Description
This Clymer Honda TRX250X 1987-1988 1991-1992 TRX300EX 1993-2006 ATV Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1987-1988, 1991-1992 Honda TRX250X and 1993-2000 Honda TRX300EX Fourtrax and 2001-2006 TRX300EX Sportrax ATVs.
TRX250X (1987-1988, 1991-1992)
TRX300EX Fourtrax (1993-2000)
TRX300EX Sportrax (2001-2006)
1987 1988 1989
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
2000 2001 2002 2003 2004 2005 2006
Table of Contents
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization , Notes, cautions and warnings , Safety first , Service hints , Washing the vehicle , Serial numbers , Torque specifications , Fasteners , Lubricants , Sealants, adhesives and cleaners , Expendable supplies , Basic hand tools , Precision measuring tools , Test equipment , Special tools , Mechanic’s tips , Ball bearing replacement , Oil seals , Riding safety
CHAPTER TWO, TROUBLESHOOTING
Operating requirements , Starting the engine , Starting difficulties , Engine is difficult to start , Poor idle speed performance , Poor medium- and high-speed performance , Engine starting system (TRX300EX) , Lighting coil (TRX250X) , Charging system (1993-on TRX300EX) , Ignition system , Carburetor troubleshooting , Engine overheating , Engine , Engine noises , Engine leak down test , Clutch , Transmission , Drive train noise , Handling , Frame noise
CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist , Service intervals , Tires and wheels , Battery (TRX300EX) , Lubricants , Periodic lubrication , Periodic maintenance , Non-scheduled maintenance , Engine tune-up , Storage
CHAPTER FOUR, ENGINE TOP END
Engine principles , Cleanliness , Cylinder head cover , Camshaft and cam chain tensioner , Cylinder head , Valves and valve components , Cylinder , Piston and piston rings , Oil pipes
CHAPTER FIVE, ENGINE LOWER END
Servicing engine in frame , Engine , Drive sprocket , Left crankcase cover and stator coil (TRX250X) , Starter reduction gears (TRX300EX) , Left crankcase cover and stator coil (TRX300EX) , Flywheel (TRX250X) , Flywheel and starter clutch (TRX300EX) , Gearshift linkage , Oil pip and oil pump , Primary gears and oil pump drive gear , Cam chain and guides , Breather plate , Crankcase and crankshaft , Kickstarter (TRX250X) , Engine break-in
CHAPTER SIX, CLUTCH AND REVERSE SHIFTER
Clutch cover , Clutch , Reverse shifter , Clutch cable , Reverse cable replacement
CHAPTER SEVEN, TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission/reverse system identification , Transmission troubleshooting , Transmission/reverse overhaul , Reverse idle gear assembly , Transmission inspection , Internal shift mechanism
CHAPTER EIGHT, FUEL AND EXHAUST SYSTEM
Carburetor , Carburetor adjustments , Throttle housing and cable , Fuel tank , Fuel valve , Air box , Exhaust system
CHAPTER NINE, ELECTRICAL SYSTEM
Lighting system (TRX250X) , Charging system (1993-on TRX300EX) , Alternator (TRX300EX) , Alternator and AC lighting system (TRX250X) / Ignition system (TRX250X) , Ignition system (TRX300EX) / Ignition coil , Electric starting system (TRX300EX) , Starter relay switch (TRX300EX) / Reverse inhibiter unit (TRX300EX) , Lighting system , Switches , Fuse (TRX300EX) , Wiring diagrams
CHAPTER TEN, FRONT SUSPENSION AND STEERING
Front wheel , Front hub , Shock absorbers , Tie rods , Steering knuckle , Control arms , Handlebar , Steering shaft , Tires and wheels
CHAPTER ELEVEN, REAR SUSPENSION
Rear wheels , Rear hub , Rear axle , Rear axle bearing holder , Drive chain , Driven sprocket , Tire changing and tire repairs , Shock absorber , Rear swing arm
CHAPTER TWELVE, BRAKES
Brake fluid selection , Disc brake , Front caliper , Front master cylinder , Rear caliper , Rear master cylinder , Brake hose replacement , Brake disc , Brake bleeding , Rear brake pedal
CHAPTER THIRTEEN, BODY
Seat/rear fender assembly , Front fender , Handlebar cover
INDEX
WIRING DIAGRAMS
