 20 60 - 80 6.0- 8.0 43 - 58 Kick starter pedal mounting bolt 8 24 - 30 2.4 - 3.0 17 - 22 Reverse selector arm attaching nut 6 10 - 14 1.0- 1.4 7- 10 Gear shift return spring pin 8 18-25 1.8-2 .5 13 - 18 Flywheel bolt 12 100 - 120 10.0- 12 .0 72- 87 Pulse generator bolt 5 5- 7 0.5- 0.7 4- 5 Stator mounting bolt 6 8- 12 0.8 - 1.2 6- 9 Left crankcase cover bolt 6 SH 8- 12 0.8 - 1.2 6- 9 6 flange 10 - 14 1.0 - 1.4 7- 10 Shift drum center bolt 8 21 - 25 2. 1- 2.5 15 - 18 Reverse shifter lever mounting pinch bolt 6 14- 18 1.4 - 1.8 10 - 13 Reverse shifter lever mounting pivot 6 18- 25 1.8 - 2.5 13 - 18 Crankcase bolt 6 10 - 14 1.0 - 1.4 7- 10 1-5

GENERAL INFORMATION FRAME Thread die Torque It em (mm) N·m kg -m It · lb Bearing holder socket bolt 8 19 - 25 1.9 - 2.5 14 - 18 Gearshift pedal mounting bolt 6 14 - 18 1.4 - 1.8 10 - 13 Tie-rod lock nut 12 50 - 60 5.0 - 6.0 36 - 43 Fuel valve lock nut 18 20 - 25 2.0 - 2.5 14 - 18 Engine mounting bolt 10 55 - 65 5.5- 6.5 40 - 47 Rear upper engine mounting bolt 10 70 - 80 7.0- 8.0 51 - 58 Front wheel nut 10 60 - 70 6.0- 7.0 43 - 51 Front brake disc socket bolt 6 14 - 16 1.4 - 1.6 10- 12 Front wheel hub nut 14 60 - 80 6.0- 8.0 43 - 58 Tie-rod bait joint 10 40 - 50 4.0- 5.0 29 - 36 Front arm ball joint nut 14 60 - 80 6.0 - 8.0 43 - 58 Front arm nut 10 50 - 60 5.0- 6.0 36 - 43 Front arm mounting bolt 10 35 - 45 3.5- 4.5 25 - 33 Front shock absorber mounting bolt 10 40 - 50 4.0-5.0 29 - 36 Steering shah nut 14 60 - 80 6.0- 8.0 43 - 58 Handlebar lower holder mounting nut 10 40 - 50 4.0 - 5.0 29 - 36 Steering shaft holder bolt 8 25 - '30 2.5 - 3.0 18 - 22 Front brake caliper mounting bolt 8 24 - 30 2.4 - 3.0 17 - 22 light/engine stop switch housing mounting screw 5 1.5 - 2.5 0. 15 - 0. 25 1.1 - 1.8 Front master cylinder mounting screw 6 10 - 14 1.0- 1.4 7- 10 Throttle cover attaching screw 4 3- 4 0.3 - 0.4 2- 3 Rear wheel nut 10 60 - 70 6.0-7 .0 43 - 51 Brake disc bolt 8 24 - 30 2.4 - 3.0 17 - 22 Axle outer lock nut 48 80 - 100 8.0- 10.0 58 -72 Brake caliper bracket bolt 8 24 - 30 2.4 - 3.0 17 - 22 Driven sprocket bolt 10 55 - 65 5.5 - 6.5 40 - 47 Axle nut 18 120 - 170 12.0- 17.0 87 - 123 Bearing holder stopper bolt 8 8- 11 0.8- 1.1 6- 8 Shock absorber mounting bolt 12 100- 120 10.0 - 12 .0 72 - 87 Swing arm pivot bolt 14 70 - 110 7.0 - 11.0 51 - 80 Skid plate mounting bolt 8 28 - 34 2.8- 3.4 20 - 25 Air bleed valve 8 4- 7 0.4 - 0.7 3- 5 Caliper mounting bolt 8 24 - 30 2.4 - 3.0 17 - 22 Oil bolt 10 25 - 35 2.5 - 3.5 18 - 25 Rear caliper socket bolt 8 20 - 25 2.0 - 2.5 15 - 18 Parking brake base bolt 8 20 - 25 2.0 - 2.5 15 - 18 Parking brake adjuster lock nut 8 15 - 20 1 .5 - 2.0 11 - 1 5 Front caliper socket bolt 8 20 - 25 2.0 - 2.5 15-18 Foot peg 10 45-55 4.5- 5.5 33 - 40 1-6

GENERAL INFORMATION Thread dia Torque Item (mm) N·m kg -m fl -I b Brake pad pin bolt plug 10 1- 2 0.1- 0.2 0.7 - 1.5 Front brake lever pivot nut 6 8- 12 0.8 - 1.2 6- 9 Rear reservoir hose connector screw 4 1- 2 0.1- 0.2 0.7- 1.5 Reservoir cover attaching scr ew 4 1- 2 0.1 - 0.2 0.7 - 1.5 Rear brake push rod lock nut 8 15 - 20 1.5 - 2.0 11 - 14 Front master cylinder mounting screw 6 10 - 14 1.0-1.4 7-10 Br ake pipe three-way joint 6 10-14 1 ,0-1.4 7-10 Rear brake master cylinder mounting bolt 8 24 - 30 2.4 - 3.0 17- 22 Muffler mounting bolt 10 50 - 60 5.0 - 6.0 36 - 43 Exhaust pipe band bolt 8 18 - 28 , .8 - 2.8 13- 20 .. .. Torque specifications listed above are for specIfic tightening pomts. If a specification IS not listed follow the standards below: STANDARD TORQUE VA LUES TYPE TORQUE N· m {kg-m, ft·lbl TYPE TORQUE N'm (kg-m, ft-lbJ 5 mm bolt , nut 4.5-6 .0 (0.45-0.6, 3.3 -4 .31 5 mm screw 3.5- 5 (0.35 - 0.5, 2.5- 3.6) 6 mm bolt, nut 8-12 (0.8-1.2, 6-9) 6 mm screw 7- 1110 .7-1.1,5 - 81 8 mm bolt, nut 18 - 25 ( 1.8 - 2.5,13 - 181 6 mm bolt with 8 mm head 7- 11 (0.7 - 1.1, 5- 81 10 mm bolt, nut 30 - 40 (3.0 - 4.0, 22 - 291 6 mm flange bolt , nut 10-1411.0-1.4,7 - 101 12 mm bolt , nut 50 - 60 (5.0-6.0, 36-431 8 mm flange bolt, nut 24 - 30 (2.4 - 3.0, 17 - 221 10 mm flange bolt , nut 35 - 45 (3.5 - 4.5, 25 - 32) 1-7

TRX250x service manual repair 1987-1988 TRX250x

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