1988-1994 Honda TRX300 Fourtrax / TRX300FW Fourtrax 4x4 Service & Repair Manual

88-94 TRX300 FOURTRAX& 88,90-94 TRX300FW FOURTRAX" L , 4X4

IMPORTANT SAFETY NOTlCE ------- 'MM. IndiNln" slronl possibility 0/ J~"~rr prrsona{ injuT}' or dt!Qth if (nslru~tJO'1S a" not !o{lo' .... m. CAUTK)N : {ndicQl t!S II possibility of pt!r$OnQI ifljury or «iuipm~nt dlimaK~ if instruclions orr no' followed. NOTE : Gives helpful information . Detailed descriptions of standard workshop procedures , safety p ri nciples lind service operations ale not inc:luded. It IS important to note that this manual contains some warnings and cauti Ons against some speCific service methods wh i ch could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not co ... er all conceivable ways in which service. whether 01 oot re<:ommended by Honda might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways . Anyone using service procedures or tools . whether or not recommended by Honda must satisfy himself thoroughly that neither personal safelY nor vehicle safety w ill be jeopardized by the service method or tools selected.

HOW TO USE TH IS MANUAL Sections 1 through 3 apply to the complete FOUATAAX. while sections 4 through 21 describe parts of the FOURTRAX, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system itlustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don 't know the source of the trouble, go to section 22. Troubleshooting . w Z (; Z w Ul CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADIVALVES CYLINDER/PISTON CLUTCH/OIL PUMP/KICK STARTER FRONT WHEEL/SUSPENSION/STEERING BRAKES in REAR WHEEUSUSPENSION ~ l: U .... 5 ~ w .... w REAR DRIVING MECHANISM CARRIERS/FENDERS/ MUFFLER IGNITION SYSTEM BATTERY/CHARGING SYSTEM STARTER SYSTEM LIGHTS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX

1. GENERAL INFORMATION GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICA nONS GENERAL SAFETY j!i. 1-1 1-1 1-2 1-4 l ithe engine must he running to do some work, make sure the area is well-I'entilated. Never run the engine in an enclosed aua. The exhaust contuins poisonous carbon monoxide gas that may cause l oss 0/ consciousness and lead to deafh. % The baiter)' generates hydrogen gas which can be hight)1 explo- sive. Do not smoke or allow flames or sparks near the battery. especiolJy while charging if, Inhaled asbestos jibers haw ! been found to cause respirato- ry disease and cancer, Never use an air hose or dry brush to clean brake or clutch assemblie s. Use an OSfiA-app,o~'ed ,'ocullm cleaner or alternate method opprOl'ed by OSHA designed to minimize the hazard cau sed by airborne asbestos jibus. SERVICE RULES TORQUE VALUES TOOLS CABLE & HARNESS ROUTING 1-7 1- 10 1- 12 Gasoline is extremel)' /lammable and is explos!\'e Ilnder cerlain conditions. Do not smoke or allow /lames or sparks in your .... ork area or where gasoline is stored. The battery electrolyte contains sulfuric acid. I~rotect your eyes, skin and clothing. In case of contact, /lush thoroughly .... ith k'ater ami call a doctor if electrolyte gets in )'our e}·es. 1. Use genuine HONDA or HONDA-recommended parts and lubricants Of their equivalents. Parts that don't 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. Mellie bolts, nuts and screws are not interchangeable with English fas- teners. 4. Install new gaskets, a-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger-diameter or inner bolt first. Then tig hten to the specified torque diago- nally in 1-7 steps. unless a particular sequence is specified. 9. Clean parts in non-flammable or high flash point so l vent upon disassembly. 7. lubricate any sliding surfaces before reassembly. 8. After reassembly. check ali parts for proper installation and operation. 1-1

GENERAL INFORMA nON MODEl IDENTIFICATION TRX300 ' 88 -' 89 : ' 90 -' 92 : After ' 92 : TRX300FW ' 88 : ' 90 -' 92: After '92: 1-2

111 FRAME SER,.,L NUMBER (1) The frame se r ia l number is stamped on the front of the frame . (3) The carburetor identification number is on the left side of the carburetor body_ GENERAL INFORMATION """AIAL NUMBER (2) The engine serial number is stamped on the upper side of the right crankcase. 1-3

