Table Of Contents - Honda TRX450R Service Manual

Table of Contents

A Few Words About Safety2
Service Information2
Important Safety Precautions2
Contents3
Symbols4
General Information5
Table Of Contents5
Service Rules6
Model Identification6
General Specifications ('04 - '05)9
General Specifications (After '05)10
Lubrication System Specifications12
Fuel System Specifications ('04-'05)12
Fuel System Specifications (After '05)12
Cooling System Specifications13
Cylinder Head/Valve/Camshaft Specifications ('04-'05)13
Cylinder Head/Valve/Camshaft Specifications (After '05)14
Cylinder/Piston Specifications ('04-'05)14
Clutch/Kickstarter/Gearshift Linkage Specifications15
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications15
Cylinder/Piston Specifications (After '05)15
Specifications (After '05)15
Crankcase/Transmission/Crankshaft Specifications ('04 - '05)16
Crankcase/Transmission/Crankshaft Specifications (After '05)16
Front Wheel/Suspension/Steering Specifications17
Rear Wheel/Suspension Specifications18
Hydraulic Brake Specifications18
Electrical Specifications ('04 - '05) -1-1418
Battery/Charging System Specifications (Trx450Er)19
Electric Starter Specifications (Trx450Er)19
Lights/Switch Specifications19
Ignition System Specifications19
Standard Torque Values20
Engine & Frame Torque Values20
(After'05)20
Lubrication & Seal Points25
Cable & Harness Routing28
Emission Control Systems47
Source Of Emissions47
Exhaust Emission Control System47
Crankcase Emission Control System47
Servicing The Honda48
Prohibited Actions48
Noise Emission Control System48
Rebuilt Engine48
Technical Features49
Unicam System Outline50
U-Shaped Roller Rocker Arm50
Auto-Decompression System50
Hot Start System51
Twin Sump Lubrication System51
Frame/Body Panels/Exhaust System52
Frame/Body Panels/Exhaust System Service Information53
Frame/Body Panels/Exhaust System Troubleshooting53
Frame/Body Panels/Exhaust System Torque Values53
Seat Removal54
Seat Installation54
Mud Guard/Footpeg Removal54
Mud Guard/Footpeg Installation55
Top Cover ('04 - '05)56
Top Cover (After '05)56
Front Fender ('04 - '05)57
Front Fender (After '05)57
Rear Fender ('04 - '05)58
Rear Fender (After '05)58
Skid Plate59
Engine Guard ('04 - '05)59
Engine Guard (After '05)59
Fuel Tank60
Heat Guard Plate ('04 - '05)60
Heat Guard Plate (After '05)60
Exhaust System Removal61
Exhaust System Installation63
Maintenance65
Maintenance Service Information66
Maintenance Schedule ('04 - '05)68
Maintenance Schedule (After '05)69
Fuel Line70
Throttle Operation70
Air Cleaner71
Spark Plug73
Valve Clearance/Decompressor System74
Valve Clearance Inspection74
Valve Clearance Adjustment75
Decompressor Clearance Inspection/Adjustment77
Engine Oil/Filter78
Oil Level Check78
Oil And Filter Change79
Transmission Oil81
Recommended Transmission Oil82
Oil Change82
Engine Idle Speed84
Radiator Coolant84
Cooling System85
Drive Chain Slack Inspection85
Recommended Antifreeze85
Replacement87
Drive Chain Slider89
Brake Fluid89
Front Brake90
Rear Brake90
Brake Pads Wear90
Brake Light Switch91
Brake System91
Hydraulic System Inspection91
Parking Brake Adjustment92
Skid Plate, Engine Guard93
Clutch System93
Brake Pedal Height Adjustment93
Front Suspension Inspection94
Rear Suspension Inspection94
Suspension •4-3094
Spark Arrester95
Nuts, Bolts, Fasteners- •4-3195
Wheels/Tires96
Steering Shaft Holder Bearing96
Steering Head Bearing- •4-3296
Steering System97
Lubrication System99
Lubrication System Diagram100
Lubrication System Service Information101
Lubrication System Troubleshooting101
Lubrication System Torque Values101
Oil Strainer/Pressure Relief Valve102
