1985-1987 Honda TRX 250 Service & Repair Manual

HOW TO USE THIS MANUAL Sections 1 through 3 apply to the whole Four Trax. while sections 4 through 18 describe parts of the Four Trax. 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 illustration, service information and troubleshooting for the section. The subse- quent pages give detailed procedures. If you don't know what the source of a prob- lem is, refer to section 19 , Troubleshooting. CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES ~ ~============================ '" CYLINDER/PISTON ~ ~============================ FRONT WHEEL/SUSPENSION/STEERING CI) BRAKES ~ ~============================ :I: REAR WHEEL/SUSPENSION/FINAL DRIVE u :=== = ======= === CARRIERS/FENDERS/ EXHAUST MUFFLER IGNITION SYSTEM ~u ~============================= BATTERY/CHARGING SYSTEM a: :========== = === t; STARTER SYSTEM ~ ~================================== LIGHTS/SWITCHES TROUBLESHOOTING

GENERAL SAFETY SERVICE RULES MOOElIDENTIFICATION SPECIFICATIONS GENERAL SAFETY Ii ,., ,., ' ·2 ' ·3 If Ih~ ~"gine must be funning 10 do some "'ork, make sure the urta ;s It'ell· j't!nlilated. Nt l 'er run the engine in a closed urea. The exhaust contains poisonous carbon monoxide gas, The botUry genua"s h)'drogen gas M 'hlch can be highly explo. sil't'. 00 nol smoke or alloK' flama or sparks near the baltery. especially while charg;ng it. SERVICE RULES 1. GENERAL INFORMATION TORQUE VALUES TOOLS CABLE & HARNESS ROUTING ' ·5 ' ·7 ' ·9 Gasoline is utremeb' flammable and is explos;,·t! und" certa;n conditions. 0 0 nOi sm oke or allow flames or sparks in J'our work Ofl!a. The battery el«trolyre contains sui/uric acid. Prot«t ),ollr I!)'es. skin and cloth;ng. 1 11 case oj CGllIoet. /lush thorollghly with ",aur Qlld call Q doctor if el«trol)'le gelS in ),our I!)'es. 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA's design specifications may cause damage to the Four Trax . 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing this Four Trax. Metric bolts, nuts and screws are not interchangeable with English fasteners. 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 tighten to the specified torque diago- nally in 1-5 steps. unless a particular sequence is specified. 6. Clean parts in non-flammable or high flash point solvent upon disassembly. 7. Lubricate any sliding surfaces before reassembly. 8. After reassembly, check all parts for proper installation and operation. 1-1

GENERAL INFORMATION MODEL IDENTIFICATION The frame serial number is stamped on the arm hinge. !31 CARBURETOR IDENTIFICATION NUMBER o ~ The carburetor identification number is on the carburetor body left side. 1-2 (2) ENGINE SERIAL NUMBER I The engine serial number is stamped on the upper side of the right crankcase.

GENERAL INFORMATION SPECIFICATIONS DIMENSIONS Overall length , ,875 mm (73.8 in) Overall width 1,080 mm 142.5 in) Overall height 1,020 mm (40.2 in) Wheel base 1,235 mm (48.6 in) Seat height 765 mm (30.1 in) Foot peg height 290 rnm (11.4 in) Ground clearance 160 mm {6.3 inl Ory weight '85 212 kg (467Ib) AFTER '85 217 kg (478Ib) FRAME Type Semi-double cradle Rim size Front 5. 5xl00C Rear 9.25 )( 9 DC Front tire size, pressure 21 )(7.00- 10,0 .2 kg/c m l 12.9 psi I Rear tire size, pressure 25 x 12.00-9, 0.' 5 kglcm~ (2.2 psi) Front brake Hydraulic oper ated leading trailing shoe Rear brake Cable operated leading trailing shoe Fuel tank capacity 10.0 liter (2.6 US gal, 2.2 Imp gal) Fuel reserve capacity 2.0 liter (0.5 US gat, 0.4 Imp gal) Toe-in a ~ 7.5 mm (0 j: 0.30 inl Caster angle ." Camber angle 1 " Trail length 42 mm (t .65 inl Tread Fr ont 800 mm 131.5 inl Rear 800 mm 131.5 inl ENGINE Type Gasoline, air-cooled 4- stroke Cylinder arrangement Single cylinder inclined 20° Bore x stroke 74 x 57.3 mm (2.9 x 2.3 in) Displacement 246 cc (15.0 cu -in) Comp ression ratio 9 : 1 Valve train Overhead camshaft, chain dr iven Maximum hor sepower 19.3 HPI7 ,000 rpm (SAEI Maximum torQue 2.03 kg -m 114.7 ft -lb)/ 6,OOO rpm (SAEI Oil capacity 2.5 liter 12.6 US Qt , 2.2 Imp QtI 2.1 liter 12.2 US Qt, 1.8 Imp QtI after draining Lubr ication system Forced pressure and wet sump Cylinder compression 12.5:t 1.0 kg/cm2 (178:t 14 psi) Intake valve Opens 8° BTDC I Closes 35° ABDC at 1 mm lift Exhaust valve Opens 5° BBDC Closes 40° ATDC Valve clearance Intake 0. 08 mm (0.003 in) (Cold) Exhaust 0.08 mm (0.003 inl CARBURETOR Type Duel velve Venturi die. 27 mm (1.06 in) Main jet #128 Pilot screw opening 2-3/8 turns out Jet needle 3rd groove Float level 18.5 mm (0.73 in) Idle speed 1,400:t 100 r pm 1-3

