This Honda TRX450 Foreman 1998-2004 Clymer Repair Manual provides service, repair and maintenance information for 1998 Honda TRX450S FourTrax Foreman S, 1998 Honda TRX450ES FourTrax Foreman ES, 1999 Honda TRX450S FourTrax Foreman S, 1999 Honda TRX450ES FourTrax Foreman ES, 2000 Honda TRX450S FourTrax Foreman, 2000 Honda TRX450ES FourTrax Foreman ES, 2001 Honda TRX450S FourTrax Foreman S, 2001 Honda TRX450ES FourTrax Foreman ES, 2002 Honda TRX450FM FourTrax Foreman S, 2002 Honda TRX450FE FourTrax Foreman ES, 2003 Honda TRX450FM FourTrax Foreman S, 2003 Honda TRX450FE FourTrax Foreman ES, 2004 Honda TRX450FM FourTrax Foreman S and 2004 Honda TRX450FE FourTrax Foreman ES ATVs.

This manual contains the following topics:

QUICK REFERENCE DATA

CHAPTER ONEGENERAL INFORMATION
Manual organizationWarnings, cautions and notesSafetySerial numbersFastenersShop suppliesBasic toolsPrecision measuring toolsElectrical systemFundamentalsBasic service methodsStorage

CHAPTER TWOTROUBLESHOOTING
Operating requirementsStarting the engineStarting difficultyPoor idle speed performancePoor medium and high speed performanceElectric starting systemCharging systemIgnition systemLighting systemCooling systemCombination meterFuel systemEngine overheatingEngineEngine noisesCylinder leakdown testClutchTransmissionDrive selector clutch Drivetrain HandlingFrame noiseBrakes

CHAPTER THREELUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride check listMaintenance scheduleTires and wheelsBatteryPeriodic lubricationUnscheduled lubricationPeriodic maintenanceEngine tune-up

CHAPTER FOURENGINE TOP END
Exhaust systemCylinder head coverRocker arms, pushrods and cylinder headValves and valve componentsCylinderPiston and piston ringsCamshaft

CHAPTER FIVEENGINE LOWER END
Servicing engine in frameEngineRecoil starterDriven pulleyAlternator coverRear crankcase coverFlywheel and starter clutchGearshift linkageReverse shaft assemblyLubrication systemOil pumpRelief valveOil strainer screenCrankcase and crankshaftEngine break-in

CHAPTER SIXCLUTCH, PRIMARY DRIVE GEAR AND ESP GEARS
ESP reduction gearsClutch coverClutch lever assemblyClutch assembliesCentrifugal clutch and primary drive gearChange clutch

CHAPTER SEVENTRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission overhaulReverse idle gear assemblyTransmission inspectionInternal shift mechanismReverse selector cable replacement

CHAPTER EIGHTFUEL SYSTEM
Carburetor serviceCarburetor adjustmentsCarburetor heaterThrottle housing and cableFuel tankFuel valveAir boxChoke cable replacement

CHAPTER NINEELECTRICAL SYSTEM
Resistance and peak Voltage testingElectrical component replacementElectrical connectorsCharging systemAlternatorIgnition systemStarterStarter relay switchDiodeElectric shift systemDrive selector clutch systemLighting systemCombination meterSwitchesOil thermosensorCooling fan control unitMeter speed sensor unitFusesWiring diagrams

CHAPTER TENFRONT SUSPENSION AND STEERING
Front wheelTires and wheelsFront hubShock absorbersTie rodsSteering knuckleControl armsHandlebarSteering shaft

CHAPTER ELEVENFRONT DRIVE MECHANISM
Front drive axlesDriveshaftFront differential and selector clutch

CHAPTER TWELVEREAR AXLE, SUSPENSION AND FINAL DRIVE
Rear wheelsTire changing and repairsShock absorbersRear axleFinal drive unitSwing arm

CHAPTER THIRTEENBRAKES
Brake serviceFront brake drumFront brake shoe replacementBrake panelWheel cylindersFront master cylinderBrake fluid drainingBrake bleedingRear drum brakeRear brake shoe replacementBrake panelFront brake hose replacementRear brake pedal and cableRear brake lever/parking Brake cable

CHAPTER FOURTEENOIL COOLER AND COOLING FAN
Oil coolerCooling fan

CHAPTER FIFTEENBODY
Retaining clipsSeatRight lower side coverSide covers and fuel tank coverCenter mud guardsFront carrier and front bumperFront fenderRear carrierRear fenderHandlebar cover

INDEX   

WIRING DIAGRAMS