User Manuals: Honda Fourtrax TRX300 ATV

Manuals and User Guides for Honda Fourtrax TRX300 ATV. We have 1 Honda Fourtrax TRX300 ATV manual available for free PDF download: Service Manual

Honda Fourtrax TRX300 Service Manual (354 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 36 MB

How to Use this Manual
3
Contents
3
General Information
4
General Safety
4
Service Rules
4
Model Identification
5
Specifications
7
Torque Values
10
Engine
10
Frame
11
Standard Torque Values
12
Tools
13
Special
13
Common
14
Cable & Harness Routing
15
Trx300
16
Trx300Fw
18
Emission Control System (after '97)
21
Emission Control Information Label (after '97 California Type Only)
22
Lubrication Diagram
23
Lubrication
24
Service Information
24
Engine Oil Level
26
Engine Oil & Filter Change
26
Oil Filter Screen
27
Front Differential (Trx300Fw)/Rear Final Drive Oil
27
Oil Change
27
Front Gear Case Oil (TRX300FW)
28
Level Check
28
Lubrication Points
29
Control Cables
29
Maintenance
30
Maintenance Schedule
32
Trx300 ('95-'97)
32
Trx300Fw ('95-'97)
33
TRX300 (after '97)
34
TRX300FW (after '97)
35
Fuel Line
36
Fuel Strainer Screen
36
Throttle Operation
36
Carburetor Choke
37
Air Cleaner Element
37
Air Cleaner Housing Drain Tube
38
Spark Plug
38
Valve Clearance
39
Engine Idle Speed
40
Cylinder Compression
41
Brake Fluid
41
Brake Shoe Wear
41
Front Brake
41
Rear Brake
42
Brake System
42
Reverse Lock System
43
Skid Plates
44
Clutch System
44
Suspension
44
Swingarm Bearings
45
Spark Arrester Cleaning
45
Wheels/Tires
46
Steering Shaft Holder Bearing
46
Steering System
46
Toe-In
46
Headlight Aim
47
Nuts, Bolts, Fasteners
47
Fuel System View
49
Fuel System
50
Fuel Tank
52
Removal
52
Installation
52
Air Cleaner Housing
53
Carburetor Removal
54
Carburetor Disassembly
55
Starting Enrichment (SE) Valve
55
Float and Jets
56
Primer Knob
57
Diaphragm/Vaccum Piston
57
Carburetor Assembly
59
Float Level Inspection
61
Carburetor Installation
62
Pilot Screw Adjustment
64
High Altitude Adjustment
66
Engine Removal/Installation View
67
Engine Removal
70
Engine Installation
71
Cylinder Head/Valves View
73
Cylinder Head/Valves
74
Cylinder Head Cover Removal
76
Disassembly
76
Camshaft/Cam Chain Tensioner Lifter Removal
78
Cylinder Head Removal
79
Valve Guide Replacement
82
Valve Seat Inspection/Refacing
83
Valve Seat Cutters
84
Valve Seat Refacing
84
Cylinder Head Assembly
86
Cylinder Head Installation
87
Camshaft/Cam Chain Tensioner Lifter Installation
87
Cylinder Head Cover Assembly/Installation
90
Cylinder/Piston View
93
Cylinder/Piston
94
Cylinder/Piston Installation
98
Clutch/Oil Pump/Kick Starter View
101
Clutch/Oil Pump/Kick Starter
102
Right Crankcase Cover Removal
104
Bearing Replacement
105
Centrifugal Clutch/Primary Drive Gear
105
Centrifugal Clutch Removal
105
Primary Drive Gear Removal
107
Primary Drive Gear Installation
109
Centrifugal Clutch Weight Assembly
110
Centrifugal Clutch Installation
111
Change Clutch
113
Reverse Lock Mechanism
118
Oil Pump
119
Removal/Disassembly
119
Kick Starter
122
Right Crankcase Cover Installation
124
Alternator/Starter Clutch/Gearshift Linkage View
127
Alternator/Starter Clutch/Gearshift Linkage
128
Starter Reduction Gear
129
Left Crankcase Cover Removal
131
Alternator-Ignition Pulse Generator Replacement
132
Flywheels/Starter Clutch
134
Flywheels Removal
134
Starter Clutch Inspection/Disassembly
134
Starter Clutch Assembly
135
Flywheel Installation
136
Gearshift Linkage
137
Left Crankcase Cover Installation
141
Crankcase/Crankshaft/Transmission View
143
Crankcase/Crankshaft/Transmission
144
Crankcase Separation
147
Transmission
148
Assembly/Installation
153
Crankshaft/Balancer
156
Output Gear
159
Backlash Inspection
160
Gear Tooth Contact Pattern Check
161
Output Shaft Disassembly
162
Output Shaft Bearing Replacement
163
Countershaft Disassembly
164
