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    2001 Honda Trx450 Foreman Service Repair Manual

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    Tim Mckenna

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    © All Rights Reserved
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    2001 Honda Trx450 Foreman Service Repair Manual

    Uploaded by

    Tim Mckenna
    287 views484 pages

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    © © All Rights Reserved

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    287 views484 pages

    2001 Honda Trx450 Foreman Service Repair Manual

    Uploaded by

    Tim Mckenna

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    RT erate IMPORTANT SAFETY NOTICE REIN iciaees» cron pest of eecooenal ey or uae atm wee e@ CAUTION sich piney sia wig Mtl a toned NOTE: hoes oration | i elf ad eon coc: ay Neb Asn rane ek Won. We neers eerie eae! 6 could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, | ‘might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recammended by Honda, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected, HOW TO USE THIS MANUAL This service manual describes the service procedures for the TRX450S/FM and TRXA5ESIFE. Follow the Maintenance Schedule (Seetion 3) recom: mendations to ensure that the vehicle is in peak ‘operating condition and the emission levels are within the standards set by the California Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removaljinstallation of components that may be required to perform service describad in the following sections. ion 4 through 23 describe parts of the vehicle, iped according to location Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with assembly or system illustration, service information and troubleshooting for the section, The subsequent pages give detailed procedure. It you are not familiar with this vehicle, read the Technical Features in section 24. If you do not know the source of the trouble, go to section 25, Troubleshooting ee ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD, RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS OR ATVS. HONDA MOTOR CO. LTD. SERVICE PUBLICATION OFFICE CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM "ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/CYLINDER/PISTON CLUTCH GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKSHAFT/BALANCER/ TRANSMISSION FRONT WHEEL/SUSPENSION/ STEERING REAR WHEEL/SUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM Gi REAR DRIVING MECHANISM - BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER ENGINE AND DRAIVE TRAIN CHASSIS LIGHTS/METERS/SWITCHES ELECTRIC SHIFT PROGRAM (ESP) -g SELECTABLE 4WD SYSTEM (After ‘01) ELECTRICAL | WIRING DIAGRAM __ TECHNICAL FEATURES | TROUBLESHOOTING | INDEX SYMBOLS The symbols used throughout this manual show specific service procedur pertaining to these symbols, it would be explained specifically in the toxt without the use of the symbols, Replace the part(s) with new one(s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1), Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent! Use molybdenum disulfide grease (containing more than 3 % molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® BR-2 plus manufactured by Dow Corning, U.S.A, Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40 % mélybdenum disulfide, NLGI #2 or equivalent). Example: Molykote®BR-2 plus, manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply @ locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 3 or DOT 4 brake fiuid. Use the recommended brake fluid unless otherwise specified. fm aah Po Rhos Use Fork or Suspension Fluid. Parmemmnyntornuca nine @& e@ oe © 6 © 1. GENERAL INFORMATION GENERAL SAFETY 11 LUBRICATION & SEALPOINTS — 1-18 SERVICE RULES 1-2 CABLE & HARNESS ROUTING 1-21 MODEL IDENTIFICATION 13 EMISSION CONTROL SYSTEMS 1-37 SPECIFICATIONS 14 EMISSION CONTROL TORGUESALUES 4-13. INFORMATION LABEL 1-38 TOOLS 1-16 GENERAL SAFETY CARBON MONOXIDE Ifthe engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area, i The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area, GASOLINE Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work ares or where gasoline is stored. Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS am Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. USED ENGINE OIL ORM Used engine oll may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oll on a daily basis, itis still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP ‘OUT OF REACH OF CHILDREN. BRAKE FLUID CAUTION: Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designad to minimize the hazard caused by airborne asbestos fivers. a Inhaled asbestos fibers have been found to cause respiratory disease and cancer. GENERAL INFORMATION BATTERY HYDROGEN GAS & ELECTROLYTE I + The battery gives off explosive gases; keep sparks. flames ‘ond cigarettes away. Provide adequate ventilation when charging + The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. “if electrolyte gets on your skin, flush with water = electrolyte gets in your eyes, flush with water for at least 15 minutes and cal a physician immediately. + Electrolyte is poisonous. = If swallowed, drink large quantities of water oF milk ‘and follow with milk of magnesia or vegetable oil and calla physicion. KEEP QUT OF REACH OF CHILDREN. SERVICE RULES 1 Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA's design specifications may cause damage to the vehicle. 2, Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. install new gaskets, O-rings, cotter pins, and lock plates when reassembling 5. When tightening bolts or nuts, begin with the larger diamotor or inner bolt first. Then tighten to the specified torque diagonally in ineremental steps unless a particular sequence is specified, 6, Clean parts in cleaning solvent upon disassemb ny sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation snd operation. {8 Route all cable and harness routing as shown on pages 1-21 through 1-29 Cable and Harness Routing. 1-2 MODEL IDENTIFICATION ©o TRX 450S/FM : GENERAL INFORMATION ‘TRX 450ES/FE : The frame serial number is stamped on the front of the frame. he x "\ [CARBURETOR NUMBER, The carburetor identification numbers are stampod on the left side of the carburetor body as shown. ENGINE SERIAL NUMBER The engine serial number is stamped on upper side. of the rear crankcase viewed from the left side. COLOR LABEL The color label is attached to the frame under the ‘seat as shown. When ordering color-coded parts, always specify the designated color cade. 1-3 GENERAL INFORMATION SPECIFICATIONS [1 '98~ "01: TRXAS0ES -GehienAL: Alter ‘01: TRXASOFE ire ‘SPECIFICATION DIMENSIONS | Overall length (98-01) 4.961 mm (7.2 in) (after ‘01) 1,963 mm (77-3 in) Overall width (98-01) 41,186 mm (45.5 in) (ater ‘o1) 1,381 mm (45.3 in) Overall height 1/148 mm (45.9 in) Wheelbase (98 -'01) 411271 mm (60.9 in) (after ‘01) 1.274 mm (60.2 in) Front tread (38-01) 912 mm (35.9 in} (after 0) 910 mm (35.8 in} Roar tread ‘905 mm (35.6 in) Seat height (98-"01) ‘860 mm (33.3 in} (after ‘01) 854 mm (33.6 in} Footbag height (98-"01) 327 mmm (12 in) [333 mm (13.1 in) (after 00) 329 mm (73,0 in} [336 mm (13.2 in} Ground clearance (38-01) 192 mm (76in) (after 01) 198 mm (7.7 in) Dry weight (38 -'01) 260 kg (575 lbs) [2685 kg (886 Ibs!) ‘after 01) 264 kg (582 ths) (270 kg (595 Ibs) Curb weight (38~"01) 270 kg (595 tbs) (276 kg (608 Ibs!) {after 01) 274 kg (604 ths) (280 kg (617 Ibs)] Maximum weight capacity FRAME Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Roar dampor Front tire size Roar tire size Front rim size Rear rim size Tire brand (DUNLOP) FR/RR Front brake Rear brake Toe Caster angle Camber angle Trail length Fuel tank capacity Fuel tank reserve capacity 220 kg (486 Ibs) Double cradle Double wish-bone 150 mm (6.91 in} Double tube Swingarm 1150 mm (6.91 in) Double tube AT 25 X 8-12 8% AT 25 X 10-12 12X60 AT 12X75 AT KT401C/‘98 ~ 01: KTAO5C, After ‘01 KT128 Hydraulic drum brake Mechanical drum brake Toe-out: 35 mm (1-3/8 in) s on" 7 mm (9/32 in) 12.0 € (3.18 US gal, 2.64 Imp gal) 2.7 20.71 US gal, 0.58 Imp gal) 1-4 ;- GENERAL (Cont'd) GENERAL INFORMATION ITEM SPECIFICATION Bore and stroke Displacement ENGINE 90.0 X 68.0 mm (3.54 X 2.68 in) 432.6 cm (26.40 cu-in) | intake valve closes 45° ABDC ) | Exhavet vale opens ae eBpe i Saas a ‘ee ars 2 tau aass Bn ve er ooehis Seren Starting system Charging system Regulator/rectitier Lighting system Starter motor and emergensy recoil starter Triple phase output alternator SCR shorteditriple phase full-wave rectification Battery GENERAL INFORMATION 7 LUBRICATION SYSTEM Wem Engine oil capacity At draining Unit: mm (in) STANDARDS SERVICE LIMIT | At disassembly 2.02 (2.10 US qt, 1.76 Imp at) | 2.7 2 (2.88 US at, 2.38 Imp at) Throttle lever free play _ t 2.11221 US at 1.85 Imp at _— Recommended engin HONDA GNA 4stroke oil or equivalent motor ci {API service classification SF or SG | pump rotor Tip clearance 0.18 (0.008) 0.20 (0.008) Body clearance 0.15~0.21 (0.006 0.008) 0.25 0.010) Sido clearance (0.02. 0.09 (0.001 0.008) Tost (0.008 FUEL SYSTEM trem. SPECIFICATIONS Carburetor identification numé ="01 : VESIA ‘itor 01: esac Main jet inital #130 | ‘High altitude setting #20 Slow jet — = #45 [Jet needle clip position - 3rd groove from 4 Pilot serew [initial opening 2-5/8 turns out | High att —_ ‘I Float level - Engine icle speed 308.0 mm V8 - 5/6) Starting enrichment (SE) valve distance 10-11 mm (0.39 ~ 0.43 in) © GENERAL INFORMATION > CYLINDER HEAD/VALVES/CAMSHAFT unit mn ind mem ‘STANDARDS SERVICE LIMIT [Cylinder | Decompressor effected 539 — 834 KPa (65-85 kgllem, compression | ee [78-121 psi) at 450 rpm Decompressor not effected 1.200 — 1,442 kPa (125-145 kgm, _ 178 206 psi at 450 rom Valve, Valve clearance iW [10.15 0.006) Valve quide | 0.15 0.006) Valve siom 0.0. 5.475 - 5.490 (0.2188 — 0.2161) 5.45 (0.278) ‘5455 -5.470 (0.2148 0.2154) 5.43.0. Vaive guide 10. 5.500 - 6512 (02165 -0.2170) 5.525 (0.2178) 5500-8512 (02165 -0.2170) 525 (02 0.010 - 0.037 (0.0004 ~0.0015) 0.12 (0.005) | (0,030 - 0.057 (0.0012 - 0.0022) 0.14 (0.006) Valve seat width 1.2 (0.005) 7.5 (0.06) Valve spring Inner 36.85 (1.457) 35.64 (1.411) free length [Outer 41.67 (1.683) 40.42 (1.591) Rocker arm/ | Racker arrn 0. 12.000 12.018(0.4724-0.4731) | 12.05 (0.474) shaft Rocker arm shaft O.. 11.964—11.984(0.4710— 0.4718) | 11.92 (0.469) 10.016 ~ 0.054 (0.0006 0.002) 1.06 (0.003) Camshaftand [Cam lobe height IN 36.4291 - 36.4291 (1.43421 - 1.44051) | 36.25 (1.427), eam follower Ex 36.2670 96.4270 (1.42783 — 1.43131) | 36.10 (1.421) Cam follower 0. IWEX 22.457 ~ 22.482 (0.8845-0.8851) | 22.45 (0.884) Cam follower bore 0.0._|IWEX 22,510 22.526 (0.962-0.6868) | 22.54 (0.887) Cam follower to bore clearance 0,028 ~0.059 (0.0011 0.0023) 0.07 (0,003) Unit: rm Gn p CYLINDER/PISTON Tre STANDARDS SERVICE Lr Cylinder 10. 