Honda TRX450ES/FE - User Manual

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Important Safety Notice2
How to Use this Manual3
Contents3
Symbols4
General Information5
General Safety5
Service Rules6
Model Identification7
Trx 450S/Fm7
Trx 450Es/Fe7
Specifications8
General8
Dimensions8
Frame8
Engine9
Carburetor9
Drive Train9
Electrical9
Lubrication System10
Fuel System10
Cylinder Head/Valves/Camshaft11
Cylinder/Piston11
Clutch/Gearshift Linkage12
Crankshaft/Transmission13
Front Wheel/Suspension/Steering14
Rear Wheel/Suspension14
Brakes14
Front Driving Mechanism14
Front Driving Mechanism (‘98-‘01)15
Front Driving Mechanism (after ‘01)15
Rear Driving Mechanism15
Battery/Charging System15
Ignition System16
Electric Starter16
Lights/Meters/Switches16
Torque Values17
Tools20
Lubrication & Seal Points22
Cable & Harness Routing25
Trx450S (‘98-‘01)25
Trx450Es (‘98-‘01)25
TRX450FM (after ‘01)26
TRX450FE (after ‘01)26
TRX450S and TRX450ES29
Top View29
Rear View29
Parts View32
TRX450S/FM and TRX450ES/FE34
Trx450S/Fm35
Trx450Es/Fe35
Emission Control Systems42
Source of Emissions42
Exhaust Emission Control System42
Crankcase Emission Control System42
Emission Control Information Label43
Noise Emission Control System43
Body Panel Locations44
Frame/Body Panels/Exhaust System45
Frame Cover Removal Chart45
Service Information46
Troubleshooting46
Seat/Side Cover47
Removal47
Seat47
Retaining Clip47
Side/Fuel Tank Cover Separation48
Front Carrier/Carry Pipe/Front Fender50
Disassembly52
Rear Carrier/Rear Fender54
Tool Box55
Installation56
Handlebar Cover57
Center Mud Guard (TRX450ES/FE)58
Exhaust System59
Muffler59
Exhaust Pipe59
Maintenance63
Specifications63
Maintenance Schedule65
Fuel Line66
Throttle Operation66
Carburetor Choke67
Air Cleaner67
Dust Cover68
Air Cleaner Housing Drain Tube69
Spark Plug69
Inspection69
Valve Clearance70
Reusing a Spark Plug70
Replacing a Spark Plug70
Engine Oil and Oil Filter72
Oil Level Inspection72
Recommended Engine Oil72
Engine Oil and Filter Change73
Engine Idle Speed75
Drive Shaft Boots75
Rear Final Gear Case Oil and Differential Oil75
Oil Level Check75
Front Differential76
Brake Fluid77
Oil Change77
Rear Final Gear Case77
Brake Shoe Wear78
Brake System78
Front Brake78
Rear Brake78
Reverse Lock System80
Skid Plates/Engine Guard81
Clutch System81
Suspension82
Spark Arrester82
Swing Arm Bearings82
Cleaning82
Nuts, Bolts, Fasteners83
Wheels/Tires83
Steering Shaft Holder Bearing83
Tire Pressure83
Steering System84
Toe84
Lubrications System Diagram86
Lubrication System87
Oil Cooler88
Assembly89
Oil Cooler Installation89
Cooling Fan Motor/Shroud Removal90
Cooling Fan Motor/Shroud Disassembly91
Cooling Fan Motor/Shroud Installation93
Oil Pump94
Removal/Disassembly94
Relief Valve97
Oil Strainer Screen98
Fuel System100
Tool102
Troubleshooting103
Air Cleaner Housing104
Carburetor Removal105
Carburetor Disassembly106
Starting Enrichment (SE) Valve106
Float and Jets107
Carburetor Heater107
Primer Knob108
Diaphragm/Vacuum Piston109
Air Cut off Valve110
Carburetor Assembly111
Float Level Inspection114
Carburetor Installation116
Pilot Screw Adjustment118
High Altitude Adjustment119
Fuel Tank Removal120
Fuel Strainer Screen122
Fuel Tank Installation122
Engine Removal/Installation124
Engine Removal126
Engine Installation130
Cylinder Head/Cylinder/Piston136
Cylinder Compression Test140
Cylinder Head Removal140
Cylinder Head Cover Removal140
Rocker Arm Holder Disassembly142
Rocker Arm Holder Inspection142
Cylinder Head Disassembly143
Cylinder Head Inspection143
Valve Spring143
Cylinder Head143
Valve/Valve Guide144
Valve Guide Replacement145
Valve Seat Inspection/Refacing146
Valve Seat Refacing146
Cylinder Head Assembly149
Cylinder Head Installation150
Rocker Arm Holder Assembly150
Rocker Arm Holder Installation151
Cylinder/Piston Removal152
Cylinder/Piston Inspection153
Piston Removal153
Piston154
Cylinder/Piston Installation156
Piston Ring Installation156
Cylinder Installation157
Camshaft/Cam Chain Tensioner158
Camshaft Removal158
Cam Chain Tensioner Remova159
Push Rod160
Cam Follower160
Cam Chain Tensioner160
Cam Chain Tensioner Installation161
Camshaft Installation161
Clutch164
Front Crankcase Cover Removal167
Bearing Replacement167
Centrifugal Clutch168
Clutch Puller169
One-Way Clutch169
Drive Plate Boss170
Clutch Drum170
