2004-2014 Honda TRX450RER Service Repair Manual Instant Download

1
2004-2014
SERVICE MANUAL
2
HOW TO USE THIS MANUAL This senses manual
describes the service procedures lor the TRX450R/
ER. Follow the Maintenance Schedule (Section 4)
Recommendations to ensure that the vahicle is in
peak operating condition and tha emission lx/els
are within the standards sat by Ihe U.S.
Environmental Protection Agency (EPA) and
California Air Resources Board (CARB). Performing
the first scheduled maintenance is very
important. It compancates for the initial wear
that Cltxxirs during tho brea1-in period.
CONTENTS GENERAL INFORMATION TECHNICAL FEATURES
Sections and 4 apply to the whole particle.
Section 3 illustrates
procedures for removal/inctallation of components
that rriay be required
LUBRICATIOFI SYSTEM (04 - 05) LUBRICATION
SYSTEM (After 05)
to perlbrm sarVice descrlboa in the fpitowing
sections. Seoions S through 25 dascribe parta of
the vehicle, grouped eccording IO lO08tiOFi.
Find the section you want on this page, than turn
to the table of contents on the first page of ihe
secM. Most sections start with an assembly or
system illustration, service information and
troubleshooting Mr the section. The subsequent
pages give detail procedure. If you are not
famlliar with this vehicle, read Technical
Features in Section 2. If you don'i know me
sourca of the trouble, go to section 26
Troubleshooting.
FUEL SYSTEM (04 - 05)
COOLING SYSTEM ENGINE REMOVAMNSTALLATION CYLINDER
HEADNALVES CYLINDER/PISTON

• Your safety, and the safety of othars, is very
  important. To help you make inlormad docision9 we
  have provided 8afaty messages and other
  information \hrcughout jhis manual. Of course,
  it is not practical or possible to warn you about
  all tha hazards associated with servicing this
  vehicle.
• Ybu must use yiur own good judgement.
• You will find important safaty information in a
  variety ol forms
• Safety Labels - on the vehicle
• Safety Messages pr0cedad by a safety alart
  symbol 3\ and one of thraa signal words, DANGER,
  WARNING, or CAUTION. Thase signal word6 mean
• You WILL be KILLED or SERIOUSLY
• HURT If you don't kilbw instructions.
• Ybu CAN be XILLED or SERIOUSLY HURT
• if you don't follow instructions.
• You CAN be HURT if you don't follow instructions.
• instructions - how to 6arvice this vehicle
  correctly and safely.
• As you read this manual, yov will find
  information ihat is preceded ay a symbol. The
  purpose of this message is to help prevent
• damage to your v0hfile, other property, or the
  environment.

CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
04 - '05
CLUTCH/STARTER CLUTCH/KiCKSTARTER/
GEARSHIFT LINKAGE After 05
CRANXCASE/TRANSMlSSlOM/CRANKSHAFT/
BALANCER
CRANKCASE/TRANSMISSION/CRANKSHAFT/
BALANCER After FRONT WHEEL/SUSPENSION/STEERING REA
R WHEEL/SUSPENSION HYDRAULIC BRAKE
ELECTRICAL (04 - 05)
BATTERY/CHARGING SYSTEM TRX450ER) IGNITION
SYSTEM (After 05) ELECTRIC STARTER (TRX450ER)
LIGHTS/SWITCHES (After 05) WIRING DIAGRAMS
3
SYMBOLS The symbols used throughout this manual
show specific servica procedures. If
supplementary information is required pei1aining
to these symbols, it would be explained
specifically In the text without the use of the
symbols. Raplace the part(s) with new one(s)
bafore aseembly Uäe the recomrñended engine
oil, unlese otherwise specified. Use molybdenum
oil solution (mixturo of the engine oil and
molybdenum grease in a raêo.of 1ï) Use
multi-purposù gæase.(lithium based multi-purpose
grease NLGI. ñ2 or aquivalerit). Uee molybdenum
disulfide grease (containing more than 39a
molybdenum diaulfide, NLGI /f2 or
aquivalem). Example MolykotW BR-2 plus
manufactured by Dctw Corning U.S.A. Mukl-purpose
M-2 manufacturad by Mitsubishi.Oil, Japan Use
.molybdenum disulfide paete (œntaining moæ that
qo_at_ motybdenum disulfîde, NLGI 1 or
equivaleñt). Example MOlgkotW. G-n PaBt0
manufactured by Dow Coming U.S.A. Honóa Móly 60
(U.S.A. only) Roúol ASP manufactured by Rocol
Limited, U,K. Rocol Paate rnanufactured by Sumico
Lubricant, Japari Use silicone gææa. Apply a
locking agent. Uae a.medium strengtb fucking
agent ünleës otherwise specified. Apply sealant.
