Honda Fourtrax TRX 250TM Manuals

Manuals and User Guides for Honda Fourtrax TRX 250TM. We have 5 Honda Fourtrax TRX 250TM manuals available for free PDF download: Service Manual, Owner's Manual

Honda Fourtrax TRX 250TM Service Manual (411 pages)

2005-2011

Brand: Honda | Category: Offroad Vehicle | Size: 44 MB

Contents
2
Symbols
3
General Information
4
Service Rules
5
Model Identification
5
General Specifications
7
Lubrication System Specifications
9
Fuel System Specifications
9
Cylinder Head/Cylinder/Piston Specifications
10
Clutch Specifications
10
Crankshaft/Transmission Specifications
11
Front Wheel/Suspension/Steering Specifications
11
Rear Wheel/Suspension Specifications
11
Brake System Specifications
12
Rear Driving Mechanism Specifications
12
Battery/Charging System Specifications
12
Ignition System Specifications
12
Electric Starter Specifications
13
Lights/Switches Specifications
13
Standard Torque Values
14
Engine & Frame Torque Values
14
Lubrication & Seal Points
18
Cable & Harness Routing
22
Source of Emissions
33
Exhaust Emission Control System
33
Crankcase Emission Control System
33
Servicing the Honda
33
Noise Emission Control System
34
Rebuilt Engine
34
Emission Control Information Label
35
Frame/Body Panels/Exhaust System
36
Frame/Body Panels/Exhaust System Service Information
37
Frame/Body Panels/Exhaust System Troubleshooting
37
Body Panel Locations
38
Seat Removal
39
Seat Installation
39
Trim Clip Removal and Retaining Procedure
39
Fuel Tank Cover
40
Side Covers
41
Front Carrier/Carry Pipe
42
Front Fender Removal
43
Front Fender Disassembly
43
Front Mudguard
44
Center Mudguard
45
Step Bar
46
Rear Carrier
46
Rear Fender
47
Handlebar Cover
47
Exhaust System Removal
48
Muffler
48
Exhaust Pipe
48
Exhaust System Disassembly
49
Exhaust System Assembly
49
Exhaust System Installation
49
Maintenance
52
Maintenance Service Information
53
Maintenance Schedule
55
Fuel Hose
56
Throttle Operation
56
Carburetor Choke
57
Air Cleaner
57
Dust Cover
58
Air Cleaner Housing Drain Plug
59
Spark Plug Inspection
59
Valve Clearance
60
Reusing Spark Plug
60
Replacing a Spark Plug
60
Engine Oil Level Inspection
62
Engine Oil Change
63
Engine Oil Strainer Screen
64
Engine Oil Centrifugal Filter
64
Engine Idle Speed
65
Rear Final Gear Case Oil
65
Oil Level Check
65
Brake Fluid
67
Brake Shoe Wear
67
Front Brake
67
Rear Brake
67
Brake Light Switch
68
Brake System
68
Reverse Lock System
70
Skid Plates/Engine Guard
71
Clutch System
71
Suspension
72
Swingarm Bearings
72
Cleaning Spark Arrester
72
Nuts, Bolts, Fasteners
73
Wheels/Tires
73
Steering Shaft Holder Bearing
73
Steering System
74
Toe
74
Lubrication System
76
Lubrication System Diagram
77
Lubrication System Service Information
78
Lubrication System Troubleshooting
78
Oil Pump Removal/Disassembly
79
Oil Pump Inspection
79
Oil Pump Assembly
81
Oil Pump Installation
82
Oil Cooler Removal
83
Oil Cooler Inspection
84
Oil Cooler Installation
84
Fuel System
86
Fuel System Component Location
87
Fuel System Service Information
88
Fuel System Troubleshooting
89
Air Cleaner Housing Removal
90
Carburettor Removal
91
Air Cleaner Housing Installation
91
Throttle Valve
91
Carburetor Body
92
Carburetor Disassembly
93
Carburetor Assembly
96
Float Level Inspection
97
Carburetor Installation
99
Pilot Screw Adjustment
101
High Altitude Adjustment Specifications
102
Fuel Tank Removal
103
Fuel Strainer Screen
104
Fuel Tank Installation
105
Engine Removal/Installation Component Location
109
Engine Removal/Installation Service Information
110
Engine Removal
111
Engine Guards
111
Engine Installation
114
Cylinder Head/Valve
120
Cylinder Head/Valve Component Location
121
Cylinder Head/Valve Service Information
122
Cylinder Head/Valve Troubleshooting
124
Cylinder Compression
125
Cylinder Head Cover Removal
125
Cylinder Head Cover Disassembly
126
Cylinder Head Cover Inspection
127
Cylinder Head Cover Assembly
128
Cylinder Head Cover Installation
129
Cylinder Head Removal
130
Cylinder Head Disassembly/Inspection
131
Valve Spring
132
Valve/Valve Guide
132
Valve Guide Replacement
133
Valve Seat Inspection/Refacing
