2003 2004 2005 Honda TRX650 Rincon ATV Service Manual

Description

This Official 2003-2005 Honda TRX650 Rincon Factory Service Manual is a reproduction of the original service manual, printed by Honda.  The photo shown may differ from the cover that you receive.

It provides detailed service information, step-by-step repair instruction and maintenance specifications for 2003-2005 Honda TRX650 Rincon ATVs.

2003 Honda TRX650FA FourTrax Rincon
2004 Honda TRX650FGA FourTrax Rincon GPScape
2004 Honda TRX650FA FourTrax Rincon
2005 Honda TRX650FGA FourTrax Rincon GPScape
2005 Honda TRX650FA FourTrax Rincon

Table of Contents

General Information
Frame/body Panels/exhaust System
Maintenance
ENGINE:
Lubrication System
Fuel System
Cooling System
Engine Removal/installation
Cylinder Head/valve/camshaft
Cylinder/piston
Alternator/starter Clutch
Sub-transmission/gearshift Linkage
Automatic Transmission
Crankcase/crankshaft/balancer
CHASSIS:
Front Wheel/suspension/steering
Rear Wheel/suspension
Brake System
Front Driving Mechanism
Rear Driving Mechanism
ELECTRICAL:
Battery/charging System
Ignition System
Electric Starter
Lights/meters/switches
Selectable 4wd System
Automatic Transmission System
Wiring Diagram
Technical Feature
Troubleshooting
Index