90.00 - 90.01 (3.543 ~ 3.544) 90.10 (3.547) Taper _ a 0.10 (0,004) Out of ound = 0:10 (0.004) [Warpage —__ [0.10 (0.004) son, Piston mark decion Tmo ——— ston rings, [Aton 0.0. 30.945 60.065 3411-36418) | B990@599 piston pin [Piston 0.0. mensurement point | 10 mm (0.4 in rom bottom of skirt = Piston pin bora LD. 1.002 19.008 (0.7481 -0.7483) | 190810750 Piston pin O.D. - 18.994 19.000 (0.7478 0.7480) | 18.96 0.746) Petrie plton pin dearance 62002-0014 0.0001 o.0008) | 0.120.029) Piston ring-toving [Ton 0.030 - 0.060 (0.0011-0.0020) [0.09 (0.0) gression Second | 0.015 =0.45 (0.0008 - 0.0018) | 0.090.008) Piston tng end ge [Top 2015 - 0.30 (0.008 - 0.012) 050002 Second | 000 0.480 0012-0018) 08 (002) Oi side ril_| 0.20 0.70 0008 - 0.026) | Cynder piston clesance 0.036 - 0.086 (0.0014 0.0022) | 6.10 (0.008) Connecting rod small end LO. 18.020 19.041 (07488 - 0.7488) | 1807 (0.7508) [Connecting rd t piston pin clearance 2020-0047 (00008-00018) | 0.102.004 — 1-7 GENERAL INFORMATION 7 CLUTCH/GEARSHIFT LINKAGE aterm. tn ITEM ‘STANDARDS SERVICE LiMiT Change clutch | Spring fee length 2228) EXETTED Bless 262-278 (0.108 0.09) 2.3 (0.09) iate warpage — [0.20 10.008) Clutch outer guide OD. __| 27950~77.580 (1.1007 1.1016) | 27.82 (1.098) iD. | 22.000 72.021 (0.8661 - 0.8670) | 22.05 0.668) ‘Maincha 0.0 at outer guide 21.972 21,993 (0.8650 0.659) | 21.93 (0.69) Centrifugal | Drum LD. —__| 140.0 740.2 (6.51 - 5.52) [140.4 (5.53) eluteh ‘Weight lining thickness 3.0 (0.12 [2.0 (0.08 ‘Clutch spring height 3.1(0.12) [29510116 ah eihesery fale 218 (085) 725 088) Primary arive [ LD. 27.000 ~ 27.021 (7.0690 10658) | 27.05 (1.065) gear Crankshaft O10. at dive gear 26.959 ~ 76.980 (1.0614 ~ 1.0622) | 26.93 (1.060) 1-8 e @ ® GENERAL INFORMATION a > CRANKSHAFT/TRANSMISSION Aa tmeticy TEM STANDARDS: ‘SERVICE LIMIT Crankshaft, | Side clearance 0.05 — 0.65 (0.002 - 0.026) 0.80 (0.031) Radial clearance 0.006 0.018 (0.0002 - 0.0007) 0.05 (0,002) Runout — 0.05 (0.002) Transmission | Gear LD. me 25,000~ 25.021 (09843-09851) | 25.05 (0.586), Ms _ 20,000 — 20.021 (0.7874 — 0.7882) 25.05 (0.986) 1.02. 26,020 28.061(7.1081— 1.1040) | 28.07 (1.105), cr 26,021 ~ 28.067(7.1082— 1.1040) | 28.07 (7.105) | Reverse ile 18,000 18.021 (0.7087 0.7095) | 18.08 (0.711) ‘shat O0. M4 ~S~*d« 2.969 27.980 (0.8645 0.8664) | 21.99 (0.883) M5 16.983 — 16.994 (0.6686 - 0.6691) 16.95 (0.667) Reverse idle 13.966 13.984 (0.5496 0.5506) | 12.03 (0.548) (Gear bushing | 27.984 = 28,005 (1.1017 - 1.1026) 27.93 (1.100) 277.999 - 78.000 (1.1018 1.1026) [2793 (1.10 71.979 ~ 78.000 (1.1015 1.1024) | 2793,(1.10 ib. | 22.000- 22.021 0.661 0.8070) | 7205 868) 0.0. 24.959 - 24.980 (0.9826 - 0.9835) 24.93 (0.981) ws [uD. | 17.016 17.094 (0.6690 - 0.67061 | 1706 (0672) 0.0. | 19.966 19.8840 7661 0.7668) 1993 0785), R 1D. | 14.000 14.025 0.8616 0.8622) | 14.05 0.863) 0.0. | 17.966 17.964 7073-0 7080) 1793 0.706) Gears Ma 02020 - 0.062 (00008-00024) [0.10 (0004) bushing Ms 0.016 0.085 10.0006 0.0022) [0.10 0004) clearance ci 10.015 ~ 0.057 (0.0006 0.0022) [0.10 (0.008) a (0020 0062 (00008-00024) [0.10 0.004) cr 10.020 0.06210.0008-0.0024) [0.10 (0004) 3 (2018-0057 (00006-00022) [0.10 (0.004) Revers dle | 0.016 0.055 «0.0006 0.0022) [0.10 (0.004) Busting ton Me 01020 0.067 00008-00028) 0.10 0.008) | shottclesrance [M5 "0.022 0.081 (0.0009 0.0020) | 0.10 (0.004) Reverse idle | 0.016 0.058 (0.0006 0.0023) [0.10 (0.008) Shift fork, Fork At 13.000 - 13.021 (0.5118 - 0.5126) 13.04 (0.513) shot Claw thickness | 499-500 0.194 -0.197) [450 0.177 Fork shah 00. 12.966 - 12964 05105-05112) 1298 0510) GENERAL INFORMATION > FRONT WHEEL/SUSPENSION/STEERING Hee It rem STANDARDS SERVICE LIMIT Minimum tre wead depth = 401 Cold tte pressure [5k 10.28 kpc 3.6 psi 229 (0.22 aller, 3.2 ps — 28 KPa (0.28 kote, 4.0 psi) 25 KPa (0.25 kgler, 3.6 psi) ad anc boron a alin 3652 10/148 2000 Tos Too out 35+ 16 mm [881976 in) = - REAR WHEEL/SUSPENSION See rem STANDARDS SERVICE LT Minimum tre weed depth = [ior Cold tire pressure ‘Standard 25 kPa (0.25 kaliem®, 3.6 psi) Minimum [22 kPa (0.22 katiem’, 32 psi) Maximum - 28 kat/om’, 4.0 psi) With cargo 75 Pa (0.25 ken, 3.6 psi = Gas Unit: mm dn) Trem STANDARDS SERVICE LIMT Front broke | Drum LD. — “| 160.0 16.30 161.0638) Lining thickness | 4.0 (0.16) - 2.0 (0.08) Brake panel warpage 0.4 (0.02) Ea poe cal soon 05 (0.02) | Water soa ip fonath T0108 [20.0 (0.79) Master cylinder LD. 14.000 14.043 (05572-08629) | 14.055 (0.553) amar pbian OO 13.957 Tabs i 5486=0.5506) [1.546 15080) Wheel cylinder LD. 19.050 19.102 (0.7500-0.7520) | 19.12 (0.753) Wheel cylinder piston OD. 18.997 - 19.090 (0.7479 0.7492) | 188110741) [Rearbate [orm io. Tessa) 01638) (Citeg titel 5.0 (0.20) To the indicator - FRONT DRIVING MECHANISM conn in) eM SERVICE LIM ana aemnaany | na a = At disassembly 200 om (6.76 US 02, 7.02 Imp oz) = minendod Hypoid gear ol SAF 460 _ Clutch ‘spring free height 2.85 (0,104), __| Clutch dis thickness z "2: -2.8(6.106 0.110) i 8 2.3-2.4(0.081-0084) (0.08) Pinion gear. a 12,000 - 12.018 (0.4724 04731) | 12.0 (0478) Pinion gear shaft. 