Oil Pump Inspection105
Oil Cooler Inspection105
Oil Cooler Removal106
Oil Cooler Installation106
Oil Strainer Removal111
Oil Strainer Installation112
Pressure Relief Valve Removal/Inspection113
Pressure Relief Valve Installation113
Piston Jet Removal/Inspection114
Piston Jet Installation114
Fuel System116
Fuel System Components117
Fuel System Service Information118
Fuel System Torque Values118
Fuel System Tool118
Fuel System Troubleshooting119
Air Cleaner Housing Removal/Installation120
Carburetor Removal121
Carburetor Disassembly123
Air Cut-Off Valve123
Starting Enrichment (Se) Valve123
Throttle Valve124
Accelerator Pump125
Float And Jets126
Carburetor Cleaning128
Carburetor Assembly129
Jets And Float130
Carburetor Installation136
Pilot Screw Adjustment138
Idle Drop Procedure138
System Components140
Troubleshooting143
Air Cleaner Housing144
High Altitude Adjustment163
Secifications167
Cooling System Service Information167
Cooling System Service Information Torque Value167
Cooling System Service Information Troubleshooting168
Cooling System Service Information Tools168
Cooling System Testing169
Coolant (Hydrometer Test)169
Coolant Gravity Chart169
Radiator Cap/System Pressure Inspection170
Coolant Replacement170
Replacement/Air Bleeding171
Thermostat Removal172
Thermostat Inspection172
Thermostat Installation173
Radiator/Cooling Fan Removal173
Water Pump178
Mechanical Seal Inspection178
Mechanical Seal Replacement180
Engine Removal/Installation183
Engine Removal187
Engine Installation191
Cylinder Head/Valve196
Cylinder Head/Valve System Components197
Cylinder Head/Valve Service Information198
Cylinder Head/Valve Specifications198
Cylinder Head/Valve Tools200
Cylinder Head/Valve Troubleshooting202
Cylinder Compression203
Cylinder Head Cover Removal203
Camshaft Holder Removal203
Camshaft/Decompressor Disassembly206
Camshaft Inspection208
Exhaust Rocker Arm/Shaft208
Camshaft Bearing Replacement209
Intake Valve Lifter209
Decompressor Cam209
Cylinder Head Removal210
Cylinder Head Disassembly211
Cylinder Head Inspection212
Valve Spring212
Valve Guide Replacement213
Valve/Valve Guide213
Valve Seat Inspection/Refacing215
Cylinder Head Assembly218
Cylinder Head Installation219
Camshaft/Decompressor Assembly222
Camshaft Holder Installation224
Cylinder Head Cover Installation226
Cylinder/Piston227
Cylinder/Piston System Components228
Cylinder/Piston Service Information229
Cylinder/Piston Torque Values229
Cylinder/Piston Troubleshooting230
Cylinder/Piston Removal231
Cylinder Removal231
Piston Removal232
Cylinder Inspection233
Piston/Piston Ring Inspection233
Cylinder Stud Bolt Replacement235
Cam Chain Tensioner Lifter235
Cylinder/Piston Installation236
Piston Ring Installation236
Piston Installation236
Cylinder Installation237
Clutch/Kickstarter/Gearshift Linkage240
Clutch/Kickstarter/Gearshift Linkage System Components241
Clutch/Kickstarter/Gearshift Linkage Service Information242
Clutch/Kickstarter/Gearshift Linkage Torque Values242
Clutch/Kickstarter/Gearshift Linkage Tools242
Clutch/Kickstarter/Gearshift Linkage Troubleshooting243
Right Crankcase Cover Removal244
Clutch Disassembly244
Clutch Plate248
Judder Spring/Spring Seat248
Clutch Center248
Clutch Outer248
Clutch Outer Guide/Bearing249
Clutch Lifter Arm Removal252
Clutch Lifter Arm Inspection252
Clutch Lifter Arm Installation253
Kickstarter Removal254
Kickstarter Disassembly254
Kickstarter Inspection254
Gearshift Linkage Removal257
Gearshift Linkage Inspection259
Gearshift Linkage Installation259
Right Crankcase Cover Installation261
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage263
