2004-2009 Honda TRX450 TRX 450ER ATV Repair Service Manual Clymer

Description

This 2004-2009 Honda TRX450 (Kickstart), TRX 450ER (Electric Start) ATV Repair Service Manual by Clymer provides service, repair and maintenance information to help Honda TRX450 and TRX450ER sport ATV owners fix their own ATVs. Everything you need to carry out your own service work is included in this 419 page Clymer manual – you get color wiring diagrams and hundreds of illustrations and original photographs developed from the complete disassembly of a Honda TRX450 ATV.

This Clymer 2004-2009 Honda TRX450 ATV manual specifically covers repairs of the following ATVs:

2009 Honda TRX450R (Kick Start)
2008 Honda TRX450R Sportrax (Kick Start)
2007 Honda TRX450R Sportrax (Kick Start)
2006 Honda TRX450R Sportrax (Kick Start)
2005 Honda TRX450R Sportrax (Kick Start)
2004 Honda TRX450R Sportrax (Kick Start)

2009 Honda TRX450ER (Electric Start)
2008 Honda TRX450ER Sportrax (Electric Start)
2007 Honda TRX450ER Sportrax (Electric Start)
2006 Honda TRX450ER Sportrax (Electric Start)

Honda TRX450 Sportrax ATV QUICK REFERENCE DATA

Honda TRX450 Sportrax ATV 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

Honda TRX450 Sportrax ATV TROUBLESHOOTING – Starting the engine, Engine will not start, Poor engine performance, Fuel system, Engine, Engine lubrication, Leakdown test, Clutch, Gearshift linkage, Transmission, Kickstarter (TRX450R), Drive train noise, Electrical testing, Front suspension and steering, Rear suspension, Brake system

Honda TRX450 Sportrax ATV LUBRICATION, MAINTENANCE 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 (TRX450R and 2006-2007 RX450R), Decompressor system plunger (2008 TRX450ER), 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

Honda TRX450 Sportrax ATV 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

Honda TRX450 Sportrax ATV 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

Honda TRX450 Sportrax ATV 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

Honda TRX450 Sportrax ATV 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

Honda TRX450 Sportrax ATV TRANSMISSION AND INTERNAL SHIFT MECHANISM – Transmission service notes, Transmission overhaul, Transmission inspection, Internal shift mechanism, Specifications

Honda TRX450 Sportrax ATV FUEL SYSTEM – Fuel tank, Fuel valve and screen, Air box, Carburetor, Float height adjustment, Pilot screw adjustment (idle drop procedure), High altitude adjustment (2006-on models), Hot start cable (TRX450R models), Throttle housing, Throttle cable, Crankcase breather system, Specifications

Honda TRX450 Sportrax ATV 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 (2004-2005), Fuse, Wiring diagrams, Specifications

Honda TRX450 Sportrax ATV COOLING SYSTEM – Safety precautions, Cooling system inspection, Water pump inspection, Pressure test, Radiator, Engine coolant temperature (ECT) sensor, Coolant reserve tank, Thermostat, Water pump, Specifications

Honda TRX450 Sportrax ATV FRONT SUSPENSION AND STEERING – Front wheel, Front hub, Shock absorbers, Tie rods, Steering knuckle, Control arms, Handlebar, Handlebar grip, Steering shaft, Tires, Specifications

Honda TRX450 Sportrax ATV REAR AXLE AND SUSPENSION – Rear wheels, Tires, Rear hub, Rear axle, Axle housing, Shock absorber, Shock linkage, Swing arm, Drive chain, Sprockets, Specifications

Honda TRX450 Sportrax ATV 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

Honda TRX450 Sportrax ATV 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

Honda TRX450 Sportrax ATV INDEX

Honda TRX450 Sportrax ATV WIRING DIAGRAMS