Description
This Official 2004-2014 Honda TRX450ER/R Sportrax ATV Repair Manual is a reproduction of the original service manual, printed by Honda. The photo shown may differ from the cover that you receive but it is an authentic Honda manual.
It provides detailed service information, step-by-step repair instruction and maintenance specifications for the following Honda ATV models:
2014 TRX450ER Sportrax (Electric Start)
2014 Honda TRX450R Sportrax (Kick Start)
2013 TRX450ER Sportrax (Electric Start)
2013 Honda TRX450R Sportrax (Kick Start)
2012 Honda TRX450R Sportrax (Kick Start)
2012 Honda TRX450ER Sportrax (Electric Start)
2011 Honda TRX450R Sportrax (Kick Start)
2011 Honda TRX450ER Sportrax (Electric Start)
2010 Honda TRX450R Sportrax (Kick Start)
2010 Honda TRX450ER Sportrax (Electric Start)
2009 Honda TRX450R Sportrax (Kick Start)
2009 Honda TRX450ER Sportrax (Electric Start)
2008 Honda TRX450R Sportrax (Kick Start)
2008 Honda TRX450ER Sportrax (Electric Start)
2007 Honda TRX450R Sportrax (Kick Start)
2007 Honda TRX450ER Sportrax (Electric Start)
2006 Honda TRX450R Sportrax (Kick Start)
2006 Honda TRX450ER Sportrax (Electric Start)
2005 Honda TRX450R Sportrax
2004 Honda TRX450R Sportrax
Table of Contents
General Information
Technical Features
Frame/body Panels/exhaust
System
Maintenance
Lubrication System (‘04 – ‘05)
Lubrication System (after ‘05)
Fuel System (‘04 – ‘05)
Fuel System (after ‘05)
Cooling System
Engine Removal/installation
Cylinder Head/valves
Cylinder/piston
Clutch/kickstarter/gearshift Linkage (‘04 – ‘05)
Clutch/starter Clutch/kickstarter/ Gearshift Linkage (after ‘05)
Crankcase/transmission/crankshaft/ Balancer (‘04 – ‘05)
Crankcase/transmission/crankshaft/ Balancer (after ‘05)
Front Wheel/suspension/steering
Rear Wheel/suspension
Hydraulic Brake Electrical (‘04 – ‘05)
Battery/charging System (trx450er)
Ignition System (after ‘05)
Electric Starter (trx450er)
Lights/switches (after ‘05)
Wiring Diagrams
Troubleshooting
Index
Index of Topics
Air Cleaner
Air Cleaner Housing
’04 – ’05
After ’05
Alternator
’04 – ’05
After ’05
Balancer Gear/balancer
’04 – ’05
After ’05
Battery (trx450er)
Battery/charging System
Specifications (trx450er)
Brake Fluid
Brake Fluid Replacement/air Bleeding Brake Light Switch
Electrical(’04-’05)
Lights/switches (after ’05)
Maintenance
Brake Pad/disc
Brake Pads Wear
Brake Pedal
Brake System
Brake/taillight
’04 – ’05
After ’05
Bulb Replacement (after ’05)
Cable & Harness Routing
Camshaft Holder Installation After ’07 Trx450er
Trx450r And ’06 – ’07 Trx450er
Camshaft Holder Removal After ’07 Trx450er
Trx450r And ’06 – ’07 Trx450er
Camshaft/decompressor Assembly After ’07 Trx450er
Trx450r And ’06 – ’07 Trx450er
Camshaft/decompressor Disassembly After’07 Trx450er
Trx450r And ’06 – ’07 Trx450er
Carburetor Assembly
’04 – ’05
After ’05
Carburetor Disassembly
’04 – ’05
After ’05
Carburetor Heater
’04 – ’05
Carburetor Installation
’04 – ’05
After ’05
Carburetor Removal
’04 – ’05
After ’05
Charging System Inspection (trx450er)-closed Throttle Position Detection System (after’05)
Clutch
’04 – ’05
After ’05
Clutch Diode (trx450er)
Clutch Switch
Clutch System
Clutch/kickstarter/gearshift Linkage Specifications ’04- ’05
Clutch/starter Clutch/kickstarter/ Gearshift Linkage Specifications After ’05
Component Location
Battery/charging System (after ’05)
Electric Starter (trx450er)
Electrical (’04 – ’05)
Ignition System (after’05)
Lights/switches (after ’05)
Coolant Replacement
Coolant Temperature Indicator
’04-’05
After ’05
Cooling Fan Motor
’04-’05
After ’05
Cooling System
Cooling System Specifications
Cooling System Testing
Crankcase Assembly
’04-’05
After ’05
Crankcase Bearing
’04-’05
After ’05
Crankcase Separation
’04-’05
After ’05
Crankcase/transmission/crankshaft Specifications
’04-’05
After ’05
Crankshaft
’04-’05
After ’05
Cylinder Compression
Cylinder Head Assembly
Cylinder Head Cover Installation
Cylinder Head Cover Removal
Cylinder Head Disassembly
Cylinder Head Installation
Cylinder Head Removal
Cylinder Heada/alve/camshaft Specifications
’04-’05
After ’05
Cylinder/piston Installation
Cylinder/piston Removal
Cylinder/piston Specifications
’04-’05
After ’05
Drive Chain
Drive Chain Slider
Electric Starter Specifications (trx450er)
Electrical Specifications (’04 – ’05)
Emission Control Systems
Engine & Frame Torque Values
Engine Coolant Temperature (ect) Sensor
’04-’05“
After ’05
Engine Guard
’04-’05
After ’05
Engine Idle Speed