GENERAL INFORMATION DR I VE TRAIN Clutch Wet multi -plate, semi-automatic Transmission 5-speed constant mesh with reverse Pri mary reduction 2.407 (65 /27 ) Gear ratio SIL 4.083 ( 49/12 ) I 2. 389 143" 8) II , . 609 (37123) III 1 . 1 79 (33/ 28 ) IV 0.906 ( 29 / 32 ) Reverse 5. 397 Final reducti on 5.684 Gear shift pattern Lett foot operated return system, Forward: N- SIL- l - 1- 3- 4 Rever se : N- R ELECTRICAL Ignit ion CDI Ignition timing Initial 13 ° BTDC at idle Fu ll advan ce 31 0 BTDC at 3, 500 rpm Alternator Capac it y 200W/5,OOO rpm Batterv 12V - 12AH Spark plug DA8ES-l (NGK) X2 4 ESA -U (NDI Spark plug gap 0.6- 0.7 mm ( 0.024 - 0. 028 in) Headlight 12V 4 5Wf 45W Taillight 12V 3. 4W)I 2 Neutral indic ator t2V 3W Reverse indic at or 12V 3W Oil temperature indic ator 12V 3.4W 1-4

GENERAL INFORMA nON TORQUE VALUES ENGINE Thread Dia. Torque Item Q'ty (mm) N·m kg-m ft-Ib Cylinder head socket bolt 3 8 22- 28 2.2- 2.8 16 - 20 Cylinder head cap nut 4 10 35 - 45 3.5 - 4.5 25 - 33 Cylinder stud bolt 4 10 8- 12 0.8 -1 .2 6- 9 Crankcase bolt 14 6 8- 12 0.8-1.2 6- 9 Gearshift return spring pin 1 8 18 - 25 1.8 - 2.5 13-18 Output drive gear bearing outer lock nut 1 64 90 - 110 9.0 - 11.0 65 - 80 Output gear case socket bolt 3 8 20 - 25 2.0 - 2.5 14 - 18 Output driven gear bearing holder socket bolt 3 8 20 - 25 2.0 - 2.5 14 - 18 Output driven gear bearing outer lock nut 1 60 90 - 110 9.0 - 11.0 65 - 80 Output driven gear bearing inner lock nut 1 28 70 - 80 7.0-8.0 51 - 58 Kick starter stopper plate socket bolt 2 6 10 - 14 1.0 - 1.4 7- 10 Flywheel bolt 1 12 100 - 120 10.0 - 12.0 72 - 87 Pulse generator screw 2 5 5- 7 0.5- 0.7 3.6 - 5.1 Right crankcase cover bolt 12 6 8- 12 0.8 - 1.2 6- 9 Left crankcase cover bolt 11 6 8- 12 0.8 - 1.2 6- 9 Oil sepa rator plate bolt 2 6 8- 12 0.8- 1.2 6- 9 Clutch lock nut 1 18 100 - 120 10.0 -1 2.0 72- 87 Clutch lifter cap bolt 4 6 10 - 14 1.0 - 1.4 7- 10 Centrifugal clutch lock nut 1 20 110 - 130 11.0 - 13.0 80 - 94 Cylinder base bolt 2 6 8- 12 0.8 - 1.2 6- 9 Cam sprocket bolt 2 7 '7 - 23 1.7 2.3 12 -::2...... Cylinder head cover bolt 7 6 8- '2 0.8 -' .2 6- 9 Valve adjusting lock nut 2 6 '5 - '8 1.5 - 1.8 1 I - 13 Cam chain guide holder socket bolt 1 6 8- '2 0.8 - 1.2 6- 9 Oil pipe bolt 3 7 8- 12 0.8- 1.2 6- 9 Spark plug 1 12 15 - 20 1.5- 2.0 11 - 14 Intake pipe band screw 1 5 3- 5 0.3- 0.5 2- 4 Oil filter cover bolt 3 6 8- '2 0.8 - 1.2 6- 9 Neutral/Reverse switch 2 10 11 15 1.1 1.5 8- 11 Starte r c lut ch socket bolt 6 8 '8 - 25 1.8- 2.5 13 - 18 Cam chain tensioner lifter bolt 2 6 8- 12 0.8 - 1.2 6- 9 Alternator stator bolt 3 6 8- 12 0.8 -1 .2 6- 9 Breather plate socket bolt 1 6 '0 - '4 1.0 - 1.4 7- 10 Clut ch adjusting screw lock nUl 1 8 '9 - 25 1.9 - 2.5 '4 - 18 Drain bolt 1 12 15 - 25 1.5 - 2.5 11 - 18 Cam chain tensioner lifter sealing bolt 1 6 8 12 0.8 1.2 6- 9 Oil temperature sensor 1 12 '5 - 20 1.5 - 2.0 11 - 14 1-5