Gear Case Bearing/Oil Seal Replacement
165
Countershaft/Output Shaft Assembly
165
Crankcase Assembly
169
Font Wheel/Suspension/Steering View
172
Font Wheel/Suspension/Steering
173
Handlebar
175
Throttle Housing
177
Front Wheel
178
Tie-Rod/Knuckle Removal (TRX300)
179
Ball Joint Replacement
182
Front Arm (TRX300)
183
Tie-Rod/Knuckle Installation (TRX300)
185
Tie-Rod Assembly
186
Tie-Rod/Knuckle Removal (TRX300FW)
188
Knuckle Bearing Inspection/Replacement (TRX300FW)
192
Front Arm (TRX300FW)
193
Tie-Rod/Knuckle Installation (TRX300FW)
196
Steering Shaft
198
Front Shock Absorber
201
Brakes View
205
Brakes
207
Brake Fluid Replacement/Air Bleeding
209
Brake Fluid Draining
209
Brake Fluid Filling
209
Brake Bleeding
210
Brake Hose/Brake Pipe/Breather Tube Inspection
210
Master Cylinder
211
Brake Shoes/Wheel Cylinder/Adjuster
213
Brake Drum Bearing Replacement (TRX300)
215
Disassembly (TRX300FW)
216
Wheel Cylinder/Adjuster Inspection (TRX300)
218
Wheel Cylinder/Adjuster Inspection (TRX300FW)
219
Front Brake Panel Inspection (TRX300)
219
Front Brake Waterproof Seal Inspection
220
Front Brake Waterproof Seal Replacement
220
Assembly (TRX300)
222
Assembly (TRX300FW)
225
Rear Brake Pedal
234
Rear Wheel/Suspension View
237
Rear Wheel/Suspension
238
Rear Wheel
240
Tires
240
Tire Repair
242
Rear Shock Absorber
244
Swingarm
246
Pivot Bearing Replacement
248
Front Driving Mechanism (TRX300FW) View
251
Front Driving Mechanism (TRX300FW)
252
Front Drive Shaft
254
Front Differential
256
Differential Case Disassembly
258
Differential Assembly Inspection
261
Differential Disassembly
262
Differential Inspection
263
Drive Pinion Removal
264
Drive Pinion Disassembly/Assembly
265
Case Bearing Replacement
266
Drive Pinion Installation
267
Differential Assembly
268
Differential Case Assembly
270
Front Drive Shaft Installation
272
Front Drive Side Shaft Removal
276
Front Gear Case
276
Gear and Shaft
278
Bearing Removal
278
Case Bearing
278
Cover Bearing
279
Bearing Installation
279
Front Drive Side Shaft Installation
282
Rear Driving Mechanism View
283
Rear Driving Mechanism
284
Rear Axle Removal
286
Rear Final Drive Removal
287
Bearing/Oil Seal Replacement
293
Rear Drive Shaft
295
Rear Final Drive Installation
296
Rear Axle Installation
298
Bumper/Carriers/Fenders/Muffler
300
Front Bumper/Carrier/Fender
300
Installation (TRX300)
301
Installation (TRX300FW)
302
Rear Carrier/Rear Fender
303
Exhaust Muffler
306
Ignition System
307
System Diagram
307
Ignition Control Module (ICM) System Inspection
310
Ignition Coil
310
Ignition Pulse Generator
311
Alternator
312
AC Sensor Line Inspection
312
Ignition Timing
312
Peak Voltage Testing
313
Battery/Charging System Diagram
317
Battery/Charging System
318
Voltage Inspection
321
Battery Testing
321
Battery Charging
322
Charging System
323
Leakage Inspection
324
Regulated Voltage/Amperage Inspection
324
Alternator Charging Coil
325
Regulator/Rectifier
325
Regulator/Rectifier Inspection
325
Starter System View
327
Starter System
328
Starter Motor
330
Starter Relay Switch
334
Operation Inspection
334
Continuity Inspection
334
Diode
335
Lights/Switches View
337
Oil Warning System Diagram
337
Lights/Switches
338
Oil Warning System
339
Headlight
340
Bulb Replacement
340
Case Removal/Installation
340
Taillight
341
Indicator Lamp
341
Ignition Switch
342
Handlebar Switches
342
Neutral Switch/Reverse Switch
343
Oil Temperature Sensor
343
Alarm Unit
344
Wiring Diagram
346
'95-'97
346
After '97
347
Troubleshooting
348
Engine Does Not Start or Is Hard to Start
348
Engine Lacks Power
349
Poor Performance at Low and Idle Speeds
350
Poor Performance at High Speeds
351
Poor Handling
351
Index
352

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User Manuals: Honda Fourtrax TRX300 ATV

Honda Fourtrax TRX300 Service Manual (354 pages)

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