1997-2004 Honda TRX250 TE TM Fourtrax Recon Service Repair Manual Instant Download

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HOW TO USE THIS MANUAL This service manual
describes the service procedures for the TRX250
TM/TE (Recon).
CONTENTS ONAENERAL NFORM T F ME BOD ANELS EXHAUST
S S
Follow the Maintenance Schedule (Section 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.
ANTENAN
SLUBR AT TON FUEL S STEM
EM
Performing the first scheduled maintenance is
very important. It compensates for the initial
wear that occurs during the break-in period.
EN NE REMOVAL NSTAL T ON C L NDER HEAD C L NDER P
STON
Sections 1 and 3 apply to the whole vehicle.
Section 2 illustrates procedures for
removal/installation of components that may be
required to perform service described in the
following sections. Sections 4 through 2t
describe parts of the vehicle, grouped according
to location.
CLUT H
GEARSHIFT LINKAGE
Find the section you want on this page, then turn
to the table of contents on the first page of the
section.
AL RNATOR STARTER LUTCH C N SHA T NSM SS
ON FRO WH E SUSPENS ON S EER N REAR WHEEL SUSPENS
ON BRA E S STE
Most sections start with an assembly or system
illustration, service information and
troubleshooting for the section. The subsequent
pages give detailed procedure.
If you do not know the source of the trouble, go
to section 22, Troubleshooting.
R AR R V N MECHAN SM BATTER CHAR N S STEM NIT ON
S STEM ELEC C STARTER LI HTS SW TCHES
C J
ELEC C SH RO M A 200 el WIRIN D AGRAMS TROUBLESHO
T N
DEX
"
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SYMBOLS The syncbols used throughout this manual
show specific service procedures. If
supplementary information is required pertains
log to these symhols, it would be explained
specifically in the text without the use of the
symbols. Replace the part(s) with new one(s)
before assembly. Use recommended engi we oil,
unless otherwise specified. Use molybdenum oil
solution (mixture of the engine oil and
molybdenum grease in a raiio of 1 1). U se nnulti
purpose grease \Lithium based mr Iti-purpose
grease NLGI - 2 or equiv a lent) Use molybdenrim
disulfide grease (containing more than 3â
molybdenum disulficle, NLGI ? 2 or
equivalent). Example Molykote BR 2 plus mans
factured by Dow Corning, U.S.A. Multi-purpose M 2
manufactured by Mitsubishi Oil, Japan Use
molybden um disulficle paste Tcontaining more
than 40.â molybden um disul fide, NLGI 2
or ecjriivalent). Example Molykote BR 2 ptus,
manufactured by Dow Corning, U.S.A. Honda Moly 60
(U.S.A. only) Rocol ASP manufactureJ by Rocol
Limited, U.K. Rocol Paste manufactrJrel by
Sumico Lubricant, Japan Use silicone
grease. Apply a locking agent. Use a middle
strength locking agent inless otherwise
specified. Apply sealant. Use DOT 3 or DOT 4
brake fluirl. Use the recommended brake fluid
unless otherwise specified. Use Fork or
Suspension Fluid.
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1. GENERAL INFORMATION
GENERAL SAFETY SERVICE RULES MODEL
IDENTIFICATION SPECIFICATIONS TORQUE VALUES
TOOLS GENERAL SAFETY CARBON MONOXIDE If the
engine must be running to do some work, make sure
the area is well ventilated. Never run the engine
in an enclosed area.
LUBRICATION SEAL POINTS CABLE HARNESS
ROUTING EMISSION CONTROL SYSTEMS EMISSION CONTROL
INFORMATION LABEL fCALIFORNIA TYPE ONLY)
1-18 1-21 1-32
-2 1-3 1-4 1-13 1-16
1-33
USED ENGINE OIL
Lfsvd engine oil may csuso skin cancer it
repoetedlz left in aontaot w"rth tha skin for
prolonged periods. AIthoczgh this is unlikely
unless yozzhandle used oil on a daily 6asia, it
is sfi// advisable to thorozzghIy wash your
fronds vvrrh soep OUT OF HEACH Oy CHILDREN.
7he exhaust contains poisonous cszbon monoxicfe
gas tlaat men cause loss of aonsciooaness end may
load to d'eafA. Run the engine in an open area
or with an exhaust evacuation system in an
enclosed area. GASOLJNE Work in a well ventilated
area. Keep cigarettes, flames or sparks away from
the work area or where gasoline is stored.