GENERAL INFORMATION FRAME Thread Dill . Torque Item a'tv (mml N'm kg -m ft-Ib Handlebar upper holder bolt 4 8 18-30 1.8- 3.0 13 - 22 Handlebar lower holder nut 2 10 40 48 4.0 4.8 29 35 Steering stem nul 1 16 80 140 80 14.0 58 101 Steering bearing adjustment nul (initial) 1 25 35 2.5 3.5 18 25 $tBtlfing bearing adjustment nut (See page 11 - 15) 1 1- 2 0.1- 0.2 0.7- 1.4 Wheel nul 16 10 50 60 5.0 6.0 36 43 Front 8)tle nul 2 16 80 120 8.0 12.0 58 87 Rear axle nut 2 16 80 120 8.0 12.0 58 87 Rear brake panel nul 4 10 80 - 90 8.0-9 .0 58-65 Front shock absorber mount bolt 2 10 40 50 4.0 5.0 29 36 Swing arm right pivot bolt 1 30 16 20 1.6 2 .0 12 14 Swing 81m pivot lock nut 1 30 100 130 10.0 13 .0 72 94 Final gear case mount bolt 4 10 50 60 5 .0 6.0 36 43 4 8 30 36 3.0 3.6 22 26 Rear left bearing housing bolt 4 8 30 36 3.0 3.6 22 26 Front engine hanger boll 3 10 60 70 6.0 70 43 51 Upper engine hanger bolt 6 10 65 75 6 .5 7.5 47 54 Rear engine hanger bolt 3 10 65 - 75 6.5 - 7.5 47-54 Lower engine hanger bolt (Frontl 1 10 65 75 6.5 7.5 47 54 lower engine hanger bolt (Aear) 1 10 80 90 8.0 9.0 58 65 Gearshift pedal bolt 1 6 10 14 1.0 1.4 7 10 Foot peg bracket bolt 4 10 40 - 50 4 .0 - 5.0 29 - 36 Intake pipe bolt 2 6 6 9 06 0 .9 4 7 Muffler clamp bolt 2 8 18 28 18 2.8 13 20 Direct current receptacle bolt 2 5 1.5 2.5 0. 15 0. 25 1.1 1.8 Master cylinder reservoir cover screw 2 4 1- 2 0.1- 0.2 0.7-1.4 Brake hose bolt 5 10 25 35 2.5 3.5 18 25 Ball joint/Tie rod nut 8 10 35 43 3.5 4.3 25 31 Kingpin lock nut 2 8 20 25 2 .0 2.5 14 18 Front arm hinge bolt 2 35 80 100 8.0 10.0 58 72 Rear shock absorber mount bolt 2 10 BO- 90 8.0 - 9.0 58-65 Final gear case cover bolt 2 10 45 50 4 .5 5.0 33 36 6 8 23 28 2.3 2.8 17 20 Pinion joint nut 1 16 100 120 10.0 12.0 72 87 Pinion bearing lock nut 1 60 90 110 9.0 11.0 65 80 Trailer hitch bolt 2 10 70 - 80 7 .0- 8.0 51-58 Grease fitting 6 3 5 0.3 0.5 2 4 Wheel cylinder hose bolt 4 8 25 35 2.5 3.5 18 25 Torque specifications listed above are for the most Important tightening pOints. If a torque specification IS not listed . follow the standards given below , ST ANDA RD TORQUE VALUES Item Torque N·m (kg-m, ft -Ib) Item Torque N·m (kg- m. It -f bI 5 mm bolt , nut 4 .5 6 (0.45 0.6.3 4) 5 mm screw 3.5 5 10 . 35 0.5. 2 4) 6 mm bolt. nut 8- 12 (0.8-1.2. 6-9) 6 mm screw. 6 mm 7- 1110.7 - 1.1.5-81 flange bolt with 8 mm head 8 mm bolt. nut 18 25 (1.8 2.5, 13 18) 6 mm flange bolt. nut 10-1411.0-1.4 ,7- 10) ,0 mm bolt , nut 30 40 (3 .0 4. 0,22 291 8 mm flange bolt , nut 24 30 (2.4 3.0, 17 22 ) 12 mm bolt, nut 50 60 (5.0 6.0,36 43) 10 mm flange bolt , nut 35 45 (3.5 4.5,25 33) 1-6