11973 11.984 (04714-04718) | 1.75 0.463) Sliptorque 17-26 Nem 17-25 4g 12-18 — | Gear backlash 105 ~ 0.0 (0.002 - 0.012) 040 (0.016) —.] A 1-10 GENERAL INFORMATION Unit: mm (in) 7 FRONT DRIVING MECHANISM (‘98 - ‘01) ireM STANDARDS: SERVICE LIMIT | oil capacity Alter draining __| 190 cm? (6.4 US 07, 67 Imp oz) ‘At disassombly 200 om’ (6.8 US 02,7.01mp oz) Recommended oil Hypoid gear oll SAE #80 ‘Clutch spring free height 2.66 (0.104) Clutch dise thickness A | 2.7-2.8 (0.106 0.110) oe - 8 2.3-2.4 (0.091 - 0.094) 2.1 (0.08) Pinion gearl.D. 12,000 - 12.018 (0.4724 ~ 0.4731) 12,05 (0.474) Pinion gear shaft O.D. 973 11,984 (0.4714 0.4778) 11.78 (0.463) __| Slintorque 17-25 Nem (17-25 4h 12-186) = Gear backlash i 0.05 - 0.30 (0,002 - 0.012) 10.40 (0.016) - FRONT DRIVING MECHANISM (After 01) oe ITEM ‘STANDARDS ‘SERVICE LIMIT — “tee eae nee — Sores | " _[Risraamany — [ase i600 8:7 mp oe 5 [Recommendedol | Hypo oar ol SAE 00 == Gearbactlash 405 - 0.25 (0.002 -0.010) [e008 [Bsektsh ciference oziecv | Slip torque TOW Nem (45-178 Kghem, | 2 Nem (L2G L_ 10-13 bi | sie Face tam to-housing dstanc 63-6.7 (025-026) 63(0.25) Differential housing cap desth | ass 2.65 0.376 0.300) 955 (0378) Cone epring feo height 28.0111 260.10) ie wen fk ; REAR DRIVING MECHANISM rem STANDARDS SERVICE LIMIT Rear axle runout — — = 300012) Rearfinal | Oil capacity After draining 80 cm? (3.0 US 07, 321 Imp o2) ative a eckaaonin Wher aa lieot an lan == Recommended ol Hypoid gear oll SAE #80 = | Gear backlash 0.05 - 0.30 (0.002 - 0.012) 0.40 (0.016) - BATTERY/CHARGING SYSTEM vrem SPECIFICATIONS Bawery | Capacity 12V-12 AH Current teakage nam Voltage Fully charged wo-wev | | ao'cwet) | Needs charging Below 12.3V — Charging current | Normal [ 7 Quick | Altemator | Capacity Charging col resistance GOTISEA amar [is a rectifier Fleguiatad valtage GENERAL INFORMATION ote nm ay [IGNITION SYSTEM rem SPECIFICATIONS w ‘Spark plug | Standard DPATEA-S(NGK) | _ X22EPR— U9 IDENSO) Farsalt ina BaowiPoNTH_——|—beaiea se avant [eater Us DENCY [Fone na awad aa, ——| benicar —| ~SchePn cus ewech ‘Spark plug gap — 7 0.8 - 0.9 mm (0,03 - 0.04 in) 2 Tae we O07 Vmi ms~«@ ‘Ignition timing 10° BTDC at 1,400 rpm 30° BTDC at 5.900 rpm Unit: mm (in) [ELECTRIC STARTER =. | ii eee] ' rem STANDARDS ‘SERVICE LIMIT Starter motor brush length 12.5 (0.49) [3.0 (0.35) | LIGHTS/METERS/SWITCHES iTeM’ ‘SPECIFICATIONS Bue aan ce 1BV29R6WK2 Atwr'o1 | av 20c0W x2 1V-5W 8 eo Bake ight (Aher01 Quebec provnes oni ‘2V-21ce Indicator (llReverse/Neutra [Fase Tai tse — | Sub fuse s0 | 16AX2, 10AX 2 | a ON || MOTOR FUSE (TRX450 ES/FE only) 1BAX2, 10AX3 A 1-12 GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TYPE Nem (gto, tte) FASTENER TYPE [Nem (kgfom,tbftt) 5 mm hex bolt and nut 5(05,36 | 5 mmscrew 4 (0.4, 2.9) 6 mm hex bolt and nut 1011.0.71 | 6mm screw 909, 65) 8 mm hex bolt and nut 22122, 16) | 6 mm flange bolt (8 mm head) 8 (03,65) 30mm hex bolt and nut 34138,25) | 6 mm flange bolt (10 mm head) and nut 12(12, 9) 32mm hex bolt and nut 54155, 40) | 8 mm flange bolt and nut 2 (27, 20) 10 mm flange bolt and nut 38 (40, 29) = Torque specificatons listed below are for important fasteners. + Others should be tightened to standard torque values listed above. NOTES: 1. Apply sealant to the threads. 2, Apply a locking agent to the threads. 3 Stake. 44. Apply oll to the threads and flange surface. 5. Apply clean engine oil to the O-ring, 6. Apply grease to the threads and flange surface. 7, ALOC bolt: replace with a new ona. 8. Do not reuse; replace with a new one. 8, Castle nut: Tighten to the specified torque then tighten to position suitable for cotter pin hole direction. ENGINE THREAD DIA, ‘TORQUE rem oy ee Nem (kgfem, thf) REMARKS Maintenance: il drain bott 1 2 29 (25,18) Oil filter cover flange bolt 3 6 101.0, 7) ‘Spark plug i 12 181.8, 13) Timing hole cap 1 14 10(1.0.7), Valve adjuster lock nut 2 6 471.7, 12) Clutch adjusting serew lock nut 1 8 22 (2.2, 16), Lubrication System: il pump rotor side plate screw 1 5 40.40, 2.9) Relief valve cap 1 14 19(19,14) | NOTE2 Fule System: Carburetor cover serew 1 5 4(0.4.29) Starting enrichment (SE) valve nut 1 4 3(03, 1.8) Insulator band screw (After ‘01) 1 5 $(0.4,29) Cylinder Head/Valves/Camshaft: Gylinder head fiange cap nut 3 10 39(4.0,29| | NOTE 4 Camshaft bearing retainer bolt 1 8 26(2.7,20) | NOTE2 Cam spracket flange dowel bo!t 2 q 20(2.0,14) | NOTE2 Cam chain tensioner lifter sealing screw 1 6 $(0.4.2.9) Cam chain tensioner mounting bolt 2 6 32(12,9) | NOTE? locker arm holder flange cap nut 3 10 39(4.0,29| | NOTE 4 Rocker arm shaft flange bolt 1 6 7(0.7, 5.1) Clutch/Gearshitt Linkage: Gearshift return spring pin 1 8 2222.16) | NOTE2 Shift drum stopper arm bolt 1 6 1211.2.) Gearshift A arm bolt i 8 252, 18) Centrifugal clutch outer lock nut 1 20 118 (120,87) NOTE3.4 Clutch spring bolt 4 6 1211.2, 9) Change cluteh center lock nut 1 18 108 (11.0,80) | NOTES.4 Drum shitter and guide plate bolt (98 -‘01) 1 6 12112,8) | NOTE {aiter 07) 1 6 16116, 12) | NOTE2 1-13 GENERAL INFORMATION y ENGINE (Cont'd) ‘THREAD DIA. TORQUE ves oy (mm) Nem (kgf-m, ibfett) | REMARKS Recoil Starter: | Recoil pulley flange bolt 1 2 108 (11,0,80) | NOTES Alternator/Starter Cluteh’ Starter one-way clutch socket bolt 6 8 3113.1.22) | NOTE2 Stator socket bolt 3 6 10(1.0,7) Ignition System: Ignition pulse