GENERAL INFORMATION SPECIFICATIONS I: TRX300FW DIMENSIONS Overall length '88-'90: 1,905 mm 175.0 in) ( 1,895 mm 174.6 in)) After '90: 1,910 mm (75.2 in) (1,910 mm (75.2 in)) Overall width '88-'90: 1,115 mm (43.9 in) 11,065 mm (41.9 in)] '91-'92: 1,125 mm (44.3 in) fl, 110 mm 143.7 in)J After '92: 1,115 mm (43.9 in) (1,110 rnm (43.7 in)] Overall height ' 88 -' 90 : 1 ,055 mm (41,5 in) {l, 100 mm (43.3 in)] '91 -'92: 1,075 mm 142.3 in) (1,085 mm (42.7 in]] After '92: 1,088 mm 142.8 in) (1,085 mm (42.7 inlJ Wheelbase '88 -' 90 : 1,245 mm (49.0 in) " ,235 mm (48 .6 inll '91 - '92: 1 ,250 mm (49.2 in) ".235 mm (48.6 in)) After '92: 1,239 mm 148.8 in) (1,238 mm (48.7 in)] Seat height '88 - '90: 765 mm (30.1 in) I 800 mm (31.5 inll ' 91 -' 92: 780 mm (30.7 inl I 790 mm (31.1 inJl After '92: 783 mm (30.8 in) I 780 mm (30.7 in)] Foot pe9 height '88~'90: 290 mm (1 1.4 in) I 315 mm (12.4 inlJ '91 ~'92: 300 mm (11.8 in) I 305 mm (12.0 in)] After '92: 305 mm (12.0 in) I 305 mm (12.0 in)] Ground clearance 160 mm (6.3 in) I 160 mm (6.3 in)] Dry weight '88: 199 kg (439 Ib) J215 kg (474 Ib)] '89~'90: 211.5 kg (466 Ib) (230 kg (507 IblJ ' 91 ~'92; 216 kg (476 Ibl [236 kg (520 Ibll After '92: 221 kg (487 Ibl [239 kg (527 )blJ FRAME Type Double cradle Rim size Front l1x6 .5AT Rear 9x9.0AT [11 x 7.5 ATI Suspension travel Front Axle travel 130 mm (5.1 in) Rear Axle travel 130 mm (5.1 in) Front tire size, pressure AT 23 x 8- 11 * * , 2.9 psi (0.20 kg/cm 2 , 20 kPa) [AT 23 x 8-11 ** , 4.4 psi (0.30 kg/cm 2 , 30 kPa)] Rear tire size, pressure '89~' 91 : AT 25 x 12-9 *, 2.9 psi (0.20 kg /cm 2 , 20 kPa) , (AT 24 x 9-" *, 2.9 psi (0.20 kg / cm 2 , 20 kPa) with cargo: 3.6 psi (0.25 kg / cm 2 , 25 kPal) Af ter ' 91: AT 25 x 11 -9 *, 2.9 psi (0.20 kg/cm 2 , 20 kpa) (AT 24 x 9-11 *,2.9 psi (0.20 kg / cm 2 , 20 kPa) with cargo: 3.6 psi (0.25 kg/cm2, 25 kPa)] Front brake Hydraulic operated leading/trailing shoe [Hydraulic operated dual leading shoeJ Rear brake Cable operated leading/trai ling shoe Fuel tank capacity 12.5 liters (3.3 US gal, 2.8 Imp gal) Fuel reserve capacity 2.5 liters (0.7 US gal, 0.6 Imp gal) , Toe-in '88-' 92 : 2 mm (0.08 in) .... After '92: 5 mm (0.2 in) Caster angle· t il' .. '88-'92: 5' After '92: 7' [Toe-in \. , '88 - '90: 8 mm (0.3 in)] .' ~ ['91 - '92 : Omm] [After '92: 4 mm 0.2 inl [Ca,:;4angle -, '88 - '90: 2'1 {'91 - '92: 2.25°] [After '92 : 2.2°J • .., Camber angle '88 -' 92: 0.5° [0°] After '92: 0.2 ° • [0°] Trail length '88 - '92: 25.0 mm (0 .98 i n) [' 0.0 mm (0.39 inll ' 93 : 33.0 mm 11.26 in) After '93: 33.0 mm (1.26 in) [10.0 mm (0.39 in)] Tread Front '88 - '92: 795 mm (31.3 in) [840 mm (33.1 in)] '93: 793 mm (31.2 in) After '93: 790 mm (31.1 in) [840 mm (33. 1 in)] Rear 840 mm (33.1 in) [840 mm (33.1 in l] 1-4 , .'