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage System Components264
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Service Information265
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Specifications265
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Torque Values265
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Troubleshooting266
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Tool266
Clutch268
Clutch Inspection271
Clutch Assembly273
Starter Clutch (Trx450Er) Removal277
Starter Clutch Disassembly/Inspection278
Kickstarter (Trx450R) Removal282
Kickstarter (Trx450R) Disassembly283
Kickstarter (Trx450R) Inspection283
Kickstarter (Trx450R) Assembly284
Kickstarter (Trx450R) Installation285
Gearshift Linkage286
Crankcase/Transmission/Crankshaft/Balancer292
Crankcase/Transmission/Crankshaft/Balancer System Components293
Crankcase/Transmission/Crankshaft/Balancer Service Information294
Crankcase/Transmission/Crankshaft/Balancer Specifications294
Crankcase/Transmission/Crankshaft/Balancer Torque Value294
Crankcase/Transmission/Crankshaft/Balancer Tools295
Crankcase/Transmission/Crankshaft/Balancer Troubleshooting297
Balancer Gear/Balancer Removal298
Balancer Gear/Balancer Inspection299
Balancer Gear/Balancer Installation300
Crankcase Separation302
Transmission Disassembly304
Reed Valve Inspection304
Transmission Assembly307
Crankshaft Removal309
Crankshaft Inspection310
Crankshaft Installation310
Crankcase Bearing Inspection311
Left Crankcase Bearing Replacement312
Right Crankcase Bearing Replacement314
Crankcase Assembly316
Balancer Gear/Balancer325
Front Wheel/Suspension/Steering346
Front Wheel/Suspension/Steering System Components347
Front Wheel/Suspension/Steering Service Information348
Front Wheel/Suspension/Steering Torque Values348
Front Wheel/Suspension/Steering Tools349
Front Wheel/Suspension/Steering Troubleshooting350
Handlebar Removal351
Handlebar Installation352
Throttle Housing Disassembly354
Throttle Housing Assembly355
Front Wheel Removal356
Front Wheel Installation356
Tires Removal356
Tire Repair358
Tire Assembly359
Recommended Tire Pressures359
Front Wheel Hub Removal360
Front Wheel Hub Disassembly360
Front Wheel Hub Assembly361
Front Wheel Hub Installation362
Front Shock Absorber Removal362
Front Shock Absorber Inspection362
Bearing Replacement363
Suspension Arm Removal364
Pivot Bearing Replacement366
Steering Shaft Removal369
Steering Shaft Inspection371
Steering Shaft Bearing Replacement371
Steering Shaft Installation373
Tie-Rod Removal375
Tie-Rod Inspection375
Tie-Rod Disassembly/Assembly375
Tie-Rod Installation376
Rear Wheel/Suspension377
Rear Wheel/Suspension System Components378
Rear Wheel/Suspension Service Information379
Rear Wheel/Suspension Torque Values380
Rear Wheel/Suspension Tools381
Rear Wheel/Suspension Troubleshooting382
Rear Wheel Removal383
Rear Wheel Installation383
Rear Axle/Bearing Holder Removal383
Rear Wheel/Suspension Installation388
Rear Shock Absorber Removal392
Rear Shock Absorber Inspection393
Rear Shock Absorber Bearing Replacement393
Rear Shock Absorber Installation394
Shock Linkage Removal394
Shock Linkage Bearing Replacement394
Shock Linkage Installation395
Swingarm Removal396
Swingarm Bearing Replacement397
Swingarm Installation398
Hydraulic Brake401
Hydraulic Brake System Components402
Hydraulic Brake Service Information403
Hydraulic Brake Torque Values403
Hydraulic Brake Specification403
Hydraulic Brake Troubleshooting404
Hydraulic Brake Tools404
Brake Fluid Replacement/Air Bleeding405
Brake Fluid Draining405
Brake Fluid Filling/Air Bleeding406
Brake Pad/Disc408
Front Brake Pad Replacement408
Rear Brake Pad Replacement409