134
Cylinder Head Assembly
138
Cylinder Head Installation
139
Cylinder/Piston/Camshaft
142
Cylinder/Piston/Camshaft Component Location
143
Cylinder/Piston/Camshaft Service Information
144
Cylinder/Piston/Camshaft Troubleshooting
145
Cylinder Removal
146
Piston Removal
146
Cylinder/Piston Inspection
147
Piston Ring Installation
150
Piston Installation
150
Cylinder Installation
151
Camshaft Removal
152
Camshaft Inspection
153
Camshaft Installation
154
Cam Follower
154
Cam Chain Tensioner
154
Clutch/Gearshift Linkage
158
Clutch/Gearshift Linkage Component Location
159
Clutch/Gearshift Linkage Service Information
160
Clutch/Gearshift Linkage Tools
161
Clutch/Gearshift Linkage Troubleshooting
162
Front Crankcase Cover Removal
163
Bearing Replacement
164
Centrifugal Clutch Removal
164
Centrifugal Clutch Inspection
166
Drive Plate Boss
167
Weight Lining
167
Clutch Drum
167
Weight Spring/Clutch Spring
168
Centrifugal Clutch Assembly
169
Crankshaft at the Primary Drive Gear
169
Centrifugal Clutch Installation
171
Change Clutch Removal
172
Clutch Center
175
Clutch Disc
175
Clutch Plate
175
Clutch Outer
176
Front Crankcase Cover Installation
179
Gearshift Linkage Removal
181
Gearshift Linkage Inspection
183
Gearshift Linkage Installation
184
Reverse Stopper Shaft Removal
187
Alternator/Starter Clutch
190
Alternator/Starter Clutch Component Location
191
Alternator/Starter Clutch Service Information
192
Alternator/Starter Clutch Troubleshooting
192
Recoil Starter Removal
193
Recoil Starter Disassembly
193
A few Words about Safety
194
Service Information
194
Important Safety Precautions
194
Recoil Starter Assembly
195
Recoil Starter Installation
198
Alternator Cover Removal
198
Alternator Cover Disassembly
200
Flywheel/Starter Clutch Removal
201
Starter Clutch Inspection/Disassembly
202
Starter Clutch Assembly
203
Flywheel/Starter Clutch Installation
204
Alternator Installation
205
Alternator Assembly
205
Crankcase/Transmission/Crankshaft
209
Crankcase/Transmission/Crankshaft Component Location
210
Crankcase/Transmission/Crankshaft Service Information
211
Crankcase/Transmission/Crankshaft Troubleshooting
213
Crankcase Separation
214
Transmission Removal/Disassembly
215
Transmission Inspection
216
Crankcase Bearing Locations
219
Crankshaft Removal
223
Crankshaft Inspection
224
Crankshaft Bearing Replacement
224
Crankcase Assembly
225
Front Wheel/Suspension/Steering
229
Front Wheel/Suspension/Steering Component Location
230
Front Wheel/Suspension/Steering Service Information
231
Front Wheel/Suspension/Steering Tools
232
Front Wheel/Suspension/Steering Troubleshooting
233
Handlebar Removal
234
Handlebar Installation
235
Throttle Housing Disassembly
237
Throttle Housing Assembly
238
Front Wheel Removal
239
Front Wheel Installation
239
Tires Removal
239
Tire Repair
241
Tire Assembly
242
Tie-Rod/Knuckle Removal
243
Tie-Rod/Knuckle Inspection
245
Tie-Rod Assembly
246
Knuckle Installation
246
Tie-Rod Installation
247
Upper/Lower Arms Removal
248
Upper/Lower Arms Inspection
249
Ball Joint Replacement
249
Upper/Lower Arms Installation
251
Steering Shaft Removal
253
Steering Shaft Inspection
254
Steering Shaft Installation
256
Front Shock Absorber Removal
258
Front Shock Absorber Installation
258
Rear Wheel/Suspension
259
Rear Wheel/Suspension Component Location
260
Rear Wheel/Suspension Service Information
261
Rear Wheel/Suspension Tools
262
Rear Wheel/Suspension Troubleshooting
263
Rear Wheel Removal
264
Rear Wheel Installation
264
Hub Removal
264
Rear Wheel Hub Inspection
265
Hub Installation
265
Rear Shock Absorber Removal
266
Rear Shock Absorber Installation
266
Swingarm Removal
267
Swingarm Inspection
268
Pivot Bearing/Rear Axle Bearing Replacement
269
Brake System Component Location
276
Brake System Service Information
277
Brake System Tools
278
Brake System Troubleshooting
279
Brake Fluid Draining
280
Brake Fluid Filling/Bleeding
280
Brake Hose/Brake Pipe Inspection
282
Master Cylinder Disassembly
282
Master Cylinder Inspection
284
Master Cylinder Assembly
284
Brake Shoes/Wheel Cylinder/Adjuster Disassembly
286
Brake Drum Bearing Replacement
288