BRAKE FLUID cAuTio
Spilling Ruid on printed, plastic or ruh6er paets
will damege them. Place a cleen shop tovval over
these parts whenever the system is serviced. KEEP
OUT OF REACH OF
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, designed to minimize the ha2ard caused by
airborne asbestos fibers.
cawin conzffrions. KEEP OUT OF REACH OF
CHILDREN. HOT COMPONENTS
Engine and exhaust system psrts fscome very hot
end remein hot for some time enter the engine is
run. Wear insiifoteñ gfoves or wit unfif the
enpins and exhaust syctvm tiers coolad before
handfinp these parts.
respiratory disease end cancer.
1-1
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GENERAL INFORMATION BATTERY HYDROGEN GAS
ELECTROLYTE

• The battery gives off oxplocive green k ap
  sparks, ffsmos and cigarettes swap. Provide
  ade9usts voriiifation when charging.
• The battery contains autturic acid (oleotrolytol.
  Contact
• with min or eyes my celtic severe turns. Wear
  protec- tive clothing nd o face shield.
• I electrolyte gets on your skin, Such with wtec.
• It sh trmyts gets in your eyes. flush with water
  for at
• least W minutes end call a physician immadiatatz.
• Electrolyte in poisonous.
• It swallowed, drink large quantifies of water or
  milk end follow with mif of magnesia or
  vegetable oil and cell a physician. KEEP Ot/T OF
  BEACH OF CfffLDfl t.
• SERVICE RULES
• Use genuine HONDA or HONDA-recommended parts and
  lubricants or their equivalents. Parts that do
  not meet HONDA's design specifications may cause
  damage to the vehicle.
• Use the special tools designed for this product
  to avoid damage and incorrect assembly.
• Use only metric tools when servicing the vehicle.
  Metric bolts, nuts and screws are not
  interchangeable with English
• fasteners.
• Install new gaskets, O-rings, cotter pins, and
  lock plates when reassembling.
• When tightening bolts or nuts, begin with the
  larger diameter or inner bolt first. Then tighten
  to the specified torque diagonally in incremental
  steps unless a particular sequence is specified.
• Clean parts in cleaning solvent upon disassembly.
  Lubricate any sliding surfaces before reassembly.
• After reassembly, check all parts for proper
  installation and operation.

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GENERAL INFORMATION
MODEL IDENTIFICATION 97 SHOWN AFTER 97 SIMILAR
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER
The frame serial number is stamped on the front o
The engine serial number is stamped on the rear
half of the lower crankcase, viewed from the
right side.
the frame.
The carburetor identification numbers are stamped
on the right side of the carburetor body as shown.
specify the designated color code.
1-3
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GENERAL INFORMATION SPECIFICATIONS GENERAL
ITEM
SPECIFICATIONS
DIME NSIONS Overall length 1,794 mm (70.6 in)
Overall width 1,034 mm (40.7 in T
Overall height 1,054 mm (41.5 in)
Wheelbase 1,131 mm (44.5 in)
From tread 783 mm 130.8 in T
Rear tread 780 mm (30.7 in)
Seat height 777 mm \30.6 in)
Footpeg height 97 2001 298 mm T11.7 in)
After 2001 97 2001
TM 298 mm (11.7 in) /TE306 mm f12.0 in) 152 mm
\6.0 in) 180 kg f397 lbs) TM 184 kg (406
lbs)/TE 188 kg (414 Ibs) 188 kg (414 Ibsl TM
191 kg T421 lbs)/TE 195 kg (430 lbs) 175 kg \386
lbs) Double cradle Double wish bone 130 mm (5.1
