Honda Trx250X, 1987-1992 & Trx300Ex, 1993-2003

by Clymer Publications

• ISBN13: 9780892878567
• ISBN10: 0892878568
• Format: Paperback
• Copyright: 2003-02-01
• Publisher: Clymer Pubns

Table of Contents

Quick Reference Data	ix
General Information	1	(34)
Manual organization
Notes, cautions and warnings
Safety first
Service hints
Washing the vehicle
Serial numbers
Torque specifications
Fasteners
Lubricants
Sealants, adhesives and cleaners
Expendable supplies
Basic hand tools
Precision measuring tools
Test equipment
Special tools
Mechanic's tips
Ball bearing replacement
Oil seals
Riding safety
Troubleshooting	35	(21)
Operating requirements
Starting the engine
Starting difficulties
Engine is difficult to start
Poor idle speed performance
Poor medium- and high-speed performance
Engine starting system (TRX300EX)
Lighting coil (TRX250X)
Charging system (1993-on TRX300EX)
Ignition system
Carburetor troubleshooting
Engine overheating
Engine
Engine noises
Engine leak down test
Clutch
Transmission
Drive train noise
Handling
Frame noise
Lubrication, Maintenance and Tune-Up	56	(40)
Pre-ride checklist
Service intervals
Tires and wheels
Battery (TRX300EX)
Lubricants
Periodic lubrication
Periodic maintenance
Non-scheduled maintenance
Engine tune-up
Storage
Engine Top End	96	(43)
Engine principles
Cleanliness
Cylinder head cover
Camshaft and cam chain tensioner
Cylinder head
Valves and valve components
Cylinder
Piston and piston rings
Oil pipes
Engine Lower End	139	(64)
Servicing engine in frame
Engine
Drive sprocket
Left crankcase cover and stator coil (TRX250X)
Starter reduction gears (TRX300EX)
Left crankcase cover and stator coil (TRX300EX)
Flywheel (TRX250X)
Flywheel and starter clutch (TRX300EX)
Gearshift linkage
Oil pipe and oil pump
Primary gears and oil pump drive gear
Cam chain and guides
Breather plate
Crankcase and crankshaft
Kickstarter (TRX250X)
Engine break-in
Clutch and Reverse Shifter	203	(25)
Clutch cover
Clutch
Reverse shifter
Clutch cable
Reverse cable replacement
Transmission and Internal Shift Mechanism	228	(17)
Transmission/reverse system identification
Transmission troubleshooting
Transmission/reverse overhaul
Reverse idle gear assembly
Transmission inspection
Internal shift mechanism
Fuel and Exhaust Systems	245	(23)
Carburetor
Carburetor adjustments
Throttle housing and cable
Fuel tank
Fuel valve
Air box
Exhaust system
Electrical System	268	(35)
Lighting system (TRX250X)
Charging system (1993-on TRX300EX)
Alternator (TRX300EX)
Alternator and AC lighting system (TRX250X)
Ignition system (TRX250X)
Ignition system (TRX300EX)
Ignition coil
Electric starting system (TRX300EX)
Starter relay switch (TRX300EX)
Reverse inhibiter unit (TRX300EX)
Lighting system
Switches
Fuse (TRX300EX)
Wiring diagrams
Front Suspension and Steering	303	(35)
Front wheel
Front hub
Shock absorbers
Tie rods
Steering knuckle
Control arms
Handlebar
Steering shaft
Tires and wheels
Rear Suspension	338	(23)
Rear wheels
Rear hub
Rear axle
Rear axle bearing holder
Drive chain
Driven sprocket
Tire changing and tire repairs
Shock absorber
Rear swing arm
Brakes	361	(31)
Brake fluid selection
Disc brake
Front caliper
Front master cylinder
Rear caliper
Rear master cylinder
Brake hose replacement
Brake disc
Brake bleeding
Rear brake pedal
Body	392	(6)
Seat/rear fender assembly
Front fender
Handlebar cover
Index	398	(4)
Wiring Diagrams	402