Wheel Cylinder/Adjuster Inspection
288
Front Brake Panel Inspection
289
Front Brake Waterproof Seal Inspection
290
Front Brake Waterproof Seal Assembly
290
Rear Brake Removal/Disassembly
293
Rear Brake Assembly/Installation
298
Brake Pedal Removal
303
Brake Pedal Installation
304
Rear Driving Mechanism
305
Rear Driving Mechanism Component Location
306
Rear Driving Mechanism Service Information
307
Rear Driving Mechanism Tools
308
Rear Driving Mechanism Troubleshooting
310
Rear Axle Removal
311
Rear Axle Inspection
311
Rear Axle Installation
311
Final Drive Removal
312
Gear Case Removal
312
Final Drive Inspection
313
Final Drive Disassembly/Inspection
313
Backlash Inspection
313
Gear Case Disassembly
314
Bearing Inspection
315
Gear Tooth Contact Pattern Check
315
Drive Pinion Removal
317
Drive Pinion Disassembly/Assembly
318
Pinion Needle Bearing Replacement
319
Case Bearing Replacement
320
Drive Pinion Installation
323
Gear Case Assembly
324
Gear Case Installation
325
Rear Drive Shaft Removal
326
Rear Drive Shaft Inspection
327
Rear Drive Shaft Installation
327
Battery/Charging System
329
Battery/Charging System Component Location
330
Battery/Charging System Service Information
331
Battery/Charging System Troubleshooting
333
Battery Removal/Installation
334
Battery Voltage Inspection
334
Battery Testing
334
Battery Charging
335
Charging Voltage Inspection
336
Current Leakage Inspection
337
Alternator Charging Coil Inspection
337
Regulator/Rectifier System Inspection
338
Regulator/Rectifier Removal/Installation
338
Ignition System
339
Ignition System Component Location
340
Ignition System Service Information
341
Ignition System Troubleshooting
342
No Spark at Spark Plug
342
Ignition System Inspection
343
Ignition Coil Primary Peak Voltage
343
Ignition Pulse Generator Peak Voltage
344
Alternator Exciter Coil Peak Voltage
345
Ignition Coil Removal/Installation
345
Ignition Timing
346
Ignition Pulse Generator Removal
346
Ignition Pulse Generator Installation
346
Electric Starter
349
Electric Starter Component Location
350
Electric Starter Service Information
351
Electric Starter Troubleshooting
352
Starter Motor Removal
353
Starter Motor Disassembly
353
Starter Motor Inspection
353
Starter Motor Assembly
356
Starter Motor Installation
358
Starter Relay Switch Operation Inspection
358
Starter Relay Switch Voltage Inspection
358
Continuity Inspection
359
Diode Removal
359
Diode Inspection
359
Diode Installation
359
Lights/Switches
361
Lights/Switches Component Location
362
Lights/Switches Service Information
363
Lights/Switches Troubleshooting
363
Tail/Stop Light Replacement
364
Headlight Bulb Replacement
364
Indicator Lamps Bulb Replacement
365
Ignition Switch Inspection
365
Handlebar Switches
366
Front Brake Lever Inspection
367
Front Brake Lever Replacement
367
Rear Brake Lever Inspection
367
Rear Brake Lever Replacement
367
Rear Brake Pedal Inspection
368
Rear Brake Pedal Replacement
368
Gear Position Switch Inspection
368
Vehicle Speed Sensor (te Model) Inspection
369
Vehicle Speed Sensor (te Model) Removal/Installation
370
Electric Shift Program (ESP: te Model)
371
Electric Shift Program (ESP: te Model) Component Location
372
Electric Shift Program (ESP: te Model) System Diagram
372
Electric Shift Program (ESP: te Model) Service Information
373
Before Starting Troubleshooting
374
Self Diagnosis Function
374
Retrieval/Erasure of Problem Code
374
Troubleshooting Chart
375
Diagnostic Troubleshooting
376
Angle Sensor System Inspection
387
Angle Sensor System Removal
388
Angle Sensor System Installation
389
Control Motor Removal
390
Control Motor Installation
391
Reduction Gears Removal
392
Reduction Gears Installation
392
Gearshift Switch System Inspection
393
Reverse Shift Switch Inspection
394
Reverse Shift Switch Removal/Installation
395
Wiring Diagrams
397
TM Model
399
TRX250TM Wiring Diagram
399
TE Model
400
TRX250TE Wiring Diagrams
400
Troubleshooting
401
Engine Does Not Start or Is Hard to Start
402
Engine Lacks Power
403
Poor Performance at Low and Idle Speed
405
Poor Performance at High Speed
406
Poor Handling
407
Index
409