Use DOT 4 bæke fluid. Use the recommended brake
fluid unlees otherwiae apecified.. Use fork or
suspension fluid.
4
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1. GENERAL INFORMATION
CRANKCASE/TRANSMISSION/ CRANKSHAFT
SPECIFICATIONS (g gg)..........................
......................... 1.jg CRANKCASE7TRANSMIS
SION/ CRANKSHAFT SPECIFICATIONS (jI\try
').............................................
..... qg FRONT WHEEL/SUSPENSION/ STEERING
SPECIFICATIONS -- - 1-16 REAR
WHEEL/SUSPENSION

• MODEL IDEMTIFKATION (04 - 07) 1-2
• MODEL IDENTIFICAWON (After 07)------ 1N
• GENERAL SPECIFICATIONS (04 - 05) 1-7
• GENERAL SPECIFICATIONS (06 - 07) 1-8
• GENERAL SPECIFICATIONS (After 07) 1-9
• LUBRICATION SYSTEM
• SPECIFICATIONS----- -----
  1-11
• FUEL SYSTEM
• SPECIFICATIONS (04 - 05)-- ---------- -
  1-t1
• FUEL SYSTEM
• SPECIFICATIONS (After 05)- - -------- 1-12
• COOLING SYSTEM SPECIFICATIONS - 1-12
• CYLINDER HEAD/VALVE/CAMSHAFT
• SPECIFICATIONS (04 - 05)-
  1-13
• CYLINDER HEAD/VALVE/CAMSHAFT
• SPECIFICATIONS (After 05)-1-13
  

SPECIFICATIONS
. 1-17
HYDRAULIC BRAKE SPECIFICATIONS - 1-17 ELECTRICAL
SPECIFICATIONS (g gg).......-..................
......................... 1.1 BATTERY/CHARGING
SYSTEM SPECIFICATIONS ITRX450ER) -
1-18 IGNITION SYSTEM SPECIFICATIONS (After
_at_/)..............................................
.... 1 _at_ ELECTRIC STARTER SPECIFICATIONS lTRx4so
ER)---------- --
----- 1-18 LIGHTS/SWITCH
SPECIFICATIONS (A y )...........................
....................... 1.19 STANDARD TORQUE
VALUES --- 1-20 ENGINE 8 FRAME
TORQUE VALUES-- 1-ZO LUBRICATION 8 SEAL POINTS
- 126 CABLE 8 HARNESS
ROUTING---- 1-29 EMISSION CONTROL
SYSTEMS ---- 1-49
CLUTCH/KICKSTARTER/GEARSH!FT
uNlacz sPciriCATIONS (gg g
).................................................
.. j.14
CLUTCH/STARTER CLUTCH/XICKSTARTER/ GEARSI4IFT
LINKAGE SPECIFICATIONS (After _at_g)
..................................................
.1.5
1-1
6

• GENERAL INFORMATION
• SERVICE RULES
• Use genuine Honda or Honda-recommended parts and
  lubricants or their equivalents. Parts that do
  not meet Honda's design specifications may cause
  damage to the vehicle.
• Use the special tools designed for this product
  to avoid damags and incorrect assembly.
• Use only metric tools when servicing the vehicle.
  Metric bolts, nuts and screws are not
  interchangeable with English fasteners.
• Install new gaskets, O-rings, cotter pins, and
  lock plates when reassembling.
• When tightening bolts or nuts, begin with the
  larger diameter or inner bolt first. Then tighten
  to the specified torque diagonally in incremental
  steps unless a particular sequence is specified.
• Clean parts in cleaning solvent upon disassembly.
  Lubricate any sliding surfaces before reassembly.
• After reassembly, check all parts for proper
  installation and operation.
• Route all electrical wires as shown in the Cable
  and Harness Routing (page 1-29).
