1995-2000 Honda FourTrax 300 (TRX300) Service & Repair Manual

~~ WARNING CAIJ11OH: "". IMPORTANT SAFETY NOTICE 'ditalliS IItrOt!p ~ it+')' of _ p«t(IMI Ml"'Y or '*-11'111 M'IIlruCIlons .. IXIf 1oOoQd. iI'IdJCIliH ... Of' " t>W!J 01 ~.,...,. Of ~ ~ If ~ •• not 1rJIIowea. GMIS IleIpfuI ,nIoonalkln Detailed des.r:nptJo". ol.landard wo ..... hop p<oeedure5 "'tty priocople$ iond MfV\f;4' QPel"Jons are no! nduded I, •• omportaI'IIl<> fIOItl!'lat til .. manl.lal conlaln. IOI'Ie WlImlllOS and CllUloons aogllRSl ."... 1PI'C,1ic HMc. ..... tnocta which could eause PERSONAL INJURY to MMoI ~neI o. could o.m~ .. Y9!1de Of..-ndlo It unn". P I_ understand Ihlllll()se w...... n;. could ncr COYer .. c:cII,,*v"" Wlft., which HnIIce. whel!lel' or IlOl fllCORlrnencled by ~ mogM 1M done or of the POII>tIIe IlazarOoiK conHqUencn 01 each COOC_ilIbie wiI)' , nor could HondI.l<I\I'lt~te .. aucll ways. Aroy009 usiog ____ PfocedUf .. ()f tools, .. heIhef or not r.comm.nded tly Honda mu.t urlsly hlfnseJ/ rtIotoughfythat n.,the< persona! .. \ely nor .8IIic1e 1.IIIIy Wlil tie jeopard,zad by the ...... oc:. m&U'IOd 0' tool. &elllClad 1 J

HOW TO USE THIS MANUAL Follow t he Maintenance Schedule (Section 3) recommendations to ensure lhal the vehicle is in peak operating condit ion and the emission levels are within the standards set by the Cal ifor- nia All Resour ces Board Sections 1 through 3 apply 10 the complete FOUATRAX, while sections 4 through 21 de scri be paris ol l he FOURTRAX, grouped according to location. Find the section you want 00 Ihis page. I'Ief1 fum 10 the table 01 contents on page 1 01 thai section. M os t sec t ions sl art Wllh an assembly Of syst em Il lustra t io n, service i nlormation and t ro ubles hooting f or the section . The subsequent pages give de t ailed proce- dures. II you don', koow the source altha trouble, go to secllon 22. Troubleshooting. All illklnnMlon. I'~ dio .... liui . _ ~ Ir'd'Wd In 1hII publlcllllon _ be..t on 1hI .... prOducI: ~ 1 ... " MOtkw' .......... • IhI rn. 01 -"""0 ..... for po1rrang. HorIdIo MoIor co, L TD. ...... .. _ right to ....... ~" wry *'- wIttlouIl>Oticto _ wtthouI lncuntno wry obligation __ . No pAI1 01 thl' publc.lor> ma r be reproduced ...1ItIout lOl lII'M" ~ ....... . - - ---' HONOA MOTOR CO .. LTD. Service Publications Cltiee CONTENTS GENERAL INFORMATION LUBRI CATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAUiNSTALLATION CLUTCH/ O IL PUMP/KICK STARTER ~~ FRONT WHEE LlS USPENSIONlSTEERING I BRA KES ~ I REAR WHEELlSU SPENSION 51 I REAR DRIVING MEC HAN ISM CARRIERSJFENDERSIMUFFLER IGNIn ON SYSTEM ~ ~;;;;;,,;;~===- < BATTERY/C HARGING SYSTEM 2 ~~~~~~~~~~== ~ ~S ~ T ~ A ~ . ~ T ~ E ~ .~ S ~ Y ~ S ~ T~ E~ M~~~~~~~_ ~ ~; L~ IG = H = T = SiS ~W ~ IT =C=H= E = S ~~~~~~~~== WIRING DIAGRAM TROUB LESHOOTING INDEX