generator socket bolt 2 5 6 (06,43) | NOTE2 Lights/Meters/Switehes: Neutraljreverse (or gear position) switch ‘mounting bolt 1 6 12(1.2,8) | NOTE2 il thermo sensor 1 12 18(18, 13) Angle sensor (TRX@S0ES only) 2 6 L 6106.43) rp FRAME THREAD DIA. TORQUE ce ar (mm) (Nem (kafom, wrt) | REMARKS Frame/Body Panels/Exhaust System: Muffler band bolt 2 8 2323.1) Exhaust pipe protector bolt 3 6 22(2.2, 16) Heat protector bolt 2 6 22 (2.2.16) Heat guard bolt 4 6 20(2.0, 14) Step bar mounting bolt 4 8 3218.3, 24) Cooling fan shroud special bolt 4 6 18(1.8, 13) Fue! tank rear bracket bolt 4 6 18 (1.8,13) Carrier mounting bolt '38~"01) 14 8 32 (3.3, 24) (after ‘01) “4 8 373.8, 27) Fuel System: Fuel valve mounting bolt 2 6 309,65) Fue! level gauge mounting bolt 2 6 12(1.2,9) By-starter cap special bolt H 4 2.3.(0.23,1.8) (Cluteh/Gearshitt Linkage: Gearshift pedal bolt ('98 -'01) 1 6 1616, 121 (after 01) 1 6 20(2.0, 14) Engine Mounting: Lower engine mounting bolt (right) 1 10 5415.5, 40) Lower engine mounting bolt (left) 1 10 54.5.5, 40) Upper engine hanger bolt 1 10 54 (5.5, 40) Upper engine hanger bracket bolt B 8 32.3.3, 24) Lower engine hanger bracket bolt 2 8 32.3.3, 24) Front Wheol/Susponsion/Steering: Throttle case cover 3 4 4 (04,25) Handlebar lower holder nut 2 10 39(4.0,2) | NOTES Steoring shaft U-nut 1 “ 108 (11.0,80) | NOTE6 Tie-t0d ball joint self lock nut 4 ” 54.5.5, 40) Tie-rod lock nut 4 2 5415.5, 40) Steering shaft holder flange bolt 2 8 328.3, 24) Upper/iower arm pivot self lock nut 8 10 4445 33) | NOTES Knuckle bal joint castle nut (98 —‘01) 4 rr 29(3.0,22| | NOTES (After ‘01) 4 ” 32033,24 | NOTES Shock absorber upper mounting self lock nut 2 10 44(65,33) | NOTES Shock absorber lower mounting self lock nut 2 10 44(465,33) | NOTES Damper rod lock nut 2 10 37(38,27) | NOTE2 Front wheel nut 8 10 64165, 47) Front whee! hub castle nut 2 16 78 (8.0.58) | NOTES 1-14 e ee 6 GENERAL INFORMATION r FRAME (Cont'd) ery | THREAD DIA. TORQUE Tee ary tone) Akot-m, Ibert) REMARKS —— = | ‘Rear Wheel/Suspension: | Fear axle castle nut 2 20 137 (14.0, 101) | NOTES Rear wheal nut a 10 54 (65,47) ‘Shock absorber lower mounting self lock nut 1 10 44 (45,33) | NOTES ‘Shock absorber upper mounting self lock nut 2 10 39 (40,29) | NOTES Shock absorber lower mounting bolt 1 10 44 (45, 33) Damper rad lock nut 2 10 37(38,27) | NOTE2 Swingarm left pivot bolt 1 30 113 (11.5, 83) Swingarm right pivot bolt (98 ~‘01) 1 30 4(0.40,29) (After 01) 1 | 30 10(1.0,7) Swintarm right pivot lock nut 1 30 113 (11.5, 83) Rear axle housing and swingarm nut a | 10 44 (45,33) | NOTES Skid plate flange bolt 3 8 82 (3.3, 24) Brakes: Rear brake arm pinch bolt/nut 1 8 20(2.0, 14) Rear brake panel drain bolt (‘98 ~ 01) 1 2 34 (35, 25) ater 01) 1 2 12 (1.2.8), Master cylinder reservoir cap screw 2 4 2 (0.20, 1.4) Master cylinder holder SH bolt 2 6 12 (1.2.9), Brake laver pivot bolt 1 6 110.10, 0.7) Brake lever pivot lock nut 1 6 6106, 4.3) Brake hose oil bolt 4 10 34 (3.5, 25) Brake hose clamp flange bolt 2 6 1211.2.9) Brake panel flange bolt 8 8 29(3.0,22) | NOTER Whee! cylinder bolwasher 4 6 8108, 5.8) Wheel cylinder nut 4 8 17 (47, 12) Wheel cylinder oil pipe 4 10 16 (1.6, 12), Broke bleeder valve 2 8 6106. 4.3) Breather hose clamp (knuckle) 2 8 323.3, 24) Brake hose 2-way joint 2 a 3515.11) Front Driving Mechanism: Differential case mounting bolvinut, 10 mm 2 10 48 (45,33), amm 1 8 22 (2.2, 16), Differential case cover flange bolt, 8 mm 6 8 25 (2.6, 19), 10mm 2 10 49(5.0, 36) NOTE 2 Pinion joint nut '98~“01) 1 16 108 (11.0,80) | NOTE 2 Pinion bearing lock nut ('98-'01) a 6a 98(10.0,72) | NOTES Differential gear case drain bolt 1 8 12(1.2,9) Differential gear case cover oll cap 1 30 12(1.2,9) Differential case cap torx bolt (38 -'01) 6 8 32(33,24) | NOTE7 Differential case UBS bolt (98-01) 6 8 49 (6.0, 36), Differential ring gear bolt (After ‘01) 6 8 4950.36) | NOTES ‘Speed sensor mounting bolt (After 01) 2 e 1011.0, 7), Final clutch speed sensor mounting bolt (After‘01) 2 6 10(1.0,7) Final clutch mounting bolt (After ‘01) 3 8 25 (2.6, 19) Final clutch cover bolt (After ‘01), 2 6 70.7.5) 3F Driving Mechanism: Gear case caver flange bolt, 8 mm 6 8 25 (2.6, 19) 10mm 2 10 49(6.0.36) | NOTE2 Pinion joint nut ('98~'01) 1 16 108 (11.0, 80) | NOTE 2 Pinion bearing lock nut 1 64 98 (10.0,72) | NOTE3 Gear case drain bolt 1 8 121.2. 9) Gear case cover oil check bolt 1 8 1201.2, 9 Gear case cover oll cap 1 30 121.2.9) 1-15 (GENERAL INFORMATION TOOLS NOTES: 1. Newly designed tool. 2. Equivalent commercially available in U.S.A. 3. Not available in U.S.A, 4. Alternative tool. DESCRIPTION Carburetor oat level gauge Flywheel holder Rotor puller Remover weight Valve guide driver, 5.5 mm Attachment, 37 X 40 mm Attachment, 42 X 47 mm ‘Attachment, 82 $5 mm ‘Attachment, 62 X 68 mm Attachment, 72 X 75 mm Attachment, 24 X 26 mm Attachment, 22 X 24 mm (After ‘01 Driver, 22 mm LD. ‘Attachment, 15 mm .D. Driver, 40:mm LD. ‘Attachment, 25 mm |.D. (98-01) ‘Attachment, 30 mm {,D. (After 01) Pilot. 10 mm Pilot, 16 mm (After “01 Pilot. 17 mm Pilot, 20 mm Pilot, 25 mm Pilot, 30 mm Pilot. 35 mm Pilot, 40 mm Pilot. 22 mm Pilot, 28 mm Pilot. 