HONDA TRX450R / TRX450ER Service & Repair Manual (2004 2005 2006) - !

A Few Words About Safety Service Information The servrce and repair information contained in this manual is intended for use by qualified, profess•onal technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. Thrs manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures requr re the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, serviCe procedure or a tool that is not recommended by Honda, must determrne the risks to their personal safety and the safe operation of the vehicle. II you need to replace a part , use genuine Honda parts with the correct part number or an eqUivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or in jury to others. For Your Safety Because this manual is intended for the professional service technicran. we do not provide warnings about many basic shop safety practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice. we recommended that you do not attempt to perform the procedures descnbed in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Important Safety Precautions A WARNING Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. A WARNING Failure to property follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. Make sure you have a clear understandrng of all basic shop safety practices and that you are weanng appropriate clothing and using safety equipment. When performrng any service task, be especially careful of the following. • Read all of the instructions before you begrn, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. • Protect your eyes by using proper safety glasses, goggles or face shrelds any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you. stop and put on gloves • Protect yourself and others whenever you have the vehicle up in the ar r. Any lime you lift the vehiCle, either with a hoist or a 1ack. make su re that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servic ing procedures, unless the instruction tells you to do otherwise. Thrs will help eliminate several potential hazards: • Carbon monoxide poisonrng from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. • Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are expl osive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries • Use only a nonflammable solvent, not gasoline, to clean parts. • Never drain or store gasoline in an open container. • Keep all cigarettes, sparks and flames away from the battery and all luel-related parts.

HOW TO USE THIS MANUAL This service manual describes the service procedures for the TRX450RI EA. Follow the Maintenance Schedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency (EPA) and California Air Resources Board (CARS). Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 4 apply to the whole vehicle. Sec1ion 3 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Sections 5 through 25 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, serv1ce information and troubleshooting for the section. The subsequent pages give detailed procedure. If you are not familiar with this vehicle, read Technical Features in Section 2. If you don't know the source of the trouble. go to section 26 Troubleshooting. Your safety, and the safety of others, is very important. To help you make 1nformed decisions we have provided safety messages and other Information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will lind important safety information in a variety of forms including: • Safety Labels -on the vehicle • Safely Messages - preceded by a safely alert symbol ffi and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY f tl•Al£ItJjjl HURT if you don't follow instructions. You CAN be KILLED or SERIOUSLY HURT ID'f'i,j'S'hVI if you don't follow instructions. faltJIJif,J:I!i You CAN be HURT 1f you don't follow --·· ••• ·-- instructions. • Instructions- how to service this vehicle correctly and safely. As you read this manual, you will find information that is preceded by a c:N:QIICEJ symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. w z C!J z w CJ) u; CJ) < ::t: (.) CONTENTS GENERAL INFORMATION PANELS/EXHAUST LUBRICATION SYSTEM ('04- '05) LUBRICATION SYSTEM (After '05) FUEL SYSTEM ('04 - '05) FUEL SYSTEM (After '05) COOLING SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVES REAR WHEEUSUSPENSION HYDRAULIC BRAKE ELECTRICAL ('04 - '05) BATTERY/CHARGING SYSTEM (TRX450ER) IGNITION SYSTEM (After '05) ELECTRIC STARTER (TRX450ER) LIGHTS/SWITCHES (After '05) 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. , Replace the part(s) with new one(s) before assembly. , Use the recommended engine oil, unless otherwise specified. 71 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1) ...-5iiiiiiif Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or ~ equivalent). Example: Molykote® BR-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® 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. Rocol Paste manufactured by Sumico Lubricant, Japan ~ Use silicone grease. L1ml Apply a locking agent. Use a medium strength locking agent unless otherwise specified . • lmru Apply sealant. I Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. ... Use fork or suspension fluid.