Brake Disc Inspection410
Front Master Cylinder Disassembly410
Hydraulic Brake Assembly413
Front Brake Caliper Disassembly415
Front Brake Caliper Inspection416
Front Brake Caliper Assembly417
Rear Master Cylinder Disassembly418
Rear Brake Caliper Disassembly422
Rear Brake Caliper Inspection424
Brake Pedal Removal428
Brake Pedal Installation428
Electrical429
Electrical Component Location430
Electrical Service Information431
Electrical Specification431
Electrical Torque Values431
Electrical Tools432
Electrical Troubleshooting433
Generating System434
Generating Voltage Inspection434
Alternator Charging Coil Inspection434
Alternator435
Left Crankcase Cover Removal436
Stator Replacement437
Flywheel Removal437
Flywheel Installation437
Left Crankcase Cover Installation438
Regulator/Rectifier439
Wire Harness Inspection439
Ignition Switch Line439
Ground Line439
Ignition System Inspection440
Ignition Coil Primary Peak Voltage440
Alternator Exciter Coil Peak Voltage441
Ignition Pulse Generator Peak Voltage442
Ignition Timing442
Ignition Coil Removal/Installation443
Icm (Ignition Control Module) Removal/Installation444
Headlight Bulb Replacement444
Headlight Bulb Removal/Installation445
Headlight Aiming445
Brake/Taillight Removal/Installation446
Ignition Switch Inspection446
Handlebar Switch Inspection447
Front Brake Light Switch447
Carburetor Heater Inspection448
Rear Brake Light Switch448
Throttle Position Sensor Inspection448
Coolant Temperature Indicator System Inspection450
Cooling Fan Motor Inspection451
Engine Coolant Temperature (Ect) Sensor Inspection452
Battery/Charging System453
Battery/Charging System Component Location454
System Diagram (Trx450Er)454
Battery/Charging System Service Information455
Battery Charging455
Battery Testing455
Battery/Charging System Specifications456
Battery/Charging System Torque Values456
Battery/Charging System Tools456
Battery/Charging System Troubleshooting457
Battery (Trx450Er) Removal/Installation458
Battery (Trx450Er) Voltage Inspection458
Battery (Trx450Er) Testing458
Charging System Inspection (Trx450Er)459
Ignition Switch Line (Trx450R)460
Charging Coil Line (Trx450Er/R)460
Ignition System467
Ignition System Component Location468
Ignition System Diagram468
Ignition System Service Information469
Ignition System Torque Value469
Ignition System Tools469
Ignition System Troubleshooting470
Closed Throttle Position Detection System478
Electric Starter (Trx450Er)481
Electric Starter (Trx450Er) Component Location482
Electric Starter (Trx450Er) System Diagram482
Electric Starter (Trx450Er) Service Information483
Electric Starter (Trx450Er) Specifications483
Electric Starter (Trx450Er) Troubleshooting484
Starter Motor Removal486
Starter Motor Disassembly/Inspection486
Starter Motor Assembly490
Starter Motor Installation492
Starter Relay Switch Operation Inspection493
Starter Relay Switch Circuit Inspection493
Power Input Line493
Clutch Diode Inspection494
Function Inspection494
Lights/Switches496
Lights/Switches Component Location497
Lights/Switches Service Information498
Lights/Switches Specifications498
Lights/Switches Torque Values498
Lights/Switches Bulb Replacement499
Headlight499
Indicators500
Brake/Taillight501
Ignition Switch Replacement502
Handlebar Switch502
Clutch Switch (Trx450Er Only)503
Coolant Temperature Indicator506
Cooling Fam Motor Inspection507
Engine Coolant Temperature (Ect) Sensor508
Wiring Diagrams510
Wiring Diagrams (After '05/Trx450Er)512
Engine Does Not Start Or Is Hard To Start515
Engine Lacks Power517
Poor Performance At Low And Idle Speed519
Poor Performance At High Speed520
Poor Handling520
Index521