TOOLS SPEC IAL DESCRIPTION UnIVersal beaflng puller Socket bit. 17 mm Pivot lock nut wrench Steering stem socket Lock nut w.ench, 30 )( 64 mm Lock nut wrench, 34 K 44 mm Clutch center holder Pmlon holder Shaft holder Clank assemhly tool set crankshaft assembly collar - threaded adapler - shaft puller Bearing .emover, 17 mm Sealing remover handle Sealing remove. weoghl Bearing remover $81, 30 mm - remover head - beallng remover, 30 mm Bearmg remover. 15 mm - remover weight Bearing ,emover, 20 mm P,nion gear dllve. Attachment. 28 )( 30 mm AttaChment Compressor base Kingpin driver Spring compressor adapter Collar Spflng compressor adapter Valve guide reamer Snap rmg pile" • Inspection adapter Ie 11 • Clutch holder • Camber/caster gauge attaChment Attachment Digital multlt8ster CirCUit teste, {SANWAI TOOL NUMBER 07631 -001 ()()()()- 07703-oo2?~ 07908-4690001- 07916-3710100 07916-M800001- 07916 - ME5OOO1- 07923 - KEl0001 07924 - HA OOOOO 07924 - ME50000 07931 - KFoooOO 07931 - KFOOIOO 07931 - KFOO200 07931 - ME40000 07936- 371 0300 07936-3710100 07741-0010201 07936-8890100 07936-8890200 07936 - 8890300 07936 KC 1 0000 07741 - 0010201 07936 - 3710600 07945 HAOOOOO 07946 - 1870100 07946 - HAOOOOO 07959 M810000 07965 - VM50000 07967 - VM50100 07967 - GA701O\ 07967 - KC100oo 07984 - 2000000 07914-3230001 07508-0012500 07923-HA80000 07910-MJ30100 07965-SA50600 07411 - 0020000 07308 0020000 GENERAL INFORMATION • Newly designed for this model ALTERNATE TOOL TOOL NUMBER REF . PAGE Equivalent commerClaliv 10·5. 13-18 ji-avall8ble In U.S A 13·13, 15 Ir~OCk nut wrench KS-HBA·08-469 13-13. 15 {U.S.A.onlvl "·14 Ir~OCk nut wrenCh, 30 I( 64 mm 07916 - MBOOOOO 10-18,20 Attachment {U.S.A. onlv! 07916 - HAOO20A 10-18,20 ~~OCk nut wrench, 34 I( 44 mm 079 I 6 - ME50000 10- 15,16,20, 21. 13-18, 21 Attachment (U.S.A. onlv) 07916 - HAOOIOA 10-15.16.20. 21. 13-18, 21 8·8, 11 13-18.19,25 10-14, 15,21 10-7 10-7 10-7 10-7, 13-19 8-14,10-6, 11 8-14,10-6. 11. 17 Remove, weight 07936 3710200 8-14.10-611, 13. 14 P-NOI available In U S.A 13-14 13-14 13-14 10 17 Remover weight 07936 3710200 10-17 8-14 Not available In U.S.A 13-9, 10,21 8-14, 10-12 10-19 13-12 11-9 11-13 11-13. 13-17 13-12 6~8 12-10 ~NOI available In U,S A. 15-2. 4 8-4, 7 3-12 12-12 01911al muilimeler tU.S.A . onlv) KS -AHM32 -003 15-1, 16 I CorCUIl lester {KOWAl TH-5H· ' IS-I , 16 1 1-7

1985-1987 Honda TRX 250 Service & Repair Manual

You're Reading a Preview

Recently Viewed