1998-2004 Honda FourTrax Foreman ATVs (TRX450S/TRX450FM/TRX450ES/TRX450FE) Service & Repair Manual

r-------IMPORTANT SAFETY NOTICE ----------, Indicates. strong possibility of severe pel$OnlJl injury or death if Instructions .r. not followed. CAunON: Indicates .. possiblUty of lHluipment dlJmage If instructions are not followed. NOTE: Gives helpful information, Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY 10 service personnel or could damage a vehicle or render it unsafe. Please understand that those warn ings could not cover 811 conceivable ways in wh ich service. whether or not recommended by Honda. might be done or of the possiblV 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 safety nor vehicle safety wi ll be jeopardized by the service mel hods or lools selected.

HOW TO USE THIS MANUAL This service manual describes the service procedures for the TAX450S/ FM and TAX450ES/FE. Follow the Maintenance Sc hedule (Section 3) recom- mendations to ensure tha t t he vehicle is in peak operating condition and the emission levels are within the standards sel by the California Air Resources Board. Performing the first scheduled maintenance is very i mportant. II compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for remova1l i nstallation of components that may be required to perform service described In the following sections. Section 4 through 23 describe parts of the vehicle, grouped according to l ocation . 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 assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. If you are not familiar with this vehicle, read the Technical Features in section 24. If you do not know the source of the trouble , go to section 25. Troubleshooting . z ~ .... W > « a: c c z « w z - (!l Z w '" <i5 '" « :I: <.J ...J 5 ~ W ...J W CONTENTS GENERAL INFORMATION MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/CYLINDER/PISTON CLUTCH GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH REAR WHEEL/SUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM REAR DRIVING MECHANISM BATIERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES ELECTRIC SHIFT PROGRAM (ESP) SELECTABLE 4WD SYSTEM (After '01) WIRING DIAGRAM TECHNICAL FEATURES 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 recommended engine oil, unless otherwise specified. -, Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1), ~..$iiiiM Use mUlti-purpose grease (lithium based multi -purpose grease NlGI #2 or equivalent). Use molybdenum disulfide grease (comaining more than 3 % molybdenum disulfide, NLGI #2 or ~ equivalent). Exampl e: Molykote e BR -2 plus manufactured by Dow Corning , U.S.A. Mult i-purpose M-2 manufactured by Mitsubishi Oil , Japan Use molybdenum disulfide paste (containing more than 40 % molybdenum disulfide, NlGI #2 or equivalent). ...-'iiiPJI Example: Molykote e BR -2 plus, 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. Cl."" Apply a locking agent. Use a middle strength locking agent unless otherwise specified. ,",'Ilml Apply sealant. I Use DOT 3 or DOT 4 brake fluid. Use the r ecommended brake fluid unless otherwise specified. - Use Fork or Suspension Fluid.

1. GENERAL INFORMATION GENERAL SAFETY 1-1 SERVICE RULES 1-2 MODEL IDENTIFICATION 1-3 SPECIFICATIONS 1-4 TORQUE VALUES 1-13 TOOLS 1-16 GENERAL SAFETY CARBON MONOXIDE If the engine must be running to do some work, make sure the area is well ventilated. Neve r run the engine in an enclosed area. The exhaust contains poi sonous carbon monoxide gas that can cause loss of consciousness Bnd may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. GASOUNE Wo rk in a well ventil ated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is stored. Gasoline is eKtremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS Engine and exhaust system parts become very hot and remain hot for some tim e ah er the engine is run . Wear insulated gloves or wait until the engine and eKhaust system have cooled before handling these parts. LUBRICATION & SEAL POINTS 1-18 CABLE & HARNESS ROUTING 1-21 EMISSION CONTROL SYSTEMS 1-37 EMISSION CONTROL INFORMATION LABEL 1-38 USED ENGINE OIL Used engine oil may cause skin cancer if repeatedly leh in contact with the skin for prolonged periOds. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible aher handling used oil. KEEP OUT OF REACH OF CHILDREN. BRAKE FLUID CAUTION: Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. BRAKE DUST Never use an ai r hose or dry br u sh to clean the brake assemblies. Use an OSHA - approved vacuum cleaner or alternate met hod approved by OSHA, designed to minimize the hazard caused by air borne asbestos fivers. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. 1-1 E

GENERAL INFORMATION BATTERY HYDROGEN GAS & ElECTAOL YTE The battery gives off explosive gases; keep sparks, flames IJnd cigarettes away. Provide adequate ventilation when charging. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause sever. burns . We.' protective clothing and II face shield. -If electrolyte gets on your skin, flush with water. - If el ectrolyte gets in your eyes, flush with water lor at least 15 minutes lind calla physician immediately. Electrolyte;s poisonous, - If swallowed, drink large quantities of watsr or milk and follow with milk of magnes's or vegetable oi/llnd call B physician. KEEP OUT OF REACH OF CHILDREN. SERVICE RULES 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 vehicle. 2. Use the speci al tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets. O-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 reassembl y, check all parts for proper installation and operation. B. Route all cable and harness routing as shown on pages 1- 21 through 1-29 Cable and Harness Routing. 1-2

MODEL IDENTIFICATION TRX 450S/FM : The frame serial number is stamped on the front of the frame. The carburetor identification numbers are stamped on the left side of the carburetor body as shown. GENERAL INFORMATION TRX 450ES/FE : ENGINE SERIAL NUMBER The engine seri al number is stamped on upper side of the rear crankcase viewed from the left side. COLOR LABEL The color label is attached to the frame under the seat as shown . When ordering color-coded paris , always specify the designated color code . • 1-3