I • , , • • , t • • f , 1. GENERAL INFORMATION GENERAL SAFETY SERVICE RULES MODEL IOENT1FICAnON SPECIFICATIONS TORQUE VALUES GENERAL SAFETY H ,-. ,-, ,~ ,-, TOOLS 1-10 CABLE & HARNESS ROUTING 1-12 EMISSION CONTROL SYSTEMS (Atler '97) H8 EMISSION CONTROL INFORMATION LABEL (ArtM '97 California tYIM only) 1019 If ~ ....... muslIN ~ ro '*' IO(ImII -*. ~ ... ",. _ Is _......eiaMd. ~ IUf'III'M MIgiIN ifI..., .>CIoBM1_ . The tIXtYuM 0C\rlIIIWII" podQlOI.<S at/tIOrI trIIlII'IO.ridi gall 111M IINIr CIIusot Joss 01 OO/~ lind Iud to dN/II. • im.1ed ubesros fibots haWl been fOlJIId to CllIIM rtlpinlrOl)' - .... Bnd C4/lCet" ~ I.e In "" hose or dry btu5Jl to dlMn Ink. or dufCfI us .Ib/ies . • Use." ~~oO\!lOd >'lICUI.OTI elM"", or .n«nlllfJ",.tnod IIPPfO"f'd by OSHA de$iQnIId ro mhi1Iint the hazard ClIUSIId by _ ftt»sI(Id fIi!MnI . ~ " ~ ~ lind is ~ ..... """"'" caodiilioo.so Do 001 smokl or ...... I)IIJICIIiiv;. stored The IJa"1If)' -'«IrotyIl oonWns su/ttHil; 1ICId. Prol«1 y/llK llYO, $/t.in .00 doItWIg. In IhfI elfN of corn.ocr, /lush tfIortJug/lIy wilt! .... ter .rI(I c,I' II dOC"'" It eMctro/yle 96'S In roor 9)188. SERVICE RULES 1 liM {I*'IIIiIM HONDA or HONDA·._oded pen. and klbri<:anlll or ar.-1IQUIYaIent1 P.". "* don' meeI HONDA', dMogn ~1Klns n'WIy __ darnage 10 !he ..... 2 u.. the~ 100II dl. ",oed Io;w 11-. produeIlO _Gllmaga and ;'OOOI,eC1 "'1 'lbIy 3. u.. aNy metric IOOIs when HrVicIng lhII-..hode MtoItIc bob, ..ns"'" sa-..,. noc IntercNO'\lI.1Jie WIth English ':as! .... _ Instal.- gu!<eI., O-mos. COIhII' p;r., and lOde pIIIl.,. -. ...-sec "bli"lI . 5. When fVl1 ..... ng bob or nul$, t.gIn with the .. .get dl_maUI( Of !me< boll ';'11\. n- IiogI\*1 ttl me I!)eCifIed \OfqIlIlI diItgonaIy In ............... , . , •. unless a particular MQlI8flCe .. 1llMCl11ed. 6 Clean parts in non-!lammable Of high !lam paint $OIYtInt Up!ll'l disassembly 7, Loonc.te any 1Iid"'ll .ul1~ bel ",. reel$ollTlbly 8. Me, , .... ombly. C!>9Ck.n pans 10< proper iNUln.hon.nd opeoIuon. 1-1 I -

GENERAL INFORMATION MODEL IDENTIFICATION TRXlOO: TRX3OOFW: 1-2

• • • • • • J • I • I ! I C ll The frame .. rial number is stamped on the ' root 01 ttIe lI'arrMI (2) The engine Mnal ...... ,-be, IS stamped on !he upper IkIe 01 the right ..... H (3) The ta/b.lfelOf Klenlitic811Qn IUI'Iber II on !he left lOde 01 the carour8lOf - GENERAL INFORMATION 1-3