• MODEL IDENTIFICATION (04 - 07)
• 04 - '05 modet shown, After 05 model similar

The model identification label is located on the
left front frame pipe.
MODEL IDENTIFICATION LABEL
1-2
7
GENERAL INFORMATION
The vehicle identification num ber (VIN) is
stamped on the front side of the frame.
VIN
The eng ine serial num ber is slamped on the left
side of the cran kcase.
E NGINE SERIAL NUMBER
The carburetor identification num ber is stamped
on the left side of lhe carburelor body.
04 - 05 The Vehicle Emission Control
Information Label is attached on the right front
frame pipe (U.S.A. onIy).
EMISSION CONTROL INFORMATION LABEL
1-3
8
GENERAL INFORMATION
After 05 The Vehicle E mission Control
Information Label is attached on the right side
of the fronl frame pipe (U.S.A. only).
After '05 U.S.A. only
The color label is attached on ihe left side of
the front frame pipe. When ordering color coded
parts, always specify the designated color code.
MODEL lDENTlFiCATlON (AKer 07)
1-4
9
GENERAL INFORMATION
08 The model identification label (IJ. S.A.
type) or safety certi ficalion label (Canada
type) is located on the right front frame pipe.
MODEL IDENTIFICATION LABE L (U.S.A
type) SAFETY CERTIFICATION LABEL (Canada type)
After 08 The certification label (U.S.A. type)
is located an atlached on the right side of the
front fra me pipe.
CERTIFICATION LABEL (U.S.A type)
After on The safety certification label (Canada
type) is located on the right fro nt frame pipe.
SAFETY CE R TIFICATION LABE L (Canada
type)
The vehicle identification number (VIN) is
siamped on the front side of the frame.
1-5
10
GENERAL INFORMATION The engine serial number is
stamped on ihe left side of the crankcase.
ENGINE SERIAL NUMBER
The carburetor identification number is stamped
on the left side of the carburetor body.
CARBURETOR IDENTIFICATION NUMBER
The Vehicle Emission Control Information Label is
attached on the right side (U.S.A.) or both sides
(Canada) of fronl frame pipe.
M SSION CONTROL INFORMATION LABEL (U.S.A. and
Canada) EMISSION CONTROL INFORMATION
LABEL (Canada)
The color label is attached on the left front
side of the upper suspen- sion bracket. When
ordering color coded parts, always specify the
des- ignated color code.
1-6
11
GENERAL INFORMATION
GENERAL SPECIFICATIONS (04 05)
ITÈM
SPECIFICATIONS
DIMENSIONS
.Overall length Overall width Overall height
Wheelbase Front tread Rear tread Seat height
1,846 mm (72.6 in)
1.177 mm (46.3 in) 1,108. mm (43.6 in) 1,251 mm
(49.2 in) 937 mrñ (36.8 in) 920 mm.136.2 in) 829
mm (32.6 in) 361 mm (14.2 in) 11.4 mm (4.5
in) 176 kg (388 lbs) 11.0 kg (243 lbs). Double
cradls
Footpeg height
Ground .clearance
Curb weight Maximum weight capacity Frame type
FRAME
Front suspension Front wheel travel Rear
suspension Rear whgel .trave! Rear damper Front
tire size Rear tira size Front rim size Rear
rim.siza Front tire.brand Rear tire brand Front
braLe Rear brake Caster angle Trail length
Camb'er angle Fuel tank capacity Fuel tank
reserve capacity " " Cyl nde rrangement Bore and
stroke Displacement Compression ratio Vslve
train Intake valve opens at 1 mm (0.04 in) lift
Intake valve closes at 1 mm (0.04 in) Ilfi
Exhaust valve.opes at 1 mm (0.04 in) lifi
Exhaust valve closes at 1 mm (0.04 in) lift
Lubrication system Oil pump type Cooling. system
Air filtration Engine dry weight hab etbo pe
Double wish-bone 215 mm (8.5 in) Swingarm 230 mm
(9.1 in) Single tube AT22 x 7R10 a a AT20 x.
