1998-2004 Honda TRX450 Foreman Repair Service Workshop Shop Manual Book M205

Description

1998-2004 Honda TRX450 Foreman Clymer Repair Manual M205
This manual gives you complete information regarding maintenance, tune-up, repair and overhaul. This Clymer Honda TRX350 Rancher manual includes color wiring diagrams and hundreds of illustrations and original photographs developed from the complete disassembly of the machine.
Models Covered:
TRX450ES (1998 1999 2000 2001)
TRX450S (1998 1999 2000 2001)
TRX450FE (2002 2003 2004)
TRX450FM (2002 2003 2004)
Every Clymer contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of the motorcycle. This, in addition to extensive research, allows Clymer to achieve an un-matched level of detail, accuracy & clarity.
The step-by-step instructions and two column text with large print are user friendly, bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb tabbed chapters, numbered table of contents and extensive index make it possible to locate the desired section quickly. This manual includes a Quick Reference Data section with frequently used specifications.
Table of Contents:
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers and information labels / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specification Specs
CHAPTER TWO / TROUBLESHOOTING
Starting the engine / Engine will not start / Poor engine performance / Fuel system / Engine / Engine lubrication / Leakdown test / Clutch / Gearshift linkage / Transmission / Kickstarter / Drive train noise / Electrical testing / Front suspension and steering / Rear suspension / Brake system
CHAPTER THREE / MAINTENANCE, LUBRICATION and TUNE-UP
Pre-ride inspection / Fuel requirements / Air filter / Engine oil and filter / Oil strainer screen / Transmission oil / Cooling system / Spark plug / Valve clearance / Decompressor clearance / Decompressor system plunger / Engine compression check / Fuel hose and valve / Engine idle speed / Exhaust system / Control cables / Throttle lever free play / Clutch lever free play / Brakes / Drive chain and sprockets / Tires and wheels / Steering system / Suspension check and lubrication / Skid plate inspection / Nuts, bolts and other fasteners / Electrical system / Engine break-in / Specification Specs
CHAPTER FOUR / ENGINE TOP END and EXHAUST SYSTEM
Exhaust system / Cylinder head cover / Camshaft holder / Camshaft holder service / Cam chain tensioner, guides and cam chain / Cylinder head / Valves / Cylinder / Piston and piston rings / Cylinder studs / Specifications
CHAPTER FIVE / ENGINE LOWER END (2004-2005)
Engine removal / Engine installation / Countershaft seal / Shift shaft seal / Balancer shaft and primary drive gear assembly / Oil pump drive gear, oil pressure relief valve and oil strainer / Crankcase / Crankcase seals and bearings / Oil pump and one-way valve / Crankshaft / Oil cooler and hoses / Specifications
CHAPTER SIX / ENGINE LOWER END (2006-2009)
Engine removal / Engine installation / Countershaft seal / Shift shaft seal / Balancer shaft, primary drive gear and starter clutch (TRX450ER) assembly / Oil pump drive gear, oil strainer and oil pressure relief valve / Crankcase / Crankcase seals and bearings / Oil pump and one-way valve / Crankshaft / Specifications
CHAPTER SEVEN / CLUTCH, EXTERNAL SHIFT MECHANISM and KICKSTARTER
Right crankcase cover / Clutch cover / Clutch / Clutch release lever / Kickstarter and idle gears / External shift mechanism / Clutch cable / Specification Specs
CHAPTER EIGHT / TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission service notes / Overhaul / Inspection / Internal shift mechanism / Specification Specs
CHAPTER NINE / FUEL SYSTEM
Fuel tank / Fuel valve and screen / Air box / Carburetor / Float height adjustment / Pilot screw adjustment (idle drop procedure) / High altitude adjustment (2006-2009 models) / Hot start cable (TRX450R models) / Throttle housing / Throttle cable / Crankcase breather system / Specifications
CHAPTER TEN / ELECTRICAL SYSTEM
Electrical basics / Electrical component replacement / Electrical connectors / Left crankcase cover / Stator and ignition pulse generator / Flywheel / Battery / Charging system / Alternator charge coil resistance test / Regulator/rectifier / Ignition coil / Fan/ignition control module (fan/ICM) / Ignition system testing / Ignition timing / Electric starting system / Starter / Starter relay switch / Clutch diode / Lighting system / Switches / Carburetor heater (2004-2005) / Throttle position sensor (TPS) / Closed throttle position detection system / Cooling system electrical components / Condenser (TRX450R) / Fuse / Wiring diagrams / Specifications
CHAPTER ELEVEN / COOLING SYSTEM
Cooling system inspection / Water pump inspection / Pressure test / Radiator / Engine coolant temperature ECT sensor / Coolant reserve tank / Thermostat / Water pump / Specification Specs
CHAPTER TWELVE / FRONT SUSPENSION and STEERING
Front wheel / Front hub / Shock absorbers / Tie rods / Steering knuckle / Control arms / Handlebar / Handlebar grip / Steering shaft / Tires / Specifications Specs
CHAPTER THIRTEEN / REAR AXLE and SUSPENSION
Rear wheels and hub / Rear axle / Axle housing / Shock absorber / Shock linkage / Swing arm / Drive chain / Sprockets / Specification Specs
CHAPTER FOURTEEN / BRAKES
Brake service notes / Brake bleeding / Brake fluid draining / Front brake pads / Front brake caliper / Front master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Brake hose and metal brake line / Rear brake pedal / Brake disc / Specifications Specs
CHAPTER FIFTEEN / BODY
Retaining clips / Seat / Top cover / Front fender / Rear fender / Heat guard plate / Engine skid plate / Swing arm skid plate / Front bumper / Mud guard / Footpegs / Specification Specs
INDEX
COLOR WIRING DIAGRAMS
Specifications:
Publisher:    Clymer Publications
Softcover:     Approx. 417 pages
Dimensions: 10.0 x 7.0 x 1.0 inches
Part number: CM205
ISBN-13: 9780892878963
Publication date: Tuesday, March 27, 2018
Language: English