-., Ahe< '97 ' 95-'97 Alief '97 0&-., AllIN '97 -., -., '95-'97 Aher '97 '95-'97 Alrer '97 1.910 nvn (75.2 in) 1.115 mm(43.gin) 1,151 mm(45.6in) 1.088 mm (42.S in) 1,017 mm (42.4 in) 1.239 mm (46.8 in) 1.239 nvn (48.8 in) 783 nvn (30.8 in) 783 nvn (30_8 in) 305 nvn (12.0 in) 297 nvn(11.7inj 180 mm (6.3 in) [1. 110nvn (43.7",)] [1.085 nvn (42.7 in)) [1.089 nvn (42_9 in)] [1.238 nvn (48.7 in)] [1.235 mm ( 48.6 in)) [780 nvn (30.7 inn [788 nvn (31_0 in)) (309 nvn (12.2 in)) 180 mm (6_3 in) [1 12 mm (S.S in)] r..'"'. __ '-.:::c= _________ --t "'=" • .:..;: .. ~~=~4:;;=C. -''------'.C'''-- k9 (5271b)] 1-4 11.6.5AT 9.I/OAT Alalr ..... 130 nvn (5 1 in) Axle lrave1130 mm (5 1 In) [11.15Al1 AT23.&-11 •• . 2.9pei(0.20~~,20 kPa) [AT 23.8·11 ", 44 psi (0 30 kgJern2. 30 kPa)] AT 25. 11·9 " 2 9 psi (0.20 k~cm2. 20 kPa) [AT 24 • 9·11 ' . 2,9 psi (0.20 k~r;:m2, 20 kPa) w1th cargo: 3.6 psi (0.25 ~r;:m2. 25 kPa)) liydraulc operated Ieadol9'lraong IIlOe [~operalOld ""...," ·"IlIIhoe] CMJIIo opotraIed" "91rlUllr"'fll-"- 12 51\en; (3_3 us gal, 2 8 q. ~ 2_51i1ers (0.7 us (181. 0,6 q. gal) 5nvn(0.25In) [4mmIO.16in)] 7 12.2) 0.2' [0 ) 33.0 nvn (1.26 on) [ 10 0 mm (0.39 1n)J 790nvn(31.1 in) 840 nvn (33.1 in) (840 nvn (33. 1 in)] [840 nvn (33. 1 in)] t. TRXlOOFW

• • , • • • • • • ENGINE CA,RBUAETOFI '''' Cyindotr an ... IO'IfTI'" ~ 8o<to • stroke "-, '"""'""'"' 000 valve trllm 0;1 cappciry lubncatiOn sys10m ey.indBr~ Intake .... Ive """' ~ Exhaust v_ -- c-. .... _- - ,- ....... '''' ldenlrficaoon number ... " Aftllr '97 Tmonle Dor8 MIl ... jet Slow jet Starter jet PiloI _ RI>aI opeo .. '" ......... - -- ... - GENERAL INFORMATION [ t. TRX300FW GasoirMo. an-cooled f-1IrOb Single cyIindIIr .Il:10_ 20- kam_oeat 74.0 .65.5 nvn (2.91 • 2.58 In) 281.7 a: (11 .2 Cl>-iI'I) 9. 0: , 0II11fhead caInSI'll!. dial" driven 2.5 iii (2.6 US qI , 2.2 Imp qr),1 <I$a$5ernb/y 2.2111 (2.3 US qt , I.SImp qI) ane< draining Fofced ptflSUtl lind ..... 1 lUmP , ,250-1 ,4500 kPa (12. 5-1 ' .S ~an2. 118-206 pso) " ,= I 32' ASOC /II 1 nvn iii! ., ."""" .2 ATDC 0.15 rnm (O.OOSin) 0.15 mm (0 .006 .. ) vacuum piQon (VEl VE91C E.cep! CllliIomLIlyPt: vUle Galifor!l;& fype VES 1 0 32mm(1.3In) . '" .W .. , /, &e8 p.'IgI ." " ,./): ltd glOCMl from ~ ~ 18.5 rrwn (0. 73 In) 1,400.1: 100 rpm ....liI: ~ 1-5 -