Engine Installation
Engine Oil/filter
Engine Removal
Exhaust System
Front Brake Caliper
Front Fender
’04- ’05
After ’05
Front Master Cylinder
Front Shock Absorber
Front Wheel
Front Wheel Hub
Front Wheel/suspension/steering Specifications
Fuel Line
Fuel System Specifications
’04- ’05
After ’05
Fuel Tank (’04-’07)
Fuel Tank (after’07)
Gearshift Linkage
’04- ’05
After ’05
General Specifications
’04- ’05
’06 – ’07
After ’07
Generating System
’04-’05
After ’05
Handlebar
Handlebar Switch
’04- ’05
After ’05
Headlight
’04-’05
Heat Guard Plate (’04 – ’05)
Heat Guard Plate (after ’05)
High Altitude Adjustment
Hot Start System (trx450r Only)
Hydraulic Brake Specifications
Icm (ignition Control Module)
’04- ’05
After ’05
Ignition Coil
’04- ’05
After ’05
Ignition Switch
’04- ’05
After ’05
Ignition System Inspection
’04- ’05
After ’05
Ignition System Specifications (after ’05)
Ignition Timing
’04- ’05
After ’05
Kickstarter
’04- ’05
After ’05
Lights/switch Specifications (after ’05)
Lubrication & Seal Points
Lubrication System Diagram
’04- ’05
After ’05
Lubrication System Specifications
Maintenance Schedule
’04 – ’05
’06-’07
After ’07
Model Identification
’04-’07
After ’07
Mud Guard/footpeg
Neutral Switches (trx450er)
Nuts, Bolts, Fasteners
Oil Cooler (’04-’05)
Oil Pump
’04 – ’05
After ’05
Oil Strainer (after’05)
Oil Strainer/pressure Relief Valve
(’04-’05)
Pilot Screw Adjustment
’04 – ’05
After ’05
Piston Jet (after’05)
Pressure Relief Valve (after ’05)
Radiator Coolant
Radiator/cooling Fan
Rear Axle/bearing Holder
Rear Brake Caliper
Rear Fender
’04 – ’05
After ’05
Rear Master Cylinder
Rear Shock Absorber
Rear Wheel
Rear Wheel/suspension Specifications
Regulator/rectifier
’04 – ’05
After ’05
Right Crankcase Cover Installation
’04 – ’05
After ’05
Right Crankcase Cover Removal
’04 – ’05
After ’05
Seat
Service Information
Battery/charging System (after’05)
Clutch/kickstarter/gearshift Linkage ’04 – ’05
Clutch/starter Clutch/kick Starter /gearshift Linkage After ’05
Cooling System
Crankcase/transmission/crankshaft/balancer
’04 – ’05
After ’05
Cylinder Heada/alve
Cylinder/piston
Electric Starter (trx450er)
Electrical (’04 – ’05)
Engine Removal/installation
Frame/body Panels/exhaust System
Front Wheel/suspension/steering
Fuel System
’04 – ’05
After ’05
Hydraulic Brake
Ignition System (after ’05)
Lights/switches (after ’05)
Lubrication System
’04 – ’05
After ’05
Maintenance
Rear Wheel/suspension
Service Rules
Shock Linkage
Skid Plate
Skid Plate, Engine Guard
Spark Arrester
Spark Plug
Standard Torque Values
Starter Clutch (trx450er)
Starter Motor (trx450er)
Starter Relay Switch (trx450er)
Steering Head Bearing
Steering Shaft
Steering Shaft Holder Bearing
Steering System
Suspension
Suspension Arm
Swingarm
System Components
Clutch/kickstarter/gearshift Linkage (’04-’05)
Clutch/starter Clutch/kick Starter /gearshift Linkage (after ’05)
Crankcase/transmission/crankshaft/ Balancer
’04-’05
After ’05
Cylinder Head/valve
Cylinder/piston
Engine Removal/installation
Front Wheel/suspension/steering
Fuel System
’04-’05
After ’05
Hydraulic Brake
Rear Wheel/suspension
System Diagram
Battery/charging System (after’05)
Electric Starter (trx450er)
Ignition System (after ’05)
Thermostat
Throttle Housing
Throttle Operation
Throttle Position Sensor
’04- ’05
After ’05
Tie-rod
’04-’07
After ’07
Tie-rod And Joint Boots (after ’07)
Tires
Top Cover
’04 – ’05
After ’05
Transmission
’04 – ’05
After ’05
Transmission Oil
Troubleshooting
Battery/charging System (after ’05)
Clutch/kickstarter/gearshift Linkage (’04- ’05)
Clutch/starter Clutch/kick Starter /gearshift Linkage (after ’05)
Cooling System
Crankcase/transmission/crankshaft/balancer
’04-’05
After ’05
Cylinder Head/valve
Cylinder/piston
Electric Starter (trx450er)
Electrical (’04-’05)
Engine Does Not Start Or Is Hard To Start
Engine Lacks Power
Frame/body Panels/exhaust System
Front Wheel/suspension/steering
Fuel System
’04- ’05
After ’05
Hydraulic Brake
Ignition System (after’05)
Lubrication System (’04 – ’05)
Lubrication System (after ’05)
Poor Handling
Poor Performance At High Speed
Poor Performance At Low And
Idle Speed
Rear Wheel/suspension
Trx450er
Twin Sump Lubrication System
Unicam System After ’07 Trx450er
Trx450r And ’06-’07
Valve Clearance/decompressor System After’07 Trx450er
Trx450r And ’06 – ’07 Trx450er
Valve Guide Replacement
Valve Seat Inspection/refacing
Water Pump
Wheels/tires
Wiring Diagram
’04-’05
After’05 (trx450er)
After ’05 (trx450r)
SKU: CPP-174