J0R9.or a 1.0.x 5.5 AT 9 x B.0 AT DUNLOP KT37.1
DUNLOP KT335H Hydraulic.disc.brake
Hydraulic/mechanical disc brake 5.87 25.58 mm
(1.00.7 in) 0º 12.0 liters.T3.17 US gal, 2.64 Imp
gel) 1.9 liters 0.50 US gai, 0.42 Imp gal)
Single cyiinder, transversaly intalIed 94 x
64.8.mm (3.70 x 2.55 in) 449.7 cm (27.44
cu-in) 10.5 1 Chain drive and OHC with rocker
arm 10º BTDC 40º ABDC 40? BBDC 10º ATDC Forced
pressure (wet sump) Trochoid Liquid coolecl Oiled
urethane foarri 34.7 kg (76.8 lbs) Piston, valvs
' ENGINE
CARBURETOR
42 mm (1.65 in)
12
GENERAL INFORMATION
ITECt Clutch system Clutch operation system
Transmission Primary reduction Final reduction
Gear ratio
SPECIFICATIONS ñfulti-plaie, wet Cable
operated Constant mesh, 5-speed 2.739
(63/23) 2.714 (38/14) 2.071 (29/14) 1.625
(26/t6) 1.333(218 1.120(2B/25 0.963
126/27) Left foot operated return system,
1-N-2-3-4-5 ACCDI Triple phase output alternator
Trigle phase full wave rectification 12 V DC
outpui
DRIVE TRAIN
1st 2nd 3rd 4th Sth
Gearshift pattern Ignition system Charging system
Regulatorlractifier Lighting system
ELECTRICAL
GENERAL SPECIFICATIONS (06 - 07)
ITEM Overall length
SPECIFICATIONS 1,862 mm 173.3 in)
DIMENSIONS
1,177 mm (46.3 in) 1,100 mm (43.3 in) 1,275 mm
(50.2 in) 967 mm (38.1 in) 920 mm (36.2 in) 833
mm (32.8 in) 349 mm (13.7 inl 111 mm (4.4 in)
Overall width Overall height Wheelbase Front
tread Rear tread Saat height Footpag
height Ground clearance Curb weight TRX450ER
TRX450R Maximum weight capacity Frame type
178 kg \392 lbs) 175kg (386tbs) 110 kg (243 lbs)
Double cradle
FRAME
Front Suspension Front wheel travel Rear
suspension Rear wheel travel Rear damper Front
tire size Rear tire size Front rim size Rear rim
size Front tire brand Rear tire brand Front
brake Rear brake Caster angle Trail length Camber
angle Fuel tank capacity Fuel tank reserve
capacity
Double wish-bone
215 mm 8.5 in) Swingsrm 237 mm (9.3 in) Single
tube AT22 x 7R106 or AT20 x 10R9 a a 10 x 5.5
AT 9 x 8.0 AT DUNLOP KT371 DUNLOP
KT335H Hydraulic disc brake Hydraulic/mechanical
disc brake 5 23 mm (0.9 in) - 1.9 11.7 liters
T3.09 US gal, 2.57 Imp gal) 2.9 liters 10.77 US
gal, 0.64 Imp gal)
1-8
13
GENERAL INFORMATION
ITEM ITEM SPECIFICATIONS
ENGINE Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens at 1.mm (0.04 in) lift Intake valve closas at 1. mm (0.04 in) lift Exhaust valva opens at 1 mm (0.04 in) lift Exhaust valve closes at 1 mm (0.04 in) lift Lubrication system Oil pump type Cooling system Air filtration Engine dry waight TRX450ER TRX450R Single cylinder, transvarsely installed 96.0 x.62.1 mm (3.78 x 2.44 ia) 449.4 cm (27.42 cu-in) 12.0 Chain .drive and OHC with rocker arm 10 BTDC 40 ABDC 40 BBDC 10 ATDC Forced pressure Twet sump) Trochoid Liquid cooled Oiled. urethane foam 34.3 kg (75.6 lbs) 33.4 kg (73.6 IbsT
CARBURETOR Carburetor type Vanturi diameter Piston valve 40 mm (1.6 in)
DRIVE TRAIN Clutch syatem Clutch operation system Transmission Primary reduction Final reduction Gear rbtió 1st 2nd 3rd 4th Sth GearshiR pattern Muh-plate, wet Cable operated Constant mesh, 5-speed 2.739 (63/22) 2.923 (38/13) 2.230 (29/13) 1.785 (25/14) 1.437 (23/16) 1.t81 (26/22) 0.962 (26/27) Left foot operated raturn system, 1-N-2-3-4-5