Honda Fourtrax TRX 250TM Owner's Manual (224 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 5 MB

Instruments & Controls

19
- A few Words about Safety
  6
- ATV Safety
  11
- Important Safety Information
  12
- Safety Labels
  15
  - Table of Contents
    19
  - Operation Component Locations
    21
  - Indicators & Displays
    24
    
    Multi-Function Display
    27
    
    Odometer
    28
    
    Tripmeter
    28
    
    Hourmeter
    29
    
    Digital Clock
    30
  - Controls & Features
    31
    
    Fuel Valve
    31
    
    Choke Knob
    32
    
    Ignition Switch
    33
    
    Start Button
    34
    
    Engine Stop Switch
    34
    
    Headlight Switch
    35
    
    Headlight Dimmer Switch
    35
    
    Horn Button
    35
    
    Recoil Starter
    36
    
    Throttle Lever
    37
    
    Reverse Selector Knob
    38
    
    Front Brake Lever
    39
    
    Rear Brake Lever/Parking Brake Lever
    39
    
    Rear Brake Pedal
    39
    
    Parking Brake
    40
    
    Flag Pole Bracket
    41
    
    Trailer Hitch
    42
Before Riding

43
- Are You Ready to Ride
  44
  - Protective Apparel
    44
  - Rider Training
    46
  - Age Recommendation
    47
  - No Passengers
    47
  - No Alcohol or Drugs
    48
- BEFORE RIDING (Cont'D)
  49
  - Load Limits & Guidelines
    52
    
