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Honda TRX680FA Service Manual

Honda TRX680FA
567 pages
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2006
SERVIC
ANUAL
RX680FA/FGA
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Table of Contents

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Honda TRX680FA Specifications

General IconGeneral
BrandHonda
ModelTRX680FA
CategoryOffroad Vehicle
LanguageEnglish

Summary

A Few Words About Safety

Service Information

Explains manual's intended audience, risks, and necessary precautions.

For Your Safety

General safety advice for technicians regarding vehicle service.

Important Safety Precautions

Lists specific safety practices to follow during service.

HOW TO USE THIS MANUAL

Safety Messages

Explanation of DANGER, WARNING, and CAUTION signal words.

NOTICE

Explanation of NOTICE messages regarding vehicle property or environment.

SYMBOLS

1. GENERAL INFORMATION

SERVICE RULES

Rules for performing service and maintenance on the vehicle.

MODEL IDENTIFICATION

Shows vehicle and engine serial number locations.

GENERAL SPECIFICATIONS

Lists overall dimensions and frame specifications.

2. TECHNICAL FEATURES

PCM (POWERTRAIN CONTROL MODULE)

Explains PCM function and control systems for engine and drivetrain.

PGM-FI SYSTEM

Describes the fuel injection system, its components, and operation.

DRIVETRAIN SYSTEM

Overview of the Automatic Transmission and selectable 4WD systems.

3. FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION

General info on body panel and exhaust system service.

BODY PANEL LOCATIONS

Identifies and illustrates the locations of various body panels.

TRIM CLIP

Procedure for removing and installing trim clips.

4. MAINTENANCE

MAINTENANCE SCHEDULE

Recommended maintenance intervals for various items.

SERVICE INFORMATION

General maintenance procedures and specifications.

ENGINE OIL

Details on checking and changing engine oil.

5. LUBRICATION SYSTEM

SERVICE INFORMATION

Covers oil pump and oil cooler service procedures.

SPECIFICATIONS

Lists engine oil capacity, recommended oil, and pressure specs.

TORQUE VALUES

Torque specifications for oil pump components.

6. FUEL SYSTEM (PGM-FI)

SYSTEM COMPONENTS

Exploded view of fuel system and air cleaner components.

SERVICE INFORMATION

General info on fuel system, fuel supply, and air cleaner service.

SYMPTOM TROUBLESHOOTING

Troubleshooting guide for various fuel system symptoms.

7. COOLING SYSTEM

SERVICE INFORMATION

General information and safety precautions for the cooling system.

SPECIFICATIONS

Coolant capacity, pressure, thermostat, and antifreeze specifications.

COOLANT REPLACEMENT

Procedure for replacing coolant and bleeding air from the system.

8. ENGINE REMOVAL/INSTALLATION

SYSTEM COMPONENTS

Exploded view of engine mounting components.

SERVICE INFORMATION

General notes and specifications for engine removal and installation.

ENGINE REMOVAL

Step-by-step procedure for removing the engine from the frame.

9. CYLINDER HEAD/VALVE/CAMSHAFT

SYSTEM COMPONENTS

Exploded view of cylinder head, valve, and camshaft components.

SERVICE INFORMATION

General information and specifications for cylinder head service.

CYLINDER COMPRESSION

Procedure for checking cylinder compression.

10. CYLINDER/PISTON

SYSTEM COMPONENTS

Exploded view of cylinder and piston assembly.

SERVICE INFORMATION

General information and specifications for cylinder and piston service.

CYLINDER/PISTON REMOVAL

Procedure for removing the cylinder and piston.

11. ALTERNATOR/STARTER CLUTCH

SYSTEM COMPONENTS

Exploded view of alternator, starter stator, and clutch components.

SERVICE INFORMATION

General information and specifications for these systems.

RECOIL STARTER

Procedure for removal and replacement of the recoil starter.

12. SUB-TRANSMISSION/GEARSHIFT LINKAGE

SYSTEM COMPONENTS

Exploded view of sub-transmission and gearshift linkage.

SERVICE INFORMATION

General information and specifications for sub-transmission and linkage.

TROUBLESHOOTING

Troubleshooting guide for shifting issues.

13. CRANKCASE/CRANKSHAFT/BALANCER

SYSTEM COMPONENTS

Exploded view of crankcase, crankshaft, and balancer.

SERVICE INFORMATION

General info and specifications for crankcase, crankshaft, and balancer.

CRANKCASE SEPARATION

Procedure for separating the crankcase halves.

14. DRIVETRAIN SYSTEM

SYSTEM COMPONENTS

Exploded view of drivetrain system components.

SERVICE INFORMATION

General info on A/T, selectable 4WD, and torque converter service.

SYMPTOM TROUBLESHOOTING

Troubleshooting guide for various drivetrain system symptoms.

15. FRONT WHEEL/SUSPENSION/STEERING

SYSTEM COMPONENTS

Exploded view of front wheel, suspension, and steering parts.

SERVICE INFORMATION

General information on front wheel, suspension, and steering service.

FRONT WHEEL

Procedure for removal and installation of the front wheel.

16. REAR WHEEL/SUSPENSION

SYSTEM COMPONENTS

Exploded view of rear wheel and suspension parts.

SERVICE INFORMATION

General information on rear wheel and suspension service.

REAR WHEEL

Procedure for removal and installation of the rear wheel.

17. BRAKE SYSTEM

SYSTEM COMPONENTS

Exploded view of front and rear brake system components.

SERVICE INFORMATION

General information and precautions for brake system service.

BRAKE FLUID REPLACEMENT/AIR BLEEDING

Procedure for replacing brake fluid and bleeding the system.

18. FRONT DRIVING MECHANISM

SYSTEM COMPONENTS

Exploded view of front driving mechanism parts.

SERVICE INFORMATION

General info on gear contact pattern and backlash.

FRONT DRIVE SHAFT

Procedure for removal and disassembly of the front drive shaft.

19. REAR DRIVING MECHANISM

SYSTEM COMPONENTS

Exploded view of rear driving mechanism parts.

SERVICE INFORMATION

General info on rear gear case and backlash inspection.

REAR DRIVE SHAFT

Procedure for removal and disassembly of the rear drive shaft.

20. BATTERY/CHARGING SYSTEM

COMPONENT LOCATION

Location of battery, alternator, and regulator/rectifier.

SERVICE INFORMATION

General information and safety precautions for the battery.

TROUBLESHOOTING

Troubleshooting for battery and charging system issues.

21. IGNITION SYSTEM

COMPONENT LOCATION

Location of ignition system components.

SERVICE INFORMATION

General information and safety for ignition system service.

TROUBLESHOOTING

Troubleshooting guide for ignition system faults.

22. ELECTRIC STARTER

COMPONENT LOCATION

Location of starter system components.

SERVICE INFORMATION

General information on starter motor service.

TROUBLESHOOTING

Troubleshooting for starter motor issues.

23. LIGHTS/METERS/SWITCHES

COMPONENT LOCATION

Location of lights, meters, and switches.

SERVICE INFORMATION

General information and color codes used in the section.

HEADLIGHT

Procedure for headlight bulb replacement.

24. WIRING DIAGRAM

TRX680FA/FGA

The main wiring diagram for the vehicle.

25. TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START

Troubleshooting steps for starting problems.

ENGINE LACKS POWER

Troubleshooting steps for engine power loss.

POOR PERFORMANCE AT LOW AND IDLE SPEED

Troubleshooting for issues with low speed and idle performance.

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