14 mm (After “01) Driver Valve spring compressor Valve seat cutter ‘Soat cutter, 29 mm (46° EX) Seat cutter, 35 mm (45° IN) Flat cutter, 30 mm (32° EX) Flat cutter, 35 mm (32° IN) Interior cutter, 30 mm (60° EX) Interior cutter, 37.5 mm (60° IN) Cutter holder, 55 mm ‘Swingarm lock nut wrench Snap ring pliers. Lock nut wrench, 30 64 mm ('38~"01) TOOL NUMBER (07401 - 0910000 (07728 - 0040000 (07733 - 0020001 (07741 - 0010201 0742 - 0010100 07746 - 0010200 (97746 - 0010300 (07746 - 0010400 (07746 - 0010500 07746 - 0010800 (07746 - 0010700 9746 - 0010800 (97746 - 0020100 07746 ~ 0020200 (0746 - 0030100 0746 ~ 0030200 07746 - 0030300 (0746 - 0040100 0746 - 0040300 07746 - 0040400 0746 ~ 0040500 0746 - 0040600 0746 — 0040700 0746 - 0080800 07746 - 0040900 07746 - 0041000 07746 - 0081100 07746 - 0041200 107749 - 0010000 07757 -0010000 07780 - 0010300 ‘0780 - 0910400 07780 - 0912200 (07780 - 0912300 (97780 - 0914000 (07780 ~ 0014100 0781 - 0010101 07908 - 4890003 07914 ~ 3230001 07916 - MB00002 REMARKS. NoTE2 NOTE &: (07933 - 3950000 (U.S.A. only) NOTE 07936 - 371020 or 07936 ~ 3770200 NoTE 2 NOTE 4 07916 - miao0001 REF. SEC, 5 0 10 8.13 18 (Atter’01) 7 1,12,13 8.11 10,11, 12,14 516 14,18 " 10,17 5 8 a 15,18 18.18 15.18 10 15 8,11, 13,14 14,12 " 2 n " n 14,15 15 8, 10,11,12, 13, 14, 15, 16 1-16 GENERAL INFORMATION DESCRIPTION Bearing remover set = Remover handle ~ Bearing remover, 20 mm = Remover weight Remover handle Bearing remover, 17 mm. Cluteh puller Attachment | Attachment, 28 X 30 mm Driver handle attachment Oil seal driver (After 01) Driver attachment il seal driver Assombly collar Assembly shaft Threaded adapter Valve guide reamer, 6.5 mm Clutch holder Inspection adaptor Peak voltage adapter Pinion puller set ~ Shaft puller ~ Pinion puller base Adjustable bearing puller (After ‘01) Remover shaft (After 01) Oil seal driver attachment Clutch center holder Differential inspection tool Ball joint remover, 28 mm Pilot, 32 mm Bal joint installer base Recoil pulley holder Pinion holder ('98- 01) Ball joint remover/installer Universal bead breaker ‘TOOL NUMBER (07936 - 3710001 07936 - 3710100 (07936 - 3710600 0741 -0010201 (07936 - 3710100 (07936 ~ 3710300 (07933 - HA80000 (07945 ~ 3330300 07946 - 1870100 07949 - 3710001 (07965 - KEB0100 (07985 - KE80200 07965 - M1C70100 07965 - vM00100 07965 - Vivi00200 07966 - vim00300 (07984 - 2000007 o7GMB- HATO101 07GMy - MLB0100 ‘O7HGJ - 0020100 o7HMC - MMB0101, (07931 - ME4000 o7HMC - MMB0110 O7JAC- PHaDt01 O7JAC - PH80200, ‘O7AD ~ PHBO101 (07JMB - MN50300 O7KMK -HC50101 o7MAC- $L00200, ‘07MAD ~ PR90Z00 O7HAF ~ SF10720 (07SMB - HMI70100 o7SMB - HM70200 (O7WMIF - HN0O100 GN-AH-958-8B1 | Notes NOTE 4: 07836 - 3710204 or 07936 - 3710200 NOTE 4 07833 - HE30008 NOTE & (0748 - 0010400 NOTE 4, 07947 - KA50100, NOTE & 07931 ~ ME40108 ang (07931 ~ HB3020A (U.S.A. only) NOTE 4: (07931 ~ KF00200 (U.S.A. only) NOTE 4: (07984 - 2000000 (U.S.A. only) NOTE 4 (07GMB-HATOIOA or (07GMB-HA7011A and O7GMB-HATO12A NOTE 4: Poak voltage tester (U.S.A. only) NOTE 3 NOTE 4: (07931 ~ ME4010B and (07931 ~ HB3020A (U.S.A. only) NOTE &: ‘O7HMC ~ MMB011A (U.S.A. only) NOTE &: O7HGB - 0010108 and O7HGB - 0010208 (U.S.A. only) NOTE OTKMK ~ HCSO104 (U.S.A. only) NOTE1 u " " u" 811,13 8,11,13 8 2 2 2 15 16 (98-01), 16 4 n n " ? 8 20 cy 15 ('98-'01), 16 1898-01), 16 15,16 16 18 10,12 8 18 12, n, 2 10 15, 12, 1-17 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS: il fiter cover inside Cylinder bore Cylinder stud bolt threads (at cap nut) Piston pin bore and piston outer surface jon ring surface Connecting rod small end inner surface Centrifugal clutch outer lock nut threads Cam follower surface Cam chain surtaco Rocker arm both ends Clutch friction dise surface Clutch lifter plate outer surface Centrifugal clutch outer sliding surface Clutch drive plate one-way cluten sliding surface Transmission bearing and gear teeth surface ‘Transmission bushing journal surface Main shaft and countershaft journal surface ‘Change cluteh center lock nut threads Shift fork shaft surface Shift drum grooves and surface Roverse stopper shaft journal surface Starter idle gear teeth Recoil pulley bolt threads Starter one-way clutch surface Each ball and needle bearing rolling area Each oll seal lip Crankshaft oil path Engine oll Piston pin outer surface Camshaft lobes Rocker arm shaft (rocker arm sliding surface) Valve stem sliding surface Clutch outer guide sliding surface ‘Starter reduction shaft A surface Starter reduction shaft surface ‘Starter motor pinion end Molybdenum disulfide oll (a mixture of 1/2 ‘engine oil and 1/2 molybdenum disulfide grease) ‘Cam sprocket bolt threads ‘Cam chain tensioner 6 mm flange bolt threads Camshaft bearing fixing plate 8 mm bolt threads Relief valve 14 mm cap threads Goarshift roturn spring pin threads Starter one-way clutch socket bolt threads Neutralreverse switch 6 mm bolt threads Ignition pulse generator 6 mm socket bolt threads Locking agent ‘Change switch grommet Alternator wire grommet Alternator cover gasket 1-18 e@ © ® GENERAL INFORMATION r- ENGINE (cont'd) LOCATION MATERIAL REMARKS Front cover shift reduction gears Unirex N2 (ESO) Apply 3 - 59 of recommended LOCATION (TRX450€S only) Unirex N3 (ESSO} grease. or equivalent | ‘APPLY SPECIFIED GREASE ‘APPLY SPECIFIED GREASE = rp FRAME MATERIAL REMARKS Steering bushing sliding surface Steering shaft oll seal lip Steering shaft dust seal lip, Steering shaft nut threads Steering shaft spline Knuckle dust seal lip and side seal Rear brake