    Loading
    52
    
    Load Limits
    53
    
    Loading Guidelines
    54
  - Accessories & Modifications
    55
    
    Accessories
    55
    
    Modifications
    56
- Is Your ATV Ready to Ride
  49
  - Pre-Ride Inspection
    49
Basic Operation & Riding

57
- Safe Riding Precautions
  59
  - Off-Road Use Only
    59
  - Keep Hands and Feet on Controls
    60
  - Control Speed
    61
  - Use Care on Unfamiliar or Rough Terrain
    62
  - Do Not Perform Stunts
    63
- Starting & Stopping the Engine
  64
  - Preparation
    64
  - Starting Procedure
    65
  - Flooded Engine
    68
  - How to Stop the Engine
    68
  - Using the Recoil Starter
    69
- Shifting Gears
  70
- Riding in Reverse
  72
- Braking
  74
- Riding Your ATV
  76
  - Making Turns
    76
  - Skidding or Sliding
    78
  - Riding up Hills
    79
  - Riding down Hills
    83
  - Crossing or Turning on Hills or Slopes
    84
  - Riding over Obstacles
    86
  - Riding through Water
    87
- Parking
  88
Servicing Your Honda/Bef Ore You Service Your Honda

89
- Bef Ore You Service Your Honda
  89
  - The Importance of Maintenance
    91
  - Maintenance Safety
    92
  - Important Safety Precautions
    93
  - Maintenance Schedule
    94
  - Maintenance Procedures
    96
  - Maintenance Record
    98
  - Maintenance Component Locations
    99
  - Tool Kit
    102
  - Owner's Manual Storage
    103
  - Seat Removal
    104
  - Fuel
    105
- Servicing Your Honda
  89
- Service Procedures Fluids & Filters Fuel
  105
  - Engine Oil
    108
  - Oil Recommendation
    109
  - Gear Case Oil
    115
  - Air Cleaner
    117
  - Throttle
    122
  - Throttle Inspection
    123
  - Carburetor Choke Cable & Knob
    124
  - Clutch Adjustment
    125
  - Clutch System
    125
  - Reverse Lock System
    126
  - Idle Speed Adjustment
    127
  - Engine Idle Speed and Air-Fuel Mixture
    127
  - Air-Fuel Mixture Adjustment
    128
  - Spark Plug
    129
  - Valves
    132
  - Spark Arrester
    133
  - Brakes
    134
  - Tyres
    149
  - Engine Guard & Skid Plates
    155
  - Electrical Battery
    156
- Battery
  156
  - Battery Charging
    160
  - Appearance Care
    161
Tips

165
- Preparing for a Ride
  166
  - What to Take to the Riding Area
    166
  - What to Take on the Trail
    167
- Transporting Your Honda
  168
- Storing Your Honda
  170
  - Preparation for Storage
    171
  - Removal from Storage
    173
- You & the Environment
  174
Taking Care of the Unexpected

175
- General Guidelines
  176
- If Your Engine Quits or Won't Start
  178
- If You Have a Flat Tyre
  181
- If the High Oil Temperature Indicator Lights
  184
- If a Fuse Blows
  185
- If You Crash
  187
- If You Lose Your Key
  188
- If the Battery Is Low (or Dead)
  189
- If a Component Fails
  190
Technical Information

191
- Vehicle Identification
  192
- Specifications
  194
- Break-In Guidelines
  198
- High Altitude Carburetor Adjustment
  199
- Petrol Containing Alcohol
  200
Table of Contents

202
- Index
  208
- Manufacturer and Authorised Representative for Eu Market
  221

Honda Fourtrax TRX 250TM Owner's Manual (219 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 4 MB