GENERAL INFORMATION SPECIFICATIONS - GENERAL ITEM DIMENSIONS Overall length ('98 - '01 I (After '01) Overall width ('98-'01' (Ahe r '01) Overall height Wheelbase ('98 - '01) (After '01) Front tread ('98 - '01) (After '01) Rear tread Seat height ('98-'01' (Afte r '01) Foolpeg height ('98 - '01) (After '011 Ground clearance ('98-'011 (After '011 Dry weigh t ('98-'01' (After '011 Curb weight ('98 - '01) (Aher '01) Maximum weight capacity FRAME Frame type Front suspension Front wheel travel Fron t damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim si ze Tire brand (DUNLOP) FAIAR Front brake Rear brake Toe Caster angle Camber angle Trail length Fuel tank capacity Fuel tank reserve capacity 1-4 S PECIFICATION 1,961 mm (77.2 in) 1,963 mm (77.3 in) 1, 1 56 mm (45.5 i n) 1, 151 mm (45.3 in) 1,144 mm (45.0 in) 1,271 mm (50.0 in) 1,274 mm (50.2 in) 912 mm (35.9 in) 910 mm (35.8 in) 905 mm (35.6 in) 860 mm (33.9 in) 854 mm (33.6 in) 327 mm (12.9 in) 1333 mm (13.1 inll 329 mm (13.0 in) 1336 mm (13.2 inll 192 mm (7.6 in) 196 mm (7.7 in) 260 kg (573 Ibs) (266 kg (586 Ibsll 264 kg (582 Ibs) [270 kg (595 Ibsll 270 kg (595 Ibs) [276 kg (608Ibs)) 274 kg (604 Ibs) (280 kg (617lbs)) 220 kg (485 Jbs) Double cradle Double wish-bone 150 mm (5.91 in) Doub le tube Swingarm 150 mm (5.91 in) Double tube AT25XB-12 ** AT 25 X 10-12 ** 12X6.0AT 12X7.5AT I: '98 - '01: TAX450ES After '01' TRX450FE KT401CI '98 - '0 1: KT405C, After '01 KT128 Hydraulic drum brake Mechanical drum brake Toe-out: 35 mm (1-3/8 in) 3· 0.1 ' 7 mm (9/32 in) 12.0 i (3. 18 US gal, 2.64 Imp gat) 2.7 f (0.71 US gat, 0.59 Imp gat)

GENERAL INFORMATION GENERAlICont'd) ITEM SPE CIFICATION ENGINE Bore and stroke 90.0 X 68.0 mm /3.54 X 2.68 in) Displacement 432.6 em l (26.40 cu-in) Compression ratio 8.5 : 1 Valve train Overhead valve Int ake valve o pens 6' BlOC Intake valve closes 45' ABDC Exhaust valve opens 36' BBDC Exhaust valve closes 10' AlOe Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Air cooled Air filtration Oited double urethane Crankshaft type Unit type , two main journals Engine weight (TRX450S/FM) 50.2 kg 01D.7 Ibsl (TRX450ESjFEj 52.2 kg (115.1 Ibs) Cylinder arrangement Single cylinder, longitudinally installed CARBURETOR Carburetor type CV (Cons tant Vacuum) type Throttle bore 32.0 mm DRIVE TRAIN Clutch system Centrifugal & multi-plate, wet Clutch operation system Automatic Transmission Constant mesh, 5-speed with reverse Primary reduction 2.103 (61/29) Secondary reduction 2.100 (42/20) Final reduction Front ('98 - '0 1) 3.153 (41/13) (A fter '01) 3.231 (42/13) Rear 3.153 (41/13) Gear ratio ,,, 4.083 (49/ 12 ) 2nd 2.388 (43/18) 3,d 1.608 (37/23) 4th 1.178 (33/28) 5th 0.848 (28/33) Reverse 4.781 (34/12 X 27/16) Gearshift pattern Left foot operated return system R-N-1-2-3-4-5 ELECTRICAL Ignition system DC - CDI Starting system Starter motor and emergensy recoil starter Charging system Trip le phase output alternator Reg ulato rlrecti fier SCR shorted/triple phase full-wave rectification Lighting system Battery 1-5

GENERAL INFORMATION LUBRICATION SYSTEM Unir mm (in) ITEM STANDARDS SERVICE LIMIT Engine oil capacity AI draining 2.0 e (2 . 10 US qt, 1.761mp qt) At disassembly 2.7 t (2.84 US qt, 2.38 Imp qt) At oil filter change 2.1 t (2.21 US qt, 1.851mp qtl - Recommended engine oil HONDA GN4 4-stroke oil or equiva lent motor oil API service classification SF or SG Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 - 0.21 (0.006 - 0.008) 0.25 (0.010) Side clearance 0.02 - 0.09 to.OOl - 0.004) 0.11 (0.004) , FUEL SYSTEM ITEM SPECIFICATIONS Carburetor identification number '98 - '01: VE93A After '01: VE93C Main jet Initial #130 High allilUde setting #120 Slow jet '45 .- Jet needle clip position 3rd groove from l Op Pi lol screw I Inilial opening 2 - 5/8 turns out I High altitude setting 2 - 5/8 turns out Float level 18.5 mm (0.73 in) Engine idle speed 1,400 ± 100 rpm Throttle lever free play 3.0 - 8.0 mm (1/8 - 5/16 in) Starting enrichment (SE) valve distance 10 - 11 mm (0.39 - 0.43 in) 1-6

1998-2004 Honda FourTrax Foreman ATVs (TRX450S/TRX450FM/TRX450ES/TRX450FE) Service & Repair Manual

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