1. GENERAL INFORMATION SERVICE RULES ........................... .............. 1-2 MODEL IDENTIFICATION ('04 - '07) ......... 1-2 MODEL IDENTIFICATION (After '07) ......... 1-4 GENERAL SPECIFICATIONS ('04- '05)·· .. · 1-7 GENERAL SPECIFICATIONS ('06 - '07) ..· .. 1-8 GENERAL SPECIFICATIONS (After '07) .... 1-9 LUBRICATION SYSTEM SPECIFICATIONS ...................................... 1-11 FUEL SYSTEM SPECIFICATIONS ('04 - '05) ........... .. .. .... .. 1-11 FUEL SYSTEM SPECIFICATIONS (After '05) ... ... .. ............ 1-12 COOLING SYSTEM SPECIFICATIONS .... 1-12 CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS ('04 - '05) ..................... 1-13 CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS (After '05) .................... 1-13 CYLINDER/ PISTON SPECIFICATIONS ('04 - '05) ................ .. .. . 1-14 CYLINDER/ PISTON SPECIFICATIONS (After '05) ...... .. ...... .. .. .. 1-14 CLUTCH/ KICKSTARTER/ GEARSHIFT LINKAGE SPECIFICATIONS ('04 - '05) ................................................... 1- 14 CLUTCH/ STARTER CLUTCH/ KICKSTARTER/ GEARSHIFT LINKAGE SPECIFICATIONS (After ' OS) .................................................. 1-15 CRANKCASE/TRANSMISSION/ CRANKSHAFT SPECIFICATIONS ('04 - '05) ....... .. ................................ .. ........ 1-15 CRANKCASE/TRANSMISSION/ CRANKSHAFT SPECIFICATIONS (After '05) ......... .. ....................................... 1-16 FRONT WHEEL/SUSPENSION/ STEERING SPECIFICATIONS ....... .......... 1-16 REAR WHEEL/SUSPENSION SPECIFICATIONS .................................... 1-17 HYDRAULIC BRAKE SPECIFICATIONS .. 1-17 ELECTRICAL SPECIFICATIONS ('04 - '05) ................................................... 1-18 BATTERY/CHARGING SYSTEM SPECIFICATIONS (TRX450ER) ...... ·· ........ 1-18 IGNITION SYSTEM SPECIFICATIONS (After '05) ........................................ .......... 1-18 ELECTRIC STARTER SPECIFICATIONS (TRX450ER) ............................ ...... .. ........... 1-18 LIGHTS/SWITCH SPECIFICATIONS (After '05) ............................... ................... 1-19 STANDARD TORQUE VALUEs ............... 1-20 ENGINE & FRAME TORQUE VALUES · .. · 1-20 LUBRICATION & SEAL POINTS .............. 1-26 CABLE & HARNESS ROUTING ............... 1-29 EMISSION CONTROL SYSTEMS ............ 1-49 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 sc rews are not interchangeable with English fasteners. 4. Install new gaskets, 0-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 and Harness Routing (page 1-29). MODEL IDENTIFICATION ('04- '07} '04- '05 model shown, After '05 model similar The model identification label is located on the left front frame pipe. 1-2

The vehicle identification number (YIN) is stamped on the front side of the frame. The engine serial number is stamped on the left side of the crankcase. '04- '05: The Vehicle Emission Control Information Label is attached on the right front frame pipe (U.S.A. only). GENERAL INFORMATION 1-3

GENERAL INFORMATION After '05: The Vehicle Emission Control Information Label is attached on the right side of the front frame pipe (U.S.A. only). The color label is attached on the left side of the front frame pipe. When ordering color coded parts, always specify the designated color code. MODEL IDENTIFICATION (After '07) 1-4

'08: The model identification label (U.S.A. type) or safety certification label (Canada type) is located on the right front frame pipe. After '08: The certification label (U.S.A. type) is located on attached on the right side of the front frame pipe. After '08: The safety certification label (Canada type) is located on the right front frame pipe. The vehicle identification number (VIN) is stamped on the front side of the frame. GENERAL INFORMATION MODEL IDENTIFICATION LABEL (U.S.A type) SAFETY CERTIFICATION LABEL (Canada type) After '08 U.S.A. only: VIN 1-5

GENERAL INFORMATION The engine serial number is stamped on the left side of the crankcase. -- ... -] ENGI NE SERIAL NUMBER The carburetor identif ication number is stamped on the left side of the ~=================: carburetor body. CARBURETOR IDENTIFICATION NUMBER The Vehicle Emission Control Information Label is attached on the ~================::::: right side (U.S.A.) or both sides (Canada) of front frame pipe. EMISSION CON TROL INFORMATION LABEL The color label is attached on the left front side of the upper suspension bracket. When ordering color coded parts, always specify the designated color code. 1-6 (U.S.A. and Canada) ;~ EMISSION CONTROL INFORMATION LABEL (Canada) COLOR LABEL

You're Reading a Preview

HONDA TRX450R / TRX450ER Service & Repair Manual (2004 2005 2006) - !

Description

Reviews

Q&A

Recently Viewed