cable end. Rear brake cam shaft sliding surface ear brake cam dust seal lip Rear brake panel dust seal lip Roar brake shoe cam contact surface Rear brake shoe anchor pin contact surface Broke pedal shaft sliding surface Brake pedal dust seal lip Brake cover seal lip and side seal Brake lever pivot sliding surface Brake lever parking arm pin sliding surface Rear brake panel O-ring Left axle housing seal lip Loft axie housing bearing Front final drive pinion joint oil seal ip Front drive shaft oll seal lip, Front differential oil cap O-ring Front differential pinion joint O-ring Front final clutch dust seal ip (After ‘01), Front final clutch oil seal lip (After 01) Front final clutch needle bearing (Aftor 07) Front drive pinion spline (After 1) Rear final drive pinion joint oil seal lip Rear final drive ring gear oil seal lip Rear final drive oil cap O-ring Roar final drive pinion joint O-ring Cross joing needle bearing ‘Swingarm bearing and grease holder ‘Swingarm bearing dust seal lip Throttle cable end ‘Multi-purpose grease Apply 2-39 of grease Apply 0.5~ 1.0 g of grease Apply 0.5 ~ 1.0 g of grease Apply 0.5 ~1.0.g of grease Fill up 3.g minimum 1-19 GENERAL INFORMATION [- FRAME (Cont'd) LOCATION MATERIAL REMARKS Front brake drum water seal lip and outside lip inside Rear axle shaft spline (lett side) (center) (right side) Rear whee! hub dust seal lip Front differential pinion joint spline Rear final drive pinion joint spline Yoke joints spline Front propeller shaft joint spline (Differential side) (Engine side) Rear propeller shaft seal lip Front propeller shaft seal lip Front drive shaft spline (Whe 5 side) Multi-purpose grease NUGINO.S Fill up 14 ~ 16 g of grease Molybdenum disulfide grease ‘Apply grease to 20 mm width of aroa of 10 mm away from spline right end 0 that spline is filled with grease. Fill up 5-8 g of grease Fill up 5-8 g of grease Fill up 5~8 g of grease Fill up 5~8 g of grease Rear final drive case #80 Front drive shaft boot inside (inboard) 40-609 (Outboard) 30-509 Rear brake inner cable Cable lubricant ‘Throttle inner cable Roverso assist innor cable Choke inner cable | Front differential ease Hypoid gear oll SAE | 200 cv (6.76 02) 100 ce (3.38 07) | Liquid sealant Front differential case mating surfaco Rear final drive case mating surface (Three-bond 1215 or equivalent) Handleber grip rubber inside Handa bond A or Comedine #540 1-20 © ve © © GENERAL INFORMATION CABLE & HARNESS ROUTING ‘TAXA60S ('98~01) THROTTLE CABLE CHOKE CABLE REAR BRAKE CABLE BRAKE HOSE REVERSE CONTROL CABLE IGNITION SWITCH WARE HANDLEBAR SWITCH WIRE COMBINATION METER CONNECTOR TRXA50ES ('98~01): THROTTLE CABLE REAR BRAKE CABLE CHOKE KNOB BRAKE HOSE IGNITION SWITCH WIRE Hi Z ul 5 COMBINATION METER = “CONNECTOR 1-21 GENERAL INFORMATION ‘TRXASOFM (After 01): ‘CHOKE CABLE REAR BRAKE ‘THROTTLE CABLE CABLE HOSE BRAKE HOS! REVERSE SWITCH 2WD/AWD SWITCH WIRE REVERSE CONTROL IGNITION swiTcH CABLE WIRE THERMO, ‘SENSOR HANDLEBAR SWITCH WIRE METER SPEED SENSOR. SONMEST COMBINATION METER ‘CONNECTOR FINAL CLUTCH SPEED. ‘SENSOR CONNECTOR FINAL CLUTCH 2WD/AWD SWITCH CONTROL UNIT CONNECTOR “TRXASOFE (After ‘01! — RENE REAR BRAKE CABLE THROTTLE CABLE BRAKE HOSE REVERSE SWITCH ‘2WD/4WD SWITCH WIRE REVERSE CONTROL CABLE IGNITION SWITCH > HANDLEBAR SWITCH WIRE WIRE THERMO SENSOR CHOKE CABLE COMBINATION METER CONNECTOR METER SPEED ‘SENSOR CONNECTOR: -2WD/AWD SWITCH FINAL CLUTCH SPEED CONNECTOR ‘SENSOR CONNECTOR Ecu 1-22 e © © © e © © Le GENERAL INFORMATION ‘TRX450S ('98-'01): IGNITION SWITCH CONNECTOR ACCESSORY SOCKET CONNECTOR RIGHT BRAKE BREATHER HOSE COMBINATION METER RIGHT BRAKE CONNECTOR rere COOLING FAN CONTROL UNIT IGNITION CONTROL MODULE LEFT BRAKE HOSE RIGHT BRAKE HOSE RIGHT BRAKE BREATHER HOSE LEFT BRAKE BREATHER HOSE DIFFERENTIAL CASE BREATHER TUBE HEADLIGHT CONNECTOR vowoaye IGNITION SWITCH TRAGGOEE RESET CONNECTOR ACCESSORY SOCKET CONNECTOR RIGHT BRAKE BREATHER HOSE RIGHT BRAKE: We HOSE ‘COMBINATION METER | CONNECTOR IGNITION CONTROL COOLING FAN MODULE CONTROL UNIT RIGHT BRAKE HOSE "LEFT BRAKE HOSE RAKE BREATHER HOSE RIGHT BRAKE BREATHER HOSE Pere SHIFT CONTROL UNIT DIFFERENTIAL CASE BREATHER HOSE HEADLIGHT CONNECTOR 1-23 GENERAL INFORMATION ‘TRXASOFM (After 01): IGNITION SWITCH CONNECTOR lem METER SPEED ACCESSORY SOCKET SENSOR CONNECTOR RIGHT BRAKE conmecron i BREATHER HOSE COMBINATION METER ‘CONNECTOR 2w/aWD ‘SWITCH CONNECTOR i RIGHT BRAKE t HOSE LEFT BRAKE HOUSE RIGHT BRAKE BREATHER HOSE COOLING FAN FINALCLUTCH” — FINAL CLUTCH CONTROLUNIT LEFT BRAKE SPEED SENSOR — CONTROLUNIT DIFFERENTIAL BREATHER HOSE ‘CONNECTOR CASE BREATHER © HEADLIGHT HOSE CONNECTOR TAXASOFE (After 01): ian IGNITION SWITCH CONNECTOR ACCESSORY SOCKET ‘CONNECTOR COMBINATION METER CONNECTOR COOLING FAN CONTROL UNIT RIGHT BRAKE HOSE _2WD/AWD SWITCH ‘CONNECTOR: LEFT BRAKE HOUSE LEFT BRAKE BREATHER LEFT BRAKE HOSE METER SPEED FINALCLUTCH — DIFFERENTIAL = HEADLIGHT. SENSOR SPEED SENSOR CASE BREATHER CONNECTOR BREATHER HOSE CONNECTOR CONNECTOR HOSE 1-24 oe 6 © GENERAL INFORMATION ‘TAX450S AND TRX4SOES: BRAKE BREATHER TUBE BRAKE HOSE TOP VIEW BRAKE HOSE a i Sj BRAKE BREATHER TUBE REAR VIEW 1-25 GENERAL INFORMATION ‘TRX4508 ('98~01 REAR BRAKE CABLE FRONT GEAR CASE BREATHER HOSE REAR GEAR CASE, BREATHER HOSE IGNITION SWITCH CONNECTOR ‘COMBINATION METER CONNECTOR ACCESSORY SockET CONNECTOR HANDLEBAR SWITCH CONNECTOR, ) ‘TRXASOES ('98~'01): es REAR BRAKE CABLE CHOKE KNOB REVERSE SWITCH FRONT GEAR CASE BREATHER HOSE REAR GEAR CASE BREATHER HOSE IGNITION SWITCH. CONNECTOR @ HANDLEBAR SWITCH CONNECTOR COMBINATION ACCESSORY SOCKET fa ia ° S (METER CONNECTOR CONNECTOR 1-26 © © © © e © GENERAL INFORMATION TRXASOFM [After 01): 2WD/AWD SWITCH WIRE REAR BRAKE CABLE REVERSE CONTROL FRONT GEAR CASE BREATHER HOSE. REAR GEAR CASE BREATHER HOSE, METER SPEED SENSOR ‘CONNECTOR FINAL CLUTCH CONTROL UNIT IGNITION SwiTcH CONNECTOR ACCESSORY SOCKET CONNECTOR ‘COMBINATION METER 2W/D/AWD SWITCH CONNECTOR ‘CONNECTOR, ‘TAXASOFE (After ‘01): 2WD/aWD SWITCH WIRE REAR BRAKE CABLE CHOKE CABLE. 