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Honda Manuals
Offroad Vehicle
TRX450R
Service manual
Honda TRX450R Service Manual
2004-2009
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Also See for TRX450R
:
Owner's manual
(240 pages)
,
Owner's manual
(257 pages)
,
Owner's manual
(238 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
A few Words about Safety
Service Information
Important Safety Precautions
Contents
Symbols
Table of Contents
Service Rules
Model Identification
General Specifications ('04 - '05)
GENERAL SPECIFICATIONS (after '05)
Lubrication System Specifications
Fuel System Specifications ('04-'05)
FUEL SYSTEM SPECIFICATIONS (after '05)
Cooling System Specifications
Cylinder Head/Valve/Camshaft Specifications ('04-'05)
CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS (after '05)
Cylinder/Piston Specifications ('04-'05)
Clutch/Kickstarter/Gearshift Linkage Specifications
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications
CYLINDER/PISTON SPECIFICATIONS (after '05)
SPECIFICATIONS (after '05)
Crankcase/Transmission/Crankshaft Specifications ('04 - '05)
CRANKCASE/TRANSMISSION/CRANKSHAFT SPECIFICATIONS (after '05)
Front Wheel/Suspension/Steering Specifications
Rear Wheel/Suspension Specifications
Hydraulic Brake Specifications
Electrical Specifications ('04 - '05) -1-14
Battery/Charging System Specifications (Trx450Er)
Ignition System Specifications
Lights/Switch Specifications
Electric Starter Specifications (Trx450Er)
(After'05)
Standard Torque Values
Engine & Frame Torque Values
Lubrication & Seal Points
Cable & Harness Routing
Crankcase Emission Control System
Source of Emissions
Exhaust Emission Control System
Emission Control Systems
Noise Emission Control System
Prohibited Actions
Rebuilt Engine
Servicing the Honda
Technical Features
Auto-Decompression System
U-Shaped Roller Rocker Arm
Unicam System Outline
Hot Start System
Twin Sump Lubrication System
Frame/Body Panels/Exhaust System
Frame/Body Panels/Exhaust System Service Information
Frame/Body Panels/Exhaust System Torque Values
Frame/Body Panels/Exhaust System Troubleshooting
Mud Guard/Footpeg Removal
Seat Installation
Seat Removal
Mud Guard/Footpeg Installation
Top Cover ('04 - '05)
TOP COVER (after '05)
Front Fender ('04 - '05)
FRONT FENDER (after '05)
Rear Fender ('04 - '05)
REAR FENDER (after '05)
Engine Guard ('04 - '05)
ENGINE GUARD (after '05)
Skid Plate
Fuel Tank
Heat Guard Plate ('04 - '05)
HEAT GUARD PLATE (after '05)
Exhaust System Removal
Exhaust System Installation
Maintenance
Maintenance Service Information
Maintenance Schedule ('04 - '05)
MAINTENANCE SCHEDULE (after '05)
Fuel Line
Throttle Operation
Air Cleaner
Spark Plug
Valve Clearance Inspection
Valve Clearance/Decompressor System
Valve Clearance Adjustment
Decompressor Clearance Inspection/Adjustment
Engine Oil/Filter
Oil Level Check
Oil and Filter Change
Transmission Oil
Oil Change
Recommended Transmission Oil
Engine Idle Speed
Radiator Coolant
Cooling System
Drive Chain Slack Inspection
Recommended Antifreeze
Replacement
Brake Fluid
Drive Chain Slider
Brake Pads Wear
Front Brake
Rear Brake
Brake Light Switch
Brake System
Hydraulic System Inspection
Parking Brake Adjustment
Brake Pedal Height Adjustment
Clutch System
Skid Plate, Engine Guard
Front Suspension Inspection
Rear Suspension Inspection
Suspension •4-30
Nuts, Bolts, Fasteners- •4-31
Spark Arrester
Steering Head Bearing- •4-32
Steering Shaft Holder Bearing
Wheels/Tires
Steering System
Lubrication System
Lubrication System Diagram
Lubrication System Service Information
Lubrication System Torque Values
Lubrication System Troubleshooting
Oil Strainer/Pressure Relief Valve
Oil Cooler Inspection
Oil Pump Inspection
Oil Cooler Installation
Oil Cooler Removal
Oil Strainer Removal
Oil Strainer Installation
