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Honda TRX450 & TRX450ER ManualThis Clymer ATV manual covers the Honda TRX450R & TRX450ER for these years: 2004, 2005, 2006, 2007, 2008, 2009
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Features
Clymer ATV repair manuals are the best reference book for repair and service information. Every Clymer service manual is written for the do-it-yourselfer as well as the experienced mechanic, Clymer repair manuals are the cheapest way to keep your four wheeler running properly. Every Clymer ATV service manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the ATV covered. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each service, troubleshooting and repair procedure.The Honda TRX450R & TRX450ER manual includes the following chapters:
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 / Specifications
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
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 / Specifications
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 5 and 6 - ENGINE LOWER END
Engine removal / Engine installation / Countershaft seal / Shift shaft seal / Balancer shaft, primary drive gear and starter clutch 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
CLUTCH, EXTERNAL SHIFT MECHANISM and KICKSTARTER
Right crankcase cover / Clutch cover / Clutch / Clutch release lever / Kickstarter and idle gears / External shift mechanism / Clutch cable / Specifications
TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission service notes / Overhaul / Inspection / Internal shift mechanism / Specifications
FUEL SYSTEM
Fuel tank / Fuel valve and screen / Air box / Carburetor / Float height adjustment / Pilot screw adjustment idle drop procedure / High altitude adjustment / Hot start cable / Throttle housing / Throttle cable / Crankcase breather system / Specifications
ELECTRICAL SYSTEM
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 / Throttle position sensor TPS / Closed throttle position detection system / Cooling system electrical components / Condenser / Fuse / Wiring diagrams / Specifications
COOLING SYSTEM
Cooling system inspection / Water pump inspection / Pressure test / Radiator / Engine coolant temperature ECT sensor / Coolant reserve tank / Thermostat / Water pump / Specifications
FRONT SUSPENSION and STEERING
Tires / Front wheel and hub / Shock absorbers / Tie rods / Steering knuckle / Control arms / Handlebar / Steering shaft / Tires / Specifications
REAR AXLE and SUSPENSION
Rear wheels and hub / Rear axle / Axle housing / Shock absorber / Shock linkage / Swing arm / Drive chain / Sprockets / Specifications
BRAKES
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
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 / Specifications
INDEX
COLOR WIRING DIAGRAMS
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