3 a FRONT GEAR CASE BREATHER HOSE REVERSE CONTROL REAR GEAR CASE 2 ae A CABLE BREATHER HOSE Z ECU. ASSIST HEADLIGHT CONNECTOR HANDLEBAR SWITCH CONNECTOR 2WD/AWD SWITCH ACCESSORY SOCKET CONNECTOR CONNECTOR IGNITION SWITCH CONNECTOR COMBINATION METER CONNECTOR 1-27 GENERAL INFORMATION ‘TAX450S ('98~011: CHOKE CABLE REAR BRAKE CABLE ‘THROTTLE CABLE REVERSE CONTROL CABLE COOLING FAN MOTOR BREATHER HOSE FRONT BRAKE BREATHER HOSE REAR BRAKE BREATHER HOSE ‘TRXAB0ES ('98~'01}: CHOKE KNOB REAR BRAKE CABLE THROTTLE CABLE REVERSE CONTROL CABLE ~ COOLING FAN MOTOR BREATHER HOSE FRONT BRAKE BREATHER HOSE REAR BRAKE BREATHER HOSE 1-28 © GENERAL INFORMATION ‘TRX450FM (After ‘01): CHOKE CABLE REAR BRAKE CABLE THROTTLE CABLE REVERSE CONTROL CABLE COOLING FAN MOTOR REAR BRAKE FRONT BRAKE BREATHER HOSE BREATHER HOSE BREATHER HOSE TRXA50FE (After ‘O11: {Hncrroe cance REAR BRAKE CABLE REVERSE CONTROL 2wovawo CABLE ‘SWITCH WIRE COOLING FAN MOTOR REAR BRAKE FRONT BRAKE BREATHER HOSE BREATHER HOSE BREATHER HOSE 1-29 GENERAL INFORMATION ‘TRX450S/FM AND TRX450ES/FE: FUEL TUBE: CHOKE CABLE CRANKCASE BREATHER TUBE ‘SPEED SENSOR WIRE THROTTLE CABLE CARBURETOR AIR VENT TUBE CHANGE SWITCH WIRE ‘STATORIGNITION PULSE GENERATOR WIRE COOLING FAN MOTOR CONNECTORS COOLING FAN MOTOR BREATHER TUBE IGNITION COIL ‘SPARK PLUG WIRE CHOKE CABLE THROTTLE CABLE 1-30 (MAIN WIRE HARNESS: e GENERAL INFORMATION ‘TRXA50S/FM: Ol COOLER LEFT OIL COOLER HOSE RIGHT OIL COOLER HOSE TRXAS0ES/FE LEFT Olt CQOLER HOSE 1, COOLER ANGLE SENSOR CONNECTOR SHIFT CONTROL MOTOR CONNECTOR 1-31 GENERAL INFORMATION TAXA50S (98-01): CARBURETOR HEATER REGULATORIRECTIFIER CONNECTOR GROUND WIRES REAR GEAR CASE, BREATHER HOSE STARTER MOTOR CABLE REAR BRAKE CABLE (HAND BRAKE) REVERSE CONTROL REAR BRAKE CABLE CABLE (FOOT BRAKE) ‘SPEED SENSOR ‘CONNECTOR THERMO STATOR/IGNITION PULSE NEUTRAUREVERSE SENSOR GENERATOR CONNECTOR SWITCH CONNECTOR CONNECTOR THERMO SENSOR WIRE SPEED SENSOR ‘CARBURETOR HEATER CONNECTOR CONNECTOR THERMO SENSOR, STATORAGNITION PULSE NEUTRAL/REVERSE SWITCH CONNECTOR THERMO GENERATOR CONNECTOR ace CONNECTOR 1-32 oe © © GENERAL INFORMATION ‘TRX450FM (After ‘01): CARBURETOR HEATER < REGULATOR/RECTIFIER CONNECTOR GROUND. WIRES @ sim CASE BREATHER HOSE. REAR BRAKE CABLE ¢ (HAND BRAKE) STARTER MOTOR CABLE REAR BRAKE CABLE ™ (FOOT BRAKE) 3 é REVERSE CONTROL CABLE STATORIGNITION’ —_NEUTRAL/REVERSE PULSE GENERATOR SWITCH Hen ( CONNECTOR CONNECTOR aoe CONNECTOR THERMO SENSOR WIRE CARBURETOR HEATER CONNECTOR ‘THERMO SENSOR. STATORIIGNITION PULSE GENERATOR CONNECTOR SWITCH CONNECTOR THERMO 1-33 GENERAL INFORMATION ‘TRXASOES ('98-'01): e REGULATORIRECTIFIER CARBURETOR HEATER CONNECTOR, GROUND WIRES "STARTER MOTOR REAR GEAR CASE é BREATHER HOSE R CABLE REAR BRAKE CABLE. (HAND BRAKE) REVERSE CONTROL CABLE REAR BRAKE CABLE (FOOT BRAKE) CONNECTOR CONNECTOR ‘STATOR/IGNITION PULSE GENERATORCONNECTOR ean rosmow src THenMoSeuscnwine QD) CONNECTOR THERMO ‘SPEED SENSOR SENSOR CONNECTOR CONNECTOR STATOR/IGNITION PULSE GENERATOR CONNECTOR GEAR POSITION SWITCH CONNECTOR 1-34 GENERAL INFORMATION rene a GROUND WIRES: scapes REVERSE CONTROL CABLE THERMO SENSOR sess = us Bas ceaneBeren, _srAlomainre oa pepe, Nessun Mee ae nee scare D wrcenorsnits aoa ‘STATOR/JIGNITION PULSE ~ ? ‘ semper nts neni ee 1-35 GENERAL INFORMATION ‘TRXA50 ('98~'01): HARNESS CLAMPS STARTER RELAY CONNECTOR MAIN FUSE, BATTERY NEGATIVE (.) CABLE ~~ STARTER RELAY FUSE BOX 4 BATTERY POSITIVE (+) CABLE ‘TRX450ES ('98~'01): ‘STARTER RELAY MAIN FUSE MAIN FUSE HARNESS CLAMPS (CONTROL MOTOR} BATTERY NEGATIVE |-) CABLE. FUSE BOX BATTERY POSITIVE (+) CABLE 1-36 GENERAL INFORMATION TRXA5OFM (After 01): BATTERY NEGATIVE (-) CABLE 2 5 2 5 STARTER RELAY SWITCH BATTERY POSITIVE (+) CABLE ‘TRXASOFE (After 01): STARTER MOTOR CABLE g 3 2 q 3 BATTERY Ni BATTERY POSITIVE (+) CABLE 1-37 GENERAL INFORMATION EMISSION CONTROL SYSTEMS ‘The California Air Resources Board (CARB) requires manufacturers to certify that their ATVs comply with applicable exhaust ‘emissions standards during their useful life, when operated and maintained according to the instructions provided. SOURCE OF EMISSIONS ‘The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, Under certain conditions, they react to from photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but itis toxic. Honda Motor Co,, Ltd. utilized 1 carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. Tho exhaust emission control system is separate from the crankcase emission control system. (CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor. AIR CLEANER DUST COVER DRAIN PLUG. BREATHER

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