GENERAL INFORMA nON ]- TRX300FW ENGINE Type Gasoline. air-cooled 4-stroke Cylinder arrangement Single cylinder inclined 20 0 from vertical Sore x stroke 74 .0 x 65 .5 mm (2 . 91 x 2.58 in) Displacement 281 .7 cc 117.2 cu-in) Compression ratio 9 .0; 1 Valve train Overhead camshaft, chain driven Oil capacity 2.5 tit 12 .6 US qt , 2.2 Imp qt ) at disassembly 2.2 lit (2.3 US qt, 1.9 Imp qt) after draining lubrication system Forced pressure and wet sump Cylinder compression 1, 250 - 1,450 kPa 112 .5 - 14.5 kg/cm 1 , 178-206 psi) Intake valve Opens '88-'90: 8 0 BTDC After '90: 11 0 BTDC Cl oses ' S8 -' 90 : 35 ° A8DC After ' 90: 32 ° ABDC 8t 1 mm lift Exhaust valve Opens '88-'90: 40 ° BaDC After '90: 43 ° BaDC Cl oses ' 88 -' 90: 5° ATOC After '90: 2° ATOC Valve clearance Intake 0.15 mm jO.006 in) jCold) Exhaust 0. 15 mm (0 .006 inl CARBURETOR Tvpe Vacuum piston (VEl Identification number '88-'90: VE90A ' 91 : VE90C '92: VE900 ' 93 : VESOE After ' S3 : VEStA Throttle bore 32 mm (1.3 in ) Main jet ' 88 -' SO : #120 After ' SO: #125 Slow jet ' 88 -' SO: #42 After ' 90 : #40 Starter jet '88-'SO: #85 ' S1 : #80 'S2: #90 After 'S2: #85 Pilot screw initial opening see page 4- 14 Jet needle setting 3rd groove from the top Float level 18.5 mm (0.73 inl Idle speed ' 88 -' 90: 1 ,500% 100 r pm After 'SO: 1,400 % 100 rpm 1-5

GENERAL INFORMATION DAIVE TRAIN Clutch Wet mult i- plate, automatic centrifugal Transmission S-speed constant mesh with reverse Primary redu ction 2.407 (65/27) Gear ratio SIL 4. 083 (49 / 12) , 2.389 (43/18) II 1.609 (37/23) "' 1. 179 (33 /2S) ,V 0.848 (28/33) Reverse 5.3 97 ( 34/ 12 x 40121) Final reduction Front (TAX300FW) 5. 554 (19/ 13 x 38 1 10 ) Rear 1. 462 (19/13) x 3. 889 (35/9) Gearshift pattern Left foot operated return system, Forward: N- S/l-1 - 2- 3-4 Reverse: N - R [Front differential oil capacity ' 88 : 100 cc (3.4 oz) at disassembly] [90 cc (3.0 oz) after draining1 [After '88: 200 cc 16.B ozl at disassembly) [190 cc (6. 4 oz) after draining) (Front gear case oil capacity 200 cc 16.8 oz) at disassembly) (190 cc (6.4 oz) after draining) Rear final drive oil capacity '00 cc (3.4 ozl at disassembly 90 cc 13. 0 021 after draining ELECTRICAL Ignition DC-COl Ignition timing Initial 13 0 BTDC at idle Full advance 31 0 BTDC at 4,500 ± 100 rpm Alternator Capacity 0.22 kW/5,000 rpm Battery 12V - 12AH Spark plugs NGK NIPPONDENSO Standard DPR8EA-9 X24EPR -U 9 For cold climate DPR7EA-9 X22EPR-U9 (Below 5°C/ 41 ° FI For extended high DPA9EA-9 X27 EPR-U9 speed riding Spark plug gap 0.8- 0.9 mm {0.031 - 0.035 inl Headlig ht 12 V 25 / 25 W x 2 Taillight 12 V 5 W Neutral indicator '88 -' 93 : 12 V 3.4 W A ft er '93 : 12V 1.7W Reverse indicator ' 88 - '93: 12 V 3.4 W After ' 93 : 12V 1 .7W Oil high temperature indicator ' 88 -' 93 : 12 V 3.4 W After ' 93 : 12 V 1_ 7W 1-6

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1988-1994 Honda TRX300 Fourtrax / TRX300FW Fourtrax 4x4 Service & Repair Manual

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