Clutch/Kickstarter/Gearshift Linkage Specifications; Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications; Cylinder/Piston Specifications (After '05); Specifications (After '05) - Honda TRX450R Service Manual

GENERAL INFORMATION
CYLINDER/PISTON SPECIFICATIONS (After
f
05)
Unit: mm (in)
ITEM
Cylinder
Piston,
piston pin,
piston ring
I.D.
Out-of-round
Taper
Warpage
Piston O.D. at 10 (0.4) from bottom
Piston pin hole I.D.
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end
gap
Piston ring-to-ring
groove clearance
Top
Second
Oil (side rail)
Top
Second
Cylinder-to-piston clearance
Connecting rod small end I.D.
Connecting rod-to-piston pin clearance
STANDARD
96.000 - 96.015 (3.7795 - 3.7801)
-
-
-
95.970 - 95.980 (3.7783 - 3.7787)
19.002 - 19.008 (0.7481 - 0.7483)
18.994 - 19.000 (0.7478 - 0.7480)
0.002 - 0.014 (0.0001 - 0.0006)
0.25-0.31 (0.010-0.012)
0.23-0.33(0.009-0.013)
0.20-0.70(0.008-0.028)
0.065 - 0.100 (0.0026 - 0.0039)
0.065 - 0.100 (0.0026 - 0.0039)
0.020 - 0.045 (0.0008 - 0.0018)
19.016 - 19.034 (0.7487 - 0.7494)
0.016 - 0.040 (0.0006 - 0.0016)
SERVICE LIMIT
96.05(3.781)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
95.87 (3.774)
19.03 (0.749)
18.98(0.747)
0.04 (0.002)
0.45 (0.018)
0.48 (0.019)
0.90 (0.035)
0.115(0.0045)
0.115(0.0045)
0.18 (0.007)
19.04 (0.750)
0.06 (0.002)
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SPECIFICATIONS
('04 - '05)
Unit: mm (in)
ITEM
Clutch
Kickstarter
Lever free play
Spring free length
Disc A thickness
Disc B thickness
Plate warpage
Pinion gear I.D.
Spindle O.D.
Idle gear I.D.
Idle gear bushing I.D.
O.D.
Countershaft O.D. at kickstarter idle gear
STANDARD
10-20(3/8-3/4)
45.7(1.80)
2.92-3.08(0.115-0.121)
3.22-3.38(0.127-0.133)
-
22.007 - 22.028 (0.8664 - 0.8672)
21.959 - 21.980 (0.8645 - 0.8654)
21.020-21.041 (0.8276-0.8284)
17.000 - 17.018 (0.6693 - 0.6700)
20.979 - 21.000 (0.8259 - 0.8268)
16.966 - 16.984 (0.6680 - 0.6687)
SERVICE LIMIT
-
44.7 (1.76)
2.85(0.112)
3.15(0.124)
0.15(0.006)
22.05 (0.868)
21.95 (0.864)
21.07 (0.830)
17.04(0.671)
20.96 (0.825)
16.95(0.667)
CLUTCH/STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
SPECIFICATIONS (After
f
05)
Unit: mm (in)
ITEM
Clutch Lever free play
Spring free length
Disc A thickness
Disc B thickness
Plate warpage
Driven gear boss (TRX450ER) I.D.
O.D.
Reduction gear A I.D. (TRX450ER)
Reduction gear B I.D. (TRX450ER)
Idle gear I.D. (TRX450ER)
Gear holder shafts O.D. (TRX450ER)
Reduction gear shaft O.D. (TRX450ER)
Kickstarter
(TRX450R)
Pinion gear I.D.
Spindle O.D.
Idle gear I.D.
Idle gear bushing I.D.
O.D.
Countershaft O.D. at kickstarter idle gear (TRX450R)
STANDARD
10-20(3/8-3/4)
45.7(1.80)
2.92-3.08(0.115-0.121)
3.22-3.38(0.127-0.133)
-
36.009 - 36.034 (1.4177 - 1.4189)
45.660 - 45.673 (1.7976 - 1.7981)
12.010 - 12.050 (0.4728 - 0.4744)
10.045 - 10.085 (0.3955 - 0.3970)
12.010 - 12.050 (0.4728 - 0.4744)
11.989 - 12.000 (0.4720 - 0.4724)
9.980 - 9.995 (0.3929 - 0.3935)
22.007 - 22.028 (0.8664 - 0.8672)
21.959 - 21.980 (0.8645 - 0.8654)
21.020-21.041 (0.8276-0.8284)
17.000 - 17.018 (0.6693 - 0.6700)
20.979 - 21.000 (0.8259 - 0.8268)
16.966 - 16.984 (0.6680 - 0.6687)
SERVICE LIMIT
-
44.7 (1.76)
2.85(0.112)
3.15(0.124)
0.15 (0.006)
36.034(1.4189)
45.660(1.7976)
12.050(0.4744)
10.085 (0.3970)
12.050(0.4744)
11.989 (0.4720)
9.980 (0.3929)
22.05 (0.868)
21.95 (0.864)
21.07 (0.830)
17.04(0.671)
20.96 (0.825)
16.95(0.667)
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