A few Words about Safety
6
Table of Contents
9
ATV Safety
10
Important Safety Information
11
Safety Labels
14
Indicators & Controls
18
Operation Component Locations
20
Controls & Features
24
Fuel Valve
24
Choke Knob
25
Ignition Switch
26
Start Button
27
Engine Stop Switch
27
Headlight Switch
28
Headlight Dimmer Switch
28
Throttle Lever
29
Front Brake Lever
30
Rear Brake Lever/Parking Brake Lever
30
Rear Brake Pedal
30
Parking Brake/Reverse Lever (P/R Lever)
31
Flag Pole Bracket
33
Before Riding
34
Are You Ready to Ride
35
Protective Apparel
35
Rider Training
37
Age Recommendation
38
No Passengers
38
No Alcohol or Drugs
39
Is Your ATV Ready to Ride
40
Pre-Ride Inspection
40
Load Limits & Guidelines
43
Loading
43
Load Limits
44
Loading Guidelines
45
Accessories & Modifications
46
Accessories
46
Modifications
47
Basic Operation & Riding
48
Safe Riding Precautions
50
Off-Road Use Only
50
Keep Hands and Feet on Controls
51
Control Speed
52
Use Care on Unfamiliar or Rough Terrain
53
Do Not Perform Stunts
54
Starting & Stopping the Engine
55
Preparation
56
Starting Procedure
57
Flooded Engine
60
How to Stop the Engine
60
Shifting Gears
61
Riding in Reverse
63
Braking
65
Riding Your ATV
67
Making Turns
67
Skidding or Sliding
69
Riding up Hills
70
Riding down Hills
74
Crossing or Turning on Hills or Slopes
75
Riding over Obstacles
77
Riding through Water
78
Parking
79
Servicing Your Honda
80
The Importance of Maintenance
82
Maintenance Safety
83
Important Safety Precautions
84
Maintenance Schedule
85
Maintenance Record
89
Maintenance Component Locations
90
Tool Kit
93
Owner's Manual Storage
94
Seat Removal
95
Fuel
96
Engine Oil
99
Gear Case Oil
105
Oil Recommendation
105
Air Cleaner
107
Throttle
112
Throttle Freeplay
112
Throttle Inspection
113
Carburetor Choke Cable & Knob
114
Clutch System
115
Clutch Adjustment
115
Reverse Inhibitor System
116
Engine Idle Speed
117
Spark Plug
118
Valves
121
Valve Inspection
121
Spark Arrester
122
Brakes
123
Brake Fluid Recommendation
123
Tires
138
Guards
144
Battery
145
Battery Storage
146
Battery Charging
149
Appearance Care
150
General Recommendations
150
Tips
154
Preparing for a Ride
155
What to Take to the Riding Area
155
What to Take on the Trail
156
Transporting Your Honda
157
Storing Your Honda
159
Preparation for Storage
159
Removal from Storage
162
You & the Environment
163
Taking Care of the Unexpected
164
General Guidelines
165
If Your Engine Quits or Won't Start
167
If You Have a Flat Tire
170
If a Fuse Blows
174
If You Crash
177
If You Lose Your Key
178
If the Battery Is Low (or Dead)
179
If a Component Fails
180
Technical Information
182
Vehicle Identification
183
Specifications
185
Break-In Guidelines
189
High Altitude Carburetor Adjustment
190
Emission Control Systems
191
Oxygenated Fuels
195
Catalytic Converter
197
Consumer Information
198
Authorized Manuals
199
Warranty Coverage
200
Warranty Service
201
Contacting Honda
202
Your Honda Dealer
203
Index
204
Quick Reference
213

Honda Fourtrax TRX 250TM Owner's Manual (229 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 6 MB

Honda Fourtrax TRX 250TM Owner's Manual (156 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 3 MB

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Honda Fourtrax TRX 250TM Owner's Manual (224 pages)

Table of Contents

Instruments & Controls

Before Riding

Basic Operation & Riding

Servicing Your Honda/Bef Ore You Service Your Honda

Tips

Taking Care of the Unexpected

Technical Information

Table of Contents

Honda Fourtrax TRX 250TM Owner's Manual (219 pages)

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