ELECTRICAL Ignition system .Starting system Charging system Ragulator/rectifier Lighting system ACCDI Elemrid starter motor (TRX450ER) Kickñtârter \TRXd50R) Triple phase output alternator Triple phasa full wave rectification Battery (TRX450ER I 12 V DC output.(TRX450R\
GENERAL SPECIFICATIONS (AHer 07)
ITEM Overall length Dverall width Overall height
Wheelbase Frónt tread Rear tread Seat height
Footpeg height Ground clearance Curb
weight TRX450ER TRX450R Maximum weight capacity
SPECiFlCAf lONg 1,862 mm (73.3 in) 1,.177 mm
(46.3 in) 1,100 mm (43.3 in) 1,275 mm (502
in) 967 mm (38.1 in) 920 mm t36.2 in) 833 mm
(32.8 in) 349 mm (13.7 in) 111 mm (4.4 in)
DIMENSIONS
176 kg (388 Ibs) 173 kg (381 Ibs) 11ò kg (243 lbs)
1-9
14
u
GENERALINFORNIATION
ITEM ITEM SPEClRCATlONC
FRAME Frama type " Front suspension Front wheel traval Rear suspension Rear wheal traval Rear dampar Front tire siza Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caater anele Trail length Camber angle Fual tank capacity Fuel tank reserve capacity Double cradle Double wish-bone 215 mm (B.5 in) Svringarm 237 mm (9.3 in) Single tube AT21 x 7R10 Nr a. AT2O x 10R9 a a 10 x 5.5.AT 9 x.8.0 AT DUNLOP KT331H DUNLOP KT355H Hydraulic disc brake Hydraulic/machanical disc brake 5 23 mm (0.9 in) - 1.9 10.3 litars (2.72 US gal, 2.27 Imp gaI) 3.0 liters (0.79 US gal, 0.66 Imp gal)
ENGINE Cylinder anangament B'ore and stroka Displacement Compression ratio Vslvs train Imaks valve opens at 1 mm (Q.04 ml lift Intake valve closas at 1 mm (0.04 in) lift Exhaust valve opans at 1 mm (0.04 in) lift Exhaust valve cIoees.at 1 mm (0.04 in) lift Lubrication syaiem Oil pump type Cooling symem Air filtration Engine dry weight TRX450ER TfiX450R Sngle cylindar, transversely installed 96.0 x 62.1. mm (3.78 x 2.44 in) 449.4 crn (27.42 cu-in) 12.0 1 Cia\n driva and OHC with rocker arm 1ooaToc 40 ABDC 40 BBDC 10 ATDC Forced pressure (wet sump) Trochold Liquid cooled Óiled urethane foam 34.2 kg (75.4 lbs) 33.4 kg (73,8 lbsl
CARBURETOR Carburetor type Vanturi diameter Piston valve 40 mm (1.ô in)
DRIVE TRAIN Clutch ayatem Clutch.operation system Transmission Primary reduction Final reduction 1st 2nd 3rd 4th Sth Gsarshift pattern Multi-plata, wet. Cabla operated Constant mesh, 5-speed 2.719 (63/23) 2.923 (3B/13) 2.230 (29/13) 5.YB5 (25/14) 1.437 (23/16) 1.11 (26/22) 0.962 (20/27) Laft foot operated return syatem. 1-N-2-3-4-5
ELECTRICAL lgnition systam Starting system Charging system Regulator/rectifier Lighting system ACCDI Elamric atartsr motor (TRX45óER) Kickstarter (TRX450R) Triple phaae output.altsrnator Triple phase full wave remiflcation Battery (TRX450ER) 12 V.DC output (TRX450R)
1-10
15
GENERAL INFORMATION LUBRICATION SYSTEM
SPECIFICATIONS