Pressure Relief Valve Installation
Pressure Relief Valve Removal/Inspection
Piston Jet Installation
Piston Jet Removal/Inspection
Fuel System
Fuel System Components
Fuel System Service Information
Fuel System Tool
Fuel System Torque Values
Fuel System Troubleshooting
Air Cleaner Housing Removal/Installation
Carburetor Removal
Air Cut-Off Valve
Carburetor Disassembly
Starting Enrichment (Se) Valve
Throttle Valve
Accelerator Pump
Float and Jets
Carburetor Cleaning
Carburetor Assembly
Jets and Float
Carburetor Installation
Idle Drop Procedure
Pilot Screw Adjustment
System Components
Service Information
Troubleshooting
Air Cleaner Housing
Carburetor Removal
Carburetor Disassembly
Carburetor Assembly
Carburetor Installation
Pilot Screw Adjustment
High Altitude Adjustment
Cooling System Service Information
Cooling System Service Information Torque Value
Secifications
Cooling System Service Information Tools
Cooling System Service Information Troubleshooting
Coolant (Hydrometer Test)
Coolant Gravity Chart
Cooling System Testing
Coolant Replacement
Radiator Cap/System Pressure Inspection
Replacement/Air Bleeding
Thermostat Inspection
Thermostat Removal
Radiator/Cooling Fan Removal
Thermostat Installation
Mechanical Seal Inspection
Water Pump
Mechanical Seal Replacement
Engine Removal/Installation
Engine Removal
Engine Installation
Cylinder Head/Valve
Cylinder Head/Valve System Components
Cylinder Head/Valve Service Information
Cylinder Head/Valve Specifications
Cylinder Head/Valve Tools
Cylinder Head/Valve Troubleshooting
Camshaft Holder Removal
Cylinder Compression
Cylinder Head Cover Removal
Camshaft/Decompressor Disassembly
Camshaft Inspection
Exhaust Rocker Arm/Shaft
Camshaft Bearing Replacement
Decompressor Cam
Intake Valve Lifter
Cylinder Head Removal
Cylinder Head Disassembly
Cylinder Head Inspection
Valve Spring
Valve Guide Replacement
Valve/Valve Guide
Valve Seat Inspection/Refacing
Cylinder Head Assembly
Cylinder Head Installation
Camshaft/Decompressor Assembly
Camshaft Holder Installation
Cylinder Head/Valve
Cylinder Head Cover Installation
Cylinder/Piston
Cylinder/Piston System Components
Cylinder/Piston Service Information
Cylinder/Piston Torque Values
Cylinder/Piston Troubleshooting
Cylinder Removal
Cylinder/Piston Removal
Piston Removal
Cylinder Inspection
Piston/Piston Ring Inspection
Cam Chain Tensioner Lifter
Cylinder Stud Bolt Replacement
Cylinder/Piston Installation
Piston Installation
Piston Ring Installation
Cylinder Installation
Clutch/Kickstarter/Gearshift Linkage
Clutch/Kickstarter/Gearshift Linkage System Components
Clutch/Kickstarter/Gearshift Linkage Service Information
Clutch/Kickstarter/Gearshift Linkage Tools
Clutch/Kickstarter/Gearshift Linkage Torque Values
Clutch/Kickstarter/Gearshift Linkage Troubleshooting
Clutch Disassembly
Right Crankcase Cover Removal
Clutch Center
Clutch Outer
Clutch Plate
Judder Spring/Spring Seat
Clutch Outer Guide/Bearing
Clutch Lifter Arm Inspection
Clutch Lifter Arm Removal
Clutch Lifter Arm Installation
Kickstarter Disassembly
Kickstarter Inspection
Kickstarter Removal
Gearshift Linkage Removal
Gearshift Linkage Inspection
Gearshift Linkage Installation
Right Crankcase Cover Installation
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage
Troubleshooting
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage System Components
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Service Information
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Specifications
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Torque Values
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Tool
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Troubleshooting
Right Crankcase Cover Removal
Clutch
Clutch Inspection
Clutch Assembly
Starter Clutch (TRX450ER) Removal
