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Repair Manual
This item for sale brand new Service Repair Manual for Honda TRX450R and TRX450ER 2004-2009. 432 pages.
Models Covered:
*This manual covers 2004-2009 TRX450R and TRX450ER models. TRX450R/ER models were available in 2010 and 2011; however, they are officially 2009 models.
CHAPTER 1 - 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 2 - 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 3 - 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 4 - 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 / Specification Specs
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 / Specification Specs
CHAPTER 7 - 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 8 - TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission service notes / Overhaul / Inspection / Internal shift mechanism / Specification Specs
CHAPTER 9 - 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 / Specification Specs
CHAPTER 10 - 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 / Specification Specs
CHAPTER 11 - 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 12 - FRONT SUSPENSION and STEERING
Tires / Front wheel and hub / Shock absorbers / Tie rods / Steering knuckle / Control arms / Handlebar / Steering shaft / Tires / Specification Specs
CHAPTER 13 - REAR AXLE and SUSPENSION
Rear wheels and hub / Rear axle / Axle housing / Shock absorber / Shock linkage / Swing arm / Drive chain / Sprockets / Specification Specs
CHAPTER 14 - 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 / Specification Specs
CHAPTER 15 - 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
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