Honda TRX250TE Fourtrax Manuals

Manuals and User Guides for Honda TRX250TE Fourtrax. We have 2 Honda TRX250TE Fourtrax manuals available for free PDF download: Service Manual, Owner's Manual

Honda TRX250TE Fourtrax Service Manual

Honda TRX250TE Fourtrax Service Manual (411 pages)

2005-2011

Brand: Honda | Category: Offroad Vehicle | Size: 44.89 MB

Table of Contents

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

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Honda TRX250TE Fourtrax Owner's Manual

Honda TRX250TE Fourtrax Owner's Manual (225 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 6.65 MB

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