Index of Topics

Accessory Socket
Air Cleaner
Air Cleaner Housing
Air Cleaner Housing Drain Plug
Alternator Charging Coil
Alternator Stator/starter
Reduction Gears
Alternator/starter Clutch
Specifications
Automatic Transmission Specifications –
Automatic Transmission System
Axle Shaft
Battery
Battery/charging System
Specifications
Before Starting Troubleshooting
Body Panel Locations
Brake Fluid
Brake Fluid Replacement/air Bleeding
Brake Light Switch
Brake Pad/disc
Brake Pads Wear
Brake Shoes Wear
Brake System
Brake System Specifications
Cable & Harness Routing
Camshaft Installation
Camshaft Removal
Carburetor Assembly
Carburetor Choke
Carburetor Disassembly/inspection
Carburetor Heater
Carburetor Installation
Carburetor Removal
Case Bearing Replacement
Center Mud Guard
Charging System Inspection
Combination Meter
Component Location
Automatic Transmission System
Battery/charging System
Electric Starter
Ignition System
Lights/meters/switches
Selectable 4WD System
Connector Location
Coolant Replacement
Cooling System
Cooling System Flow Pattern
Cooling System Specifications
Cooling System Testing
Crankcase Assembly
Crankcase Bearing Replacement
Crankcase Separation
Crankcase/crankshaft/balancer
Specifications
Crankshaft
Cylinder Compression
Cylinder Head Assembly
Cylinder Head Cover Assembly/
Installation
Cylinder Head Cover Removal/
Disassembly
Cylinder Head Disassembly
Cylinder Head Installation
Cylinder Head Removal
Cylinder Head/valve/camshaft
Specifications
Cylinder/piston Installation
Cylinder/piston Removal
Cylinder/piston Specifications
Diagnostic Troubleshooting
Differential Assembly
Differential Disassembly/inspection
Differential Installation
Differential Removal
Diode
Drive Mode Select Switch
Drive Shaft Boots
Electric Starter Specifications
Emission Control Information
Label (usa Only)
Emission Control Systems
Engine & Frame Torque Values
Engine Guard
Engine Idle Speed
Engine Installation
Engine Oil
Engine Oil Filter
Engine Removal
Engine Side Cover
Exhaust System
Final Drive Assembly
Final Drive Disassembly/inspection
Final Drive Installation
Final Drive Removal
Final Gear Case Bearing Replacement
Flywheel/starter Clutch
Front Brake Master Cylinder
Front Brake Shoes/drum
Front Brake Switch
Front Carrier
Front Carry Pipe
Front Crankcase Cover
Front Drive Shaft
Front Driving Mechanism Specifications-
Front Fender
Front Grille
Front Mud Guard
Front Shock Absorber
Front Wheel
Front Wheel Cylinder/brake Panel
Front Wheel/suspension/steering
Specifications
Fuel Gauge/fuel Level Sensor
Fuel Line
Fuel System Specifications
Fuel Tank
Fuel Tank Cover
Fuel Tank Side Cover
Gear Position Switch
Gear Selector Lever Linkage
Gearshift Switch
General Specifications
Gps Receiver (gps Model Only)
Handlebar
Handlebar Switch
Headlight
High Altitude Adjustment
Ignition Coil
Ignition Switch
Ignition System Inspection
Ignition System Specifications
Ignition Timing
Inner Fender
Lights/meters/switches Specifications
Lubrication & Seal Points
Lubrication System Diagram
Lubrication System Specifications
Meter Cover
Model Identification
Muffler Protector
Nuts, Bolts, Fasteners
Oil Cooler
Oil Pressure Check
Automatic Transmission
Lubrication System
Oil Pump
Outer Fender
Pilot Screw Adjustment
Radiator Coolant
Radiator Reserve Tank
Radiator/cooling Fan
Rear Brake Caliper
Rear Brake Disc
Rear Brake Master Cylinder/
Brake Pedal
Rear Carrier/mud Guard
Rear Crankcase Cover
Rear Driving Mechanism Specifications
Rear Fender
Rear Final Gear Case Oil And
Differential Oil
Rear Shock Absorber/suspension Arm
Rear Wheel
Rear Wheel/suspension Specifications
Recoil Starter
Regulator/rectifier
Right Side Cover
Seat
Selector Cable Adjustment
Service Information
Alternator/starter Clutch
Automatic Transmission
Automatic Transmission System
Battery/charging System
Brake System
Cooling System
Crankcase/crankshaft/balancer
Cylinder Heada/alve/camshaft
Cylinder/piston
Electric Starter
Engine Removal/installation
Frame/body Panels/exhaust System
Front Driving Mechanism
Front Wheel/suspension/steering
Fuel System
Ignition System
Lights/meters/switches
Lubrication System
Maintenance
Rear Driving Mechanism
Rear Wheel/suspension
Selectable 4WD System
Sub-transmission/gearshift Linkage
Service Rules
Shift Clutch/mainshaft Assembly
Shift Clutch/mainshaft Disassembly
Shift Valve Body
Skid Plate, Engine Guard
Spark Arrester
Spark Plug
Standard Torque Values
Starter Motor
Starter Relay Switch
Steering Cover
Steering Shaft
Steering Shaft Holder Bearing
Steering System
Sub-transmission
Sub-transmission/gearshift Linkage
Specifications
Suspension
Suspension Arm
System Components
Alternator/starter Clutch
Automatic Transmission
Brake System
Crankcase/crankshaft/balancer
Cylinder Heada/alve/camshaft
Cylinder Piston
Engine Removal/installation
Front Driving Mechanism
Front Wheel/suspension/steering
Fuel System
Rear Driving Mechanism
Rear Wheel/suspension
Sub-transmission/gearshift Linkage
System Diagram
Automatic Transmission System
Battery/charging System
Electric Starter
Ignition System
Selectable 4WD System
Temperature Indicator/thermosensor
Thermostat
Throttle Housing
Throttle Operation
Throttle Position (tp) Sensor
Taillight
Tie-rod
Tires
Torque Converter Installation
Torque Converter Removal
Troubleshooting
Alternator/starter Clutch
Automatic Transmission
Battery/charging System
Brake System
Cooling System
Crankcase/crankshaft/balancer
Cylinder Head/valve/camshaft
Cylinder/piston
Electric Starter
Engine Does Not Start Or Is
Hard To Start
Engine Lacks Power
Frame/body Panels/exhaust System
Front Driving Mechanism
Front Wheel/suspension/steering
Fuel System
Ignition System
Lubrication System
Poor Handling
Poor Performance At High Speed
Poor Performance At Low And
Idle Speed
Rear Driving Mechanism
Rear Wheel/suspension
Selectable 4WD System
Sub-transmission/gearshift Linkage
Troubleshooting Chart
Valve Clearance
Valve Guide Replacement
Valve Seat Inspection/refacing
Water Pump
Wiring Diagrams
Trx650FA (standard Model)
Trx650FGA (gps Model)
Wheel Hub/knuckle(front)
Wheel Hub/knuckle(rear)
Wheels/tires