Starter Clutch Disassembly/Inspection
Kickstarter (TRX450R) Removal
Kickstarter (TRX450R) Disassembly
Kickstarter (TRX450R) Inspection
Kickstarter (TRX450R) Assembly
Kickstarter (TRX450R) Installation
Gearshift Linkage
Right Crankcase Cover Installation
Crankcase/Transmission/Crankshaft/Balancer
Crankcase/Transmission/Crankshaft/Balancer System Components
Crankcase/Transmission/Crankshaft/Balancer Service Information
Crankcase/Transmission/Crankshaft/Balancer Specifications
Crankcase/Transmission/Crankshaft/Balancer Torque Value
Crankcase/Transmission/Crankshaft/Balancer Tools
Crankcase/Transmission/Crankshaft/Balancer Troubleshooting
Balancer Gear/Balancer Removal
Balancer Gear/Balancer Inspection
Balancer Gear/Balancer Installation
Crankcase Separation
Reed Valve Inspection
Transmission Disassembly
Transmission Assembly
Crankshaft Removal
Crankshaft Inspection
Crankshaft Installation
Crankcase Bearing Inspection
Left Crankcase Bearing Replacement
Right Crankcase Bearing Replacement
Crankcase Assembly
System Components
Service Information
Troubleshooting
Balancer Gear/Balancer
Crankcase Assembly
Front Wheel/Suspension/Steering
Front Wheel/Suspension/Steering System Components
Front Wheel/Suspension/Steering Service Information
Front Wheel/Suspension/Steering Torque Values
Front Wheel/Suspension/Steering Tools
Front Wheel/Suspension/Steering Troubleshooting
Handlebar Removal
Handlebar Installation
Throttle Housing Disassembly
Throttle Housing Assembly
Front Wheel Installation
Front Wheel Removal
Tires Removal
Tire Repair
Recommended Tire Pressures
Tire Assembly
Front Wheel Hub Disassembly
Front Wheel Hub Removal
Front Wheel Hub Assembly
Front Shock Absorber Inspection
Front Shock Absorber Removal
Front Wheel Hub Installation
Bearing Replacement
Suspension Arm Removal
Pivot Bearing Replacement
Steering Shaft Removal
Steering Shaft Bearing Replacement
Steering Shaft Inspection
Steering Shaft Installation
Tie-Rod Disassembly/Assembly
Tie-Rod Inspection
Tie-Rod Removal
Tie-Rod Installation
Rear Wheel/Suspension
Rear Wheel/Suspension System Components
Rear Wheel/Suspension Service Information
Rear Wheel/Suspension Torque Values
Rear Wheel/Suspension Tools
Rear Wheel/Suspension Troubleshooting
Rear Axle/Bearing Holder Removal
Rear Wheel Installation
Rear Wheel Removal
Rear Wheel/Suspension Installation
Rear Shock Absorber Removal
Rear Shock Absorber Bearing Replacement
Rear Shock Absorber Inspection
Rear Shock Absorber Installation
Shock Linkage Bearing Replacement
Shock Linkage Removal
Shock Linkage Installation
Swingarm Removal
Swingarm Bearing Replacement
Swingarm Installation
Hydraulic Brake
Hydraulic Brake System Components
Hydraulic Brake Service Information
Hydraulic Brake Specification
Hydraulic Brake Torque Values
Hydraulic Brake Tools
Hydraulic Brake Troubleshooting
Brake Fluid Draining
Brake Fluid Replacement/Air Bleeding
Brake Fluid Filling/Air Bleeding
Brake Pad/Disc
Front Brake Pad Replacement
Rear Brake Pad Replacement
Brake Disc Inspection
Front Master Cylinder Disassembly
Hydraulic Brake Assembly
Front Brake Caliper Disassembly
Front Brake Caliper Inspection
Front Brake Caliper Assembly
Rear Master Cylinder Disassembly
Rear Brake Caliper Disassembly
Rear Brake Caliper Inspection
Brake Pedal Installation
Brake Pedal Removal
Electrical
Electrical Component Location
Electrical Service Information
Electrical Specification
Electrical Torque Values
Electrical Tools
Electrical Troubleshooting
Alternator Charging Coil Inspection
Generating System
Generating Voltage Inspection
Alternator
Left Crankcase Cover Removal
Flywheel Installation
Flywheel Removal
Stator Replacement
Left Crankcase Cover Installation
Ground Line
Ignition Switch Line
Regulator/Rectifier
Wire Harness Inspection
Ignition Coil Primary Peak Voltage