in) Double tube Swingarm 125 mm I4.9 in) Double
tube
Ground clearance Dry weight
After 2001
CLVrb weight '97 2001
After 2001
MaximrJm weight capacity Frame type Front
suspension Front wheel trAveI Front damper Rear
suspension Rear wheel travel Rear damper Front
tire size Rear tire size Front rim size Rear rim
s ize
FRAME
AT22 AT22
7-116 10 9 A
11 5.5 AT 9 8.0 AT TRACKER HP
Tire brand (Goodyear I FR./RR
Front brake Rear brake Toe Caster angle Ca mber
angle Trail length Frel tank capacity Fuel tank
reserve capacity Bore and stroke Displacement
Compression ratio Valve train Intake ma\ve opens
Intake valve closes Exhaust valve opens Exhaust
valve closes Luhrication systen Oil pump type
Cooling system Air filtration Crar kshah type
Hydraulic Clrum brake
Mechanical drum brake Toe-in 8 mm t5/16 in T
0.1" 42 mln (1-5/8 in) 9.1 L (2.40 US gal , 2.00
Imp gal) 2.4 L t0.63 US gal , 0.53 Imp
gal 68.5 62.2 mm 12.70 2.45 in)
ENGINE
229 cm" f1 4.0 cu in)
9.0 1 Overhead valve 8" BTDC 37" ABDC 38
BBDC 7 ATDC Forced pressure and wet sump
Trochoid Air cooled Oiled double irethane Unit
type, two main journals 34.6 kg /76.3 lbs)
Engine clry weight 97 2001 AMer 2001 TM 35.9
kg (79.1 Ibs) /TE 37.4 kg T82.5 lbs)
Cylinder arrangement Single cylinder,
longitudinally installed
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GENERAL INFORMATION
GENERAL (Cont'd) EM
SPECIFICATIONS
CARBURETOR
Carburetor type Th rott ie bore CIutch
system CIutch operation system Transmission Primar
y redr ction Final reduction Gear ratio 97 2001
Piston valve 20 mm (0 8 in) Centrifugal
multi-plate, wet Automatic Co stant mesh, 5
speed with reverse 3.086 (7 1,'23t 3.692 \48,13\
DRIVE TRAIN
1st 2nd 3rd 4th Sth Reverse
3.545139 111 2.267(34,'15) 1.631 31/19 1.273
T28,22 042 t25 24) 850 T39/20 33/11
After 200 â
1st 2ncl 3rd 4th Sth Reverse
3.23 1 (42/ 131 2 l67T39 18 1.667(35.'21 1.280
t32,'25) 1.042 !25/24) 5.550 39,'20 37, 131 Left
foot operated return system (97
Gea rs hilt pattern
2001 After 2001 TM!
Electric shift Cleft hand operatedl return system
(After 2001 TE I N 1 2 AC-CDI Sta rter motor
and emergency recoil starter Single phase output
alternator SCR shorted/single phase full wave
rectification Batter
ELECTRICAL
Ignition system Starting system Charging system
ReguIator,recti fier Liohtin stem
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GENERAL INFORMATION
LUBRICATION SYSTEM ITEM Engine oil capacity At
draining
SPECIFICATIONS 1.6 4 (1.7 US qt , 1.4 Imp qt) 1.5
0 (1.6 US qt , 1.3 Imp qt) 1.8 ü (1.9 US qt , 1.6
Imp qt) 1.9 4 (2.0 US qt , 1.7 Imp qt) HONDA GN4
4-stroke oil or equivalent motor oil API service
classification SF or SG 0.15 (0.006)
SERVICE LIMIT
97 2001 After 2001 97 2001 After 2001
At disassembly
Recommended engine oil
0.2010.008) 0.2510.0101 0.15(0.0061
Tip clearance Body clearance Side clearance
0.15 0.21 t0.006 0.008T 0.05 0.13 \0.002 0.005)
FUEL SYSTEM
SPECIFICATIONS PDCIB PDC1C PDC1E 95 - 38 3rd
groove from top 2nd groove from top 2-7/8 turns
out 2-3/4 turns out 2 5/8 turns out 2 turns
out 1/8 turns in from initial opening 14 mm (0.6
in) 1,400 100 rpm 3 8 mm \1/8 5/16 in)
ITEM
Carburetor identification number
97 \except California type) 97 California
type,98 2001 All types After 2001
Main jet Slow jet Jet needle clip position
97 After 97 97 iexcept California type T 97
California type 98 2001
Pilot screw
