Honda TRX250EX Sportrax ATV Repair Manual 2001-2005

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Item # M215  ISBN: 9780892879885




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This repair and service manual covers Honda TRX250EX Sportrax ATVs from 2001 to 2005.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Precision measuring tools | Electrical system fundamentals | Basic service methods | Storage | Specifications

CHAPTER TWO: TROUBLESHOOTING
Water damage | Engine operating requirements | Engine will not start | Poor idle speed performance | Poor medium and high speed performance | Electrical testing | Starting system | Charging system | Ignition system | Lighting system | Fuel system | Engine overheating | Engine | Engine noises | Cylinder leakdown test | Clutch | Transmission | Final drive | Handling | Frame noise | Brakes

CHAPTER THREE: LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride check list | Maintenance schedule | Tires and wheels | Battery | Engine oil and filter | Final drive gearcase oil | Control cable lubrication | General lubrication | Air and fuel system | Brake system | Spark arrestor | Suspension | Fasteners | Valve clearance | Engine compression test | Spark plug | Ignition timing | Idle speed adjustment | Specifications

CHAPTER FOUR: ENGINE TOP END
Cylinder head cover | Rocker arms, pushrods and cylinder head | Valves and valve components | Cylinder | Piston and piston rings | Camshaft | Specifications

CHAPTER FIVE: ENGINE LOWER END
Engine removal/installation | Oil cooler | Alternator cover | Flywheel and starter gears | Gearshift linkage | Oil pump | Oil screen and strainer | Crankcase and crankshaft | Engine break-in | Specifications

CHAPTER SIX: CLUTCH AND PRIMARY DRIVE GEAR
Clutch cover | Clutch release mechanism | Centrifugal clutch and primary drive gear | Change clutch | Specifications

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

CHAPTER EIGHT: FUEL, AIR AND EXHAUST SYSTEMS
Carburetor | Carburetor adjustments | Throttle housing | Throttle cable replacement | Choke cable replacement | Fuel tank | Fuel valve | Air box | Exhaust system | Specifications

CHAPTER NINE: ELECTRICAL SYSTEM
Electrical component replacement | Electrical connectors | Battery negative terminal | Charging system | Alternator | Ignition system | Starter | Starter relay | Starter relay | Diode | Lighting system | Switches | Fuse | Specifications

CHAPTER TEN: WHEELS, HUBS AND TIRES
Front wheel | Front hub | Rear wheel | Rear hub | Tires | Specifications

CHAPTER ELEVEN: FRONT SUSPENSION AND STEERING
Handlebar | Steering shaft | Tie rods | Steering knuckle | Control arms | Ball joint replacement | Shock absorbers | Specifications

CHAPTER TWELVE: REAR AXLE, SUSPENSION AND FINAL DRIVE
Shock absorber | Rear axle | Final drive | Driveshaft | Swing arm | Specifications

CHAPTER THIRTEEN: BRAKES
Brake service | Front brake pads | Front brake caliper | Front master cylinder | Brake hose replacement | Brake fluid draining | Brake bleeding | Rear brake drum | Rear brake pedal and cable | Rear brake lever/parking brake cable | Specifications

CHAPTER FOURTEEN: BODY
Retaining clips | Retaining tabs | Seat | Side covers | Fuel tank cover | Front fender | Front and rear guards | Rear fender | Footpegs and mud guards | Handlebar cover

COLOR WIRING DIAGRAMS

Clymer motorcycle and ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Honda TRX250EX Sportrax ATV Repair Manual 2001-2005