• GENERAL INFORMATION DRIVE TRAIN CIuId'I WMlTllJlb.plala. automabl; ~ s.speed cons/aIII .... -. with r-.. 2.07 (65IV) ELECTRICAL 1-6 , .. "., ..... , Pr'rT..ry .... ort.m ae... Ramo " '" " RevafM .. 0B3 (.~12) 2.389 (U/ 18) 1 609 (37/23) , 179 (33128) 0.848 (28133) 5.397 (301112 ~ 4Ml) Fronl (TRX3OOPN) S5M (191' 13 x 38110) GHtIhIl pattern AN, 1 462 (19113) .3.869 (3S'9) laIIloot """",hid retum ~, FOIW/II,d ~-1 -2-3-<I Reverse: P+-R [Front dille<entJal oil eapIIdIy 2OOcc(8.8oz1 at~J [1510 CC (6.4 0Cl) llfter dollii.ogl [Front goat ~ oil ~ 2OOcc{6_8Ql)_~1 [ 190 a: (6.4 02) alief dfaIning] Rear INI dIrIve 01 capac/!y HIO CC (3.4 oz) 81 dosassemilly 90 CC (3 0 Ill) aIle< cQIning 19n1tiQrl l lrr\ing Inll,al 13 " BTOClllidkt Full a<toarca 31 • Bl OC ., 4,SOO j; 100 rpm AAalnlltor C._ 0.22 kW/5 ,OOO tpOl Battery 12 V-12 AH .... ...,. ~" OPf'l7EA'9 ""., .... , ....... "" ~2S:2~5W'2 Hutlli!1l1 ,- I lV 5W Neutral indicator 12V'.7W R&v<ll'$llindicalor 12V L7W 001 tugh !emperaMe iodocalor 12V 17W . X22£PR.U9 X27EPR-U9

GENERAL INFORMAnON TORQUE VALUES ENGINE ,- C', Thread Dill. ,- Remarks I~I Nom .... , .. Engine 01 drain boll • " " ,., " OiINW_boIt , , " .. , , NO'" Ct.IIch IIII]iIIs.Ilog talIW kid< nuc • , " " .. VaNe ~ lock nuc , , " ... " ........ • " " .. , " InIuiBtor band _ • , • , .. " Carbu,8IOr cove, SCrew • , '" ,." ,., Starttog enrichmenI (SE) valve nul • .. ,., 0.25 ••• CyIinde< head COV&I'(6 mm SH bolt) , , " .. , , (6 ..... IIanoe bolt) " , " .., • CyIindoJf head (~ nu1 ) • " '" .. , " (1IOCkeI bolt) , • " .. " "" ....... - , , " " .. OOTE 1 Cam d\aIn IfInISionef IiIItt (mounang bolt) , , " " , (aealing ball) • , " " , Oil pope boll (Bl.ACI<) • , " ... 9 011 pump assembly bolt , , , " , .. Oil PIOIh pipe boll , , " .. , • Cy1;ndef rnountiog boll , , " ., , Cen1ritugal cIuId\ lock nul • " ." 12.0 " NOTE 113/. Change du\ctllock f\U! • " '" 11 .0 OJ NOTE 1/3 CIuICh IPM\I boll • , " .., • -_ .. • , " ... • NO" • RIghI crankcase _ boil " • " " , Kid< Slarlllf ratche4 go...M , , " ... • SIarte< .............. QIOI' _ boll , , " " , Ignobon pU:se generator socI(eI bolt , , • ,., • NOTE 1 MemalOf sunor boll , , " .. , , Sterle< o;:IkJb;:h TQrI( boll • • .. ••• " NO" • ,,..,.."'" • " '" 11 .0 OJ , Gearshift retum IPritIQ pio1 • , " " " L.eII Cfankcue _ bolt • , " .. , , s.o. lhall CQ\I8I' boll (TRX3OOFW) • , " .. , , 0VTI'lIT G,," Qulpulsl'laft b .. l ug I'IOII:It< boll , • " ,. " CounIIK5haIl beating lode nul • ~ . ., '" n NOTE 213 0u\pu1 wll beamg DU\eI raoe lode nul • " . ., 10.0 n NOTE 213 0u\pu1 shaM beamg inner race lock nu1 • " " " " NOTE 213 0u\pu1 O&i" case mounung boll , • " " " Cr/lnkcllse bolt " , " ••• , Buring SOlI plale boll , , " ., • NOTE 1 Cam a-. ~ holder boll • , " ... • NOTE 1 _.- • " " ., • _ .... • " " " • OIl8ollpanllure MOSOI • " .. ... " 1-7 , --'

1995-2000 Honda FourTrax 300 (TRX300) Service & Repair Manual

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