Initial opening
After 200 J
High altitude setling Float level Idle
speed Throttle lever free play

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GENERAL INFORMATION
CYLINDER HEAD/CYLINDER/PISTON Unit mm (in
SPECIFICATIONS 1,275 kPa (13.0 kgf.cm- , 185
psi) at 800 rpm
ITEM
SERVICE LIMIT
Cylinder compression
Cylinever head warpage Valve and Valve clearance
0.10 0.004i
IN/EX
0.13 t0.005)
valve guide Valve stem O.D. IN 5.475 5.490 t0.2156 0.2161) 5.45 0.215)
EX 5.455 5.470 (0.2148 0.2154) 5.43 (0.214)
Valve guide l. D. IN 5.500 5.512 T0.2165 0.2170) 5.525 10. 2 75 I
EX 5.500 5.512 (0.2165 0.21701 5.525 10. 2 75 I
Stem-to-g uide clearance IN 0.010 0.037 t0.0004 0.0015) 0.12 t0.005I
EX 0.030 0.057 f0.0012 0.0022) 0.14 \0.006)
Valve spring Valve seat width Inner IN/EX IN/EX 1 2 t0.05) 36.95 !1.455T 1 2 t0.05) 36.95 !1.455T 1.510.06) 35.7 1. 41)
free length Rocker arm Outer Rocker arm I. D. IN EX IN/EX 41.01 (1.615T 12.000 12.018 (0.4724 41.01 (1.615T 12.000 12.018 (0.4724 0.4731) 39.8 (1.57T 12.05 f0.474t
Rocker arm shaft O. D. IN/EX 11.964 11.984 (0.4710 11.964 11.984 (0.4710 0.4718) 11.92 f0.469)
Rocker arm-to-shaft clearance Cam lobe height
0.016 0.054 10.0006 0.0021I
0.08 10.003\ 35.211.391 35.0 11 381 22.46
0.884 22.54 t0.887 0.07 t0.003 68.6 t2.70T 0.10
t0.004) 0.10 !0.004 0.10 (0.0041
Camshaft and cam follower
IN EX IN./EX IN/EX
1.3997) 1.3917)
35.393 35.552 (1.3934 35.190 35.350
f1.3854 22.467 22.482 (0.8845 22.510 22.526
t0.8862
Cam follower 0. D. Cac follower bore I.D.
0.8851) 0.8868J
Cam follower-to bore clearance I. D. Out-of-rou
nd Taper Wa rpage
0.028 0.059 10.0011 0.0023T 68.500 68.510 T2.6968
2.6972)
Cylinder
Piston, piston ring
Piston mark direction Piston O. D. Piston O. D.
measurement point Piston pin bore l. D. Piston
pin 0. D Piston to-piston pin clearance
IN mark toward the intake side 68.462 68.482
f2.6953 2.6961) 6 18 t0.2 0.7) from bottom of
the skirt 15.002 J5.008 (0.5906 0.5909\ J4.994
15.000 (0.5903 0.5906t 0.002 0.014 t0.0001
0.0006! 0.015 0.045 (0.0006 0.0018 0.015 0.045
t0.0006 0.0018 T 0.20 0.35 (0.008 0.014) 0.40
0.55 t0.016 0.022) 0.20 0.70 \0.008 0.028) 0.018
0.048 (0.0007 0.0019) 15.010 15.028 t0.5909
0.5917)
68.4 \2.69 I
15.04 f0.592 14.96 t0.589 0.020 t0.0008 0.09
!0.004 I 0.09 (0.004 05(0021 07(0031
Piston ring-to-ring groove clearance Piston ring
end gap
Top Second Top Second Oil (side railI
Cylinder-to-piston clearance Connecting rod small
encl I.D.
0.10 f0.004\ 15.06 i0.593
Connecting rod-to-pi ston pin clearance 0.010
0.034 f0.0004 0.0013I 0.10 t0.00 4
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GENERAL INFORMATION
U nit nJm (in
CLUTCH
ITEM SPECIFICATIONS SERVICE LIMIT
Cha i cjc cIutch Spring free length 35.2 (1.39T 34.5 \1.36
Disc thickness 2.9 3.0 \0. 11 0.12T 2.6 (0.10T
Plate warpage 0.20 (0.008T
Clutch outer guide O. D. 27.959 27.980 (1.1007 1.10 J61 27.92 (1.099)
Centr ifugat Clutch outer loss I. D. Drum I. D. 28.000 28.021 (1.1024 1.1032) 116.00 116.20 t4.567 4.57 5) 28.05 (1.104) 116.5 (4.59
CI LI tc h Weight liniiJg thickness Clutch spring height CIutch weight spring free length 2.0 (0.08" " " " 3.0 (0.12I 30.75 1.211) 1.2 t0.05T 2.85 t0.112) 31.6 I 1.24)
Drum bushing I. D. 24.000 24.021 (0.9449 0.9457 t 24.05 t0.947)
Crankshalt O. D. at drive gear 23.959 23.980 (0.9433 0.9441) 23.93 t0. 942I
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