Ignition System Inspection
Alternator Exciter Coil Peak Voltage
Ignition Pulse Generator Peak Voltage
Ignition Timing
IGNITION COIL Removal/Installation
Headlight Bulb Replacement
ICM (Ignition Control Module) Removal/Installation
Headlight Aiming
Headlight Bulb Removal/Installation
Brake/Taillight Removal/Installation
Ignition Switch Inspection
Front Brake Light Switch
Handlebar Switch Inspection
Carburetor Heater Inspection
Rear Brake Light Switch
Throttle Position Sensor Inspection
Coolant Temperature Indicator System Inspection
Cooling Fan Motor Inspection
Engine Coolant Temperature (ECT) Sensor Inspection
Battery/Charging System
Battery/Charging System Component Location
System Diagram (Trx450Er)
Battery Charging
Battery Testing
Battery/Charging System Service Information
Battery/Charging System Specifications
Battery/Charging System Tools
Battery/Charging System Torque Values
Battery/Charging System Troubleshooting
Battery (TRX450ER) Removal/Installation
Battery (TRX450ER) Testing
Battery (TRX450ER) Voltage Inspection
Charging System Inspection (TRX450ER)
Charging Coil Line (Trx450Er/R)
Ignition Switch Line (Trx450R)
Ignition System
Ignition System Component Location
Ignition System Diagram
Ignition System Service Information
Ignition System Specifications
Ignition System Tools
Ignition System Torque Value
Ignition System Troubleshooting
Closed Throttle Position Detection System
Electric Starter (TRX450ER)
Electric Starter (TRX450ER) Component Location
Electric Starter (TRX450ER) System Diagram
Electric Starter (TRX450ER) Service Information
Electric Starter (TRX450ER) Specifications
Electric Starter (TRX450ER) Troubleshooting
Starter Motor Disassembly/Inspection
Starter Motor Removal
Starter Motor Assembly
Starter Motor Installation
Power Input Line
Starter Relay Switch Circuit Inspection
Starter Relay Switch Operation Inspection
Clutch Diode Inspection
Function Inspection
Lights/Switches
Lights/Switches Component Location
Lights/Switches Service Information
Lights/Switches Specifications
Lights/Switches Torque Values
Headlight
Lights/Switches Bulb Replacement
Indicators
Brake/Taillight
Handlebar Switch
Ignition Switch Replacement
CLUTCH SWITCH (TRX450ER Only)
Coolant Temperature Indicator
Cooling Fam Motor Inspection
Engine Coolant Temperature (Ect) Sensor
Wiring Diagrams
Wiring Diagrams (after '05/Trx450Er)
Troubleshooting
Engine Does Not Start or Is Hard to Start
Engine Lacks Power
Poor Performance at Low and Idle Speed
Poor Performance at High Speed
Poor Handling
Index
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Quick Links
1
Model Identification
2
General Specifications
3
Cylinder He Ad/Valve/Camshaft Specifications
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See also:
Owner's Manual
Table of
Contents
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Table of Contents
Troubleshooting
Frame/body panels/exhaust system service information
53
Lubrication system service information
101
Fuel system troubleshooting
119
TROUBLESHOOTING
143
Cooling system service information troubleshooting
168
Cylinder head/valve troubleshooting
202
Cylinder/piston troubleshooting
230
Clutch/kickstarter/gearshift linkage troubleshooting
243
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage
263
Clutch/Starter Clutch/Kick Starter/Gearshift Linkage Troubleshooting
266
Crankcase/Transmission/Crankshaft/Balancer Troubleshooting
297
TROUBLESHOOTING
324
Front Wheel/Suspension/Steering Troubleshooting
350
Rear Wheel/Suspension Troubleshooting
382
Hydraulic Brake Troubleshooting
404
Electrical Troubleshooting
433
Battery/charging system Troubleshooting
457
Ignition System Troubleshooting
470
Electric Starter (TRX450ER) Troubleshooting
484
Troubleshooting
514
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