Primary Drive Gear171
Weight Spring/Clutch Spring171
Crankshaft at the Primary Driver Gear172
Change Clutch176
Clutch Lifter Bearing178
Clutch Spring178
Clutch Center178
Clutch Disc178
Clutch Plate179
Clutch Outer179
Mainshaft at the Clutch Outer Guide179
Front Crankcase Cover Installation182
Gearshift Linkage184
Gearshift Linkage Removal186
Gearshift Linkage Inspection188
Gearshift Linkage Installation188
Reverse Stopper Shaft191
Alternator/Starter Clutch194
Recoil Starter196
Alternator Removal200
Alternator Cover Removal200
Alternator Cover Disassembly201
Flywheel/Starter Clutch203
Flywheel/Starter Clutch Removal203
Rear Crankcase Cover Removal203
Starter Clutch Inspection/Disassembly204
Starter Clutch Assembly205
Drive Shaft Oil Seal Replacement206
Rear Crankcase Cover Installation206
Flywheel/Starter Clutch Installation207
Alternator Installation208
Alternator Assembly208
Alternator Cover Installation208
Crankshaft/Balancer/Transmission212
Crankshaft Noisy215
Transmission Jumps out of Gear215
Hard to Shift215
Crankcase Separation216
Transmission216
Front Crankcase220
Rear Crankcase221
Crankcase Bearing Locations222
Assembly/Installation223
TRX450S/FM Main Shaft223
Countershaft224
TRX450ES/FE Mainshaft225
Crankshaft/Balancer228
Crankcase Assembly231
Front Wheel/Suspension/Steering234
Hard Steering236
Steers to One Side or Does Not Track Straight236
Front Wheel Wobbling236
Soft Suspension236
Handlebar237
Throttle Housing240
Front Wheel242
Tires242
Tire Repair244
Tire Pressure245
Tie-Rod/Knuckle246
Ball Joint Replacement249
Knuckle Bearing Inspection/Replacement250
Tie-Rod Assembly252
Knuckle Installation252
Tie-Rod Installation252
Standard Setting252
Upper/Lower Arms254
Lower Arm255
Steering Shaft257
Front Shock Absorber263
Rear Wheel/Suspension266
Wobble or Vibration in Vehicle268
Hard Suspension268
Suspension Noise268
Rear Wheel269
Rear Shock Absorber269
Swingarm270
Left Shock Absorber270
Right Shock Absorber270
Pivot Bearing Replacement273
Brake System278
Front Wheel Wobbling and Noise280
Poor Brake Performance280
Brake Fluid Draining281
Brake Fluid Filling281
Brake Bleeding282
Brake Hose/Brake Pipe Inspection282
Master Cylinder283
Brake Shoes/Wheel Cylinder/Adjuster285
Wheel Cylinder/Adjuster Inspection288
Front Brake Panel Inspection288
Front Brake Waterproof Seal Inspection289
Front Brake Waterproof Seal Replacement289
Rear Brake293
Brake Pedal301
Front Driving Mechanism304
'98-'01304
After '01305
Consistent Noise During Cruising308
Gear Noises While Running308
Abnormal Noises When Turning (after '01)308
Abnormal Noises at Start or During Acceleration308
Front Drive Shaft309
Grease Capacity313
Drive Shaft Length314
Front Differential315
Backlash Inspection ('98-'01)317
Backlash Inspection (after '01)318
Difference of Measurement318
Ring Gear Spaces318
Differential Case Disassembly ('98-'01)319
Ring Gear Shims319
Differential Case Disassembly (after '01)320
Bearing Inspection322
Gear Tooth Contact Pattern Check ('98-'01)322
Pinion Spacers323
Normal323
Too High323
Too Low323
Gear Tooth Contact Pattern Check (after '01)324
Differential Assembly Inspection ('98-'01)325
Differential Assembly Inspection (after '01)326
Differential Assembly ('98-'01)327
Differential Inspection328
Pinion328
Service Limits328
Differential Assembly (after '01)329
Differential Housing329
Differential Components Inspection (after '01)330
Differential Cap330
Differential Housing/Face Cam/Cam Follower330
Drive Pinion Removal ('98-'01)331
Side Cone Spring331
Drive Pinion Removal (after '01)332
Drive Pinion Disassembly/Assembly ('98-'01)333
Drive Pinion Installation (after '01)333
Case Bearing Replacement334
Pinion Needle Bearing Replacement335
Drive Pinion Installation ('98-'01)336
Differential Assembly ('98 - '01)338
Differential Assembly (after '01)341
Differential Assembly342
Differential Shims342
Differential Case Assembly343
Final Clutch Assembly343
Rear Driving Mechanism348
Rear Axle350
Rear Final Drive350
Excessive Noise350
Oil Leak350
Rear Axle Removal351
Gear Case Removal354
Backlash Inspection355
Gear Case Disassembly356
Gear Tooth Contact Pattern Check357
Drive Pinion Removal358
Drive Pinion Disassembly/Assembly359
Drive Pinion Installation363
Gear Case Assembly364
Gear Case Installation366
Rear Axle Installation367
Rear Drive Shaft370
