1986 1987 1988 1989 Honda TRX 250R Fourtrax Service Repair Maintenance Manual 224 Pages

The document is a Honda Service Manual for the 1986-1989 TRX 250R Fourtrax, detailing maintenance, safety notices, troubleshooting, specifications, and procedures for repairs and adjustments of various components such as the engine, cooling system, suspension, brakes, and electrical system. It includes torque values, tools, and part replacement guidelines.

General Information

•    Model Identification and Specifications: Covers dimensions, weight, and engine details.

•    Safety Notices: Includes warnings for hazardous materials and safety guidelines.

•    Torque Values and Tools: Lists torque specifications and special tools required for maintenance.
Maintenance and Service

•    Service Rules: Use genuine parts, clean parts properly, and follow assembly instructions.

•    Cooling System: Details on removal, inspection, and installation of water pump components.

•    Clutch and Gearshift Linkage: Instructions for removal, inspection, and reassembly.
Troubleshooting

•    Engine Issues: Diagnoses starting problems, power loss, and overheating.

•    Suspension Noise: Identifies causes like worn bearings or loose fasteners.

•    Electrical System: Covers wiring diagrams and ignition troubleshooting.
Components and Systems

•    Fuel System: Includes carburetor specifications and adjustments.

•    Rear Suspension: Removal and inspection of shock absorber and related components.

•    Exhaust System: Instructions for removal and installation of mufflers and chambers.
Index and References

•    Index Overview: Lists topics like brakes, transmission, and electrical systems for quick reference.

•    Honda Fourtrax 250R Service Manual Overview: Covers maintenance, troubleshooting, and repair instructions for 1986-1989 models.

•    Safety Precautions: Includes warnings about hazardous materials like gasoline and asbestos, and emphasizes using proper tools and parts.

•    General Maintenance: Provides torque values, specifications, and step-by-step procedures for assembly and disassembly.

•    System-Specific Instructions: Details on fuel system, engine, cooling system, and electrical components, including troubleshooting guides.

•    Troubleshooting Guidance: Includes diagnostics for engine performance issues, poor startup, and power loss.

•    Special Tools: Lists required tools for specific tasks like bearing removal, seal installation, and clutch repairs.

•    Suspension and Brakes: Instructions for inspecting, repairing, and replacing rear suspension, shock absorbers, and hydraulic disc brakes.

•    Wiring and Electrical: Wiring diagrams and electrical system troubleshooting for ignition, lighting, and other components.

The troubleshooting section of the Honda Service Manual for the TRX 250R includes the following components and areas for diagnosis:

•    Engine Issues:
    
•    Lack of power
    
•    Overheating
    
•    Knocking
    
•    Poor performance at low and idle speeds
    
•    Compression problems

•    Ignition System:
    
•    Weak or no spark at the spark plug
    
•    Ignition timing checks and related components (e.g., CDI unit, pulse generator)

•    Fuel System:
    
•    Restricted fuel flow
    
•    Clogged fuel tank breather tube
    
•    Clogged carburetor

•    Air Intake:
    
•    Clogged air cleaner

•    Exhaust System:
    
•    Clogged muffler

•    Cooling System:
    
•    Clogged radiator

•    Clutch:
    
•    Slipping clutch
    
•    Worn or warped clutch plates
    
•    Faulty clutch lifter system

•    Electrical System:
    
•    Faulty alternator
    
•    AC regulator issues
    
•    Lighting system problems

•    Wheels and Suspension:
    
•    Brake dragging
    
•    Worn or damaged axle bearings
    
•    Suspension noise or improper adjustment

•    General Maintenance Issues:
    
•    Tire pressure problems
    
•    Drive chain adjustment
These components are addressed with step-by-step diagnostic procedures to identify and resolve issues effectively.

The chapters in the Honda Service Manual for the TRX 250R are organized as follows:

1.    General Information

2.    Maintenance

3.    Fuel System

4.    Engine Removal/Installation

5.    Cylinder Head/Cylinder/Piston

6.    Alternator

7.    Clutch/Balancer/Gearshift Linkage/Kick Starter

8.    Transmission/Crankshaft

9.    Cooling System

10.    Front Wheel/Suspension/Steering

11.    Rear Wheel/Drive Mechanism

12.    Rear Suspension

13.    Hydraulic Disc Brakes

14.    Fenders/Exhaust System

15.    Electrical System

16.    Troubleshooting
Each chapter provides detailed information, including assembly illustrations, specifications, torque values, tools, and troubleshooting procedures for the respective sections.

The tools required for servicing the Honda TRX 250R include:
General Tools:

•    Metric tools: Essential for most components, as the TRX 250R uses metric bolts, nuts, and screws.

•    Torque wrench: For ensuring proper tightening of bolts and nuts to specified torque values.

•    Snap ring pliers: For removing and installing snap rings.

•    Feeler gauge: For measuring clearances, such as clutch plate warpage.

•    Circuit tester or multimeter: For electrical system troubleshooting.
Specialized Tools:

1.    Clutch/Transmission Tools:
    
•    Clutch center holder: For holding the clutch center during removal and installation.
    
•    Gear holder: For securing gears during maintenance.
    
•    Driveshaft dis/assembly tool: For crankshaft and crankcase assembly.

2.    Suspension Tools:
    
•    Shock absorber compressor: For compressing the shock spring during disassembly.
    
•    Ball joint remover: For removing ball joints in the suspension system.

3.    Bearing Tools:
    
•    Bearing remover and remover handles: For removing and installing bearings.
    
•    Driver and attachments: For installing bearings and seals, with various sizes depending on the component.

4.    Cooling System Tools:
    
•    Mechanical seal installer: For installing water pump seals.
    
•    Universal holder: For holding the flywheel during water pump or alternator servicing.

5.    Tire Tools:
    
•    Universal bead breaker: For removing tires from rims.
    
•    Tire irons and rim protectors: For manual tire removal if a tire changer is unavailable.

6.    Electrical Tools:
    
•    Rotor puller: For removing the alternator rotor.
    
•    Universal holder: For securing the rotor during removal.

7.    Optional Tools:
    
•    Pin spanner: For specific adjustments in suspension components.
    
•    Thread adapters and assembly bolts: For crankcase assembly.
Notes:

•    Always use genuine Honda tools or their equivalents to avoid damage or incorrect assembly.

•    Refer to the service manual for specific tool numbers and their applications for various components.
These tools ensure accurate and safe servicing of the TRX 250R.

The chapters in the Honda Service Manual for the TRX 250R are as follows:

1.    General Information

2.    Maintenance

3.    Fuel System

4.    Engine Removal/Installation

5.    Cylinder Head/Cylinder/Piston

6.    Alternator

7.    Clutch/Balancer/Gearshift Linkage/Kick Starter

8.    Transmission/Crankshaft

9.    Cooling System

10.    Front Wheel/Suspension/Steering

11.    Rear Wheel/Drive Mechanism

12.    Rear Suspension

13.    Hydraulic Disc Brakes

14.    Fenders/Exhaust System

15.    Electrical System

16.    Troubleshooting

17.    Index
These chapters cover all aspects of maintenance, troubleshooting, and repair for the TRX 250R.

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