Battery/Charging System372
Battery Charging374
Battery Testing374
Battery Is Damaged or Has Low Power375
Battery377
Voltage Inspection377
Charging System Inspection380
Regulated Voltage Inspection380
Current Leakage Inspection381
Alternator Charging Oil382
Regulator/Rectifier383
System Inspection383
Ignition System384
No Spark at Plug387
Ignition System Inspection388
Ignition Coil Primary Peak Voltage388
Ignition Pulse Generator Peak Voltage389
AC Sensor Line390
Ignition Oil391
Ignition Pulse Generator391
Ignition Timing392
Electric Starter394
Starter Motor Does Not Turn396
Starter Motor Turns Engine Slowly396
Starter Motor Turns, but Engine Does Not Turn396
Starter Motor and Engine Turns, but Engine Does Not Start396
Starter Motor397
Starter Relay Switch401
Operation Inspection401
Continuity Inspection401
Lights/Meters/Switches402
Light Does Not Come on When Light Switch Is Turned on404
Headlight Beams Do Not Shift When Dimmer Switch Is Operated404
Combination Meter405
The Speedometer Operates Normally, but the Hour Meter or Odometer/Tripmeter Does Not Operate405
The Hour Meter or Odometer/Tripmeter Operates Normally, but the Speedometer Does Not Operate405
Oil Cooling System407
Oil Warning Indicator Does Not Go off407
Oil Warning Indicator Does Not Come On, When the Oil Is over the Specified Temperature407
Cooling Fan Motor Does Not Start, When the Oil Is over the Specified Temperature408
Cooling Fan Motor Does Not Stop409
Taillight411
Bulb Replacement411
Speed Sensor413
Removal ('98-'01)413
Speed Sensor Removal (after '01)414
Front Final Clutch Speed Sensor Removal (after '01)415
Accessory Socket415
Ignition Switch417
Handlebar Switches417
Dimmer Switch417
Engine Stop Switch417
Neutral/Reverse Switch418
2WD/4WD Switch (after '01)418
Cooling Fan Control Unit419
Oil Thermosensor419
Carburetor Heater420
Electric Shift Program (ESP)422
System Diagram ('01)422
System Diagram (after '01)423
Troubleshooting ('98-'01)425
Troubleshooting Feature425
Before Troubleshooting425
Electric Shift Does Not Operate425
Electric Shift Malfunction During Vehicle Operation431
Gear Position Indicator Operates Abnormally432
Electric Shift Does Not Operate When Engaging the Reverse Gear434
Control Motor Turns When the Shift Switch Is Pushed down with the Reverse Selector Not Operated435
Troubleshooting (after '01)436
Troubleshooting Procedure436
Diagnosis Table437
Gear Indicator Problem438
Problem Code 1: ECU (Writing and Recording Circuit)440
Problem Code 2: es Shift Switch System (up and Down)440
Problem Code 3, 8, 9: Angle Sensor System441
Problem Codes 4 or 12: Gear Position Switch System443
Problem Code 5: ECU Motor Driver Circuit444
Problem Code 6: ECU Fail-Safe Circuit or Problem Code 7: ECU Voltage Convert Circuit445
Problem Code 10: Ignition Pulse Generator System446
Problem Code 11: Speed Sensor System (Vehicle Speed)447
Angle Sensor448
Neutral Resistance448
Shift-Up Resistance448
Shift-Down Resistance448
Control Motor450
Recommended Grease451
Gear Position Switch Inspection452
Shift Switch Inspection453
Reverse Shift Switch Inspection453
Main Relay ('98-'01)453
Selectable 4WD System (after '01)454
4WD Indicator Problem Code 2: Front Final Clutch Speed Sensor457
4WD Indicator Problem Code 3: Meter Speed Sensor459
4WD Indicator Problem Code 4: FCC Unit System Voltage461
4WD Indication Problem Code 5: FCC Unit Driver462
4WD Indicator Problem Code 6: Alternator463
Trx450S ('98 - '01)465
Wiring Diagram466
Trx450Es ('98 - '01)467
TRX450FM (after '01)469
Wiring Diagram TRX450FE (after '01)471
Technical Features473
Component Diagram474
Description of Major Components475
Electronic Control Unit475
Construction477
Operation (at Front Differential)478
2WD Torque Transmission478
4WD Torque Transmission478
Troubleshooting479
Engine Does Not Start or Is Hard to Start479
Engine Lacks Power480
Poor Performance at Low and Idle Speed481
Poor Performance at High Speed482
Poor Handling482
Index483

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Honda TRX450ES/FE Specifications

General

Brand	Honda
Model	TRX450ES/FE
Category	Offroad Vehicle
Language	English

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Honda TRX450ES/FE - User Manual

Table of Contents

Honda TRX450ES/FE Specifications

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