I i EM STANDARD Engine oil 04 05 .Altar draining 0.78 liter (0.82 US qt, .0.87 lmp qt) capacity Aft filter change 0.82 liter (0.87 US qt, 0,72 Imp.qt) Afier disassembly 1.20. liter (1.27 US qt, 1.06 Imp qt) Afier 05 Afier draining 0.65 liter (0.69 US qt, 0.57 Imp. qt) Afier filtar change 0.69 liter (0.73 US qt, 0..6\ Imp qt) Aft d' embly 0.85 liter (0.90 US qt, 0.75.lmp qt) SERvicE uz/iiT
I i EM STANDARD Engine oil 04 05 .Altar draining 0.78 liter (0.82 US qt, .0.87 lmp qt) capacity Aft filter change 0.82 liter (0.87 US qt, 0,72 Imp.qt) Afier disassembly 1.20. liter (1.27 US qt, 1.06 Imp qt) Afier 05 Afier draining 0.65 liter (0.69 US qt, 0.57 Imp. qt) Afier filtar change 0.69 liter (0.73 US qt, 0..6\ Imp qt) Aft d' embly 0.85 liter (0.90 US qt, 0.75.lmp qt)
I i EM STANDARD Engine oil 04 05 .Altar draining 0.78 liter (0.82 US qt, .0.87 lmp qt) capacity Aft filter change 0.82 liter (0.87 US qt, 0,72 Imp.qt) Afier disassembly 1.20. liter (1.27 US qt, 1.06 Imp qt) Afier 05 Afier draining 0.65 liter (0.69 US qt, 0.57 Imp. qt) Afier filtar change 0.69 liter (0.73 US qt, 0..6\ Imp qt) Aft d' embly 0.85 liter (0.90 US qt, 0.75.lmp qt)
I i EM STANDARD Engine oil 04 05 .Altar draining 0.78 liter (0.82 US qt, .0.87 lmp qt) capacity Aft filter change 0.82 liter (0.87 US qt, 0,72 Imp.qt) Afier disassembly 1.20. liter (1.27 US qt, 1.06 Imp qt) Afier 05 Afier draining 0.65 liter (0.69 US qt, 0.57 Imp. qt) Afier filtar change 0.69 liter (0.73 US qt, 0..6\ Imp qt) Aft d' embly 0.85 liter (0.90 US qt, 0.75.lmp qt)
I i EM STANDARD Engine oil 04 05 .Altar draining 0.78 liter (0.82 US qt, .0.87 lmp qt) capacity Aft filter change 0.82 liter (0.87 US qt, 0,72 Imp.qt) Afier disassembly 1.20. liter (1.27 US qt, 1.06 Imp qt) Afier 05 Afier draining 0.65 liter (0.69 US qt, 0.57 Imp. qt) Afier filtar change 0.69 liter (0.73 US qt, 0..6\ Imp qt) Aft d' embly 0.85 liter (0.90 US qt, 0.75.lmp qt)
I i EM STANDARD Engine oil 04 05 .Altar draining 0.78 liter (0.82 US qt, .0.87 lmp qt) capacity Aft filter change 0.82 liter (0.87 US qt, 0,72 Imp.qt) Afier disassembly 1.20. liter (1.27 US qt, 1.06 Imp qt) Afier 05 Afier draining 0.65 liter (0.69 US qt, 0.57 Imp. qt) Afier filtar change 0.69 liter (0.73 US qt, 0..6\ Imp qt) Aft d' embly 0.85 liter (0.90 US qt, 0.75.lmp qt)
Recommended engine oil Pro Honda Ghl4 4-stroke.oil (U.S.A. and Canada) or equivalent mator oil API service classification SG or Higher JASO T 903 standard MA Viscosity SAE tOW-30
Transmis- 04 - 05 After draining 0.55 liter (0.SB US qt 0.48 Imp qt.) sion.oil After disassembly 0.65 liter.(0.69 Us qt 0.57.Imp qt) p'' After 05 After draining 0.68 litar (0.72 US qt, 0.60 Imp qt) After disassembly 0.80 litar (0.8B US qt, 0.70 Irnp qt) Recommended transmission.oil Pro Honda GN44-stroke oil (U.S.A. and Canada) or equivalent motor oil API service.classification SG or Higher JASO'T 903 standard MA Viscosity SAE 10W-30 Oil pump rotor Tip clearance 0.15 (0.006) Body clearance o.1s o.21 o.oos o.ooze Side clearance (04 - 05) 0.05 0.1.3 (0..002 0.005) Side clearance (After05) 0.04 0.1.3 (0.002 0.005)
Transmis- 04 - 05 After draining 0.55 liter (0.SB US qt 0.48 Imp qt.) sion.oil After disassembly 0.65 liter.(0.69 Us qt 0.57.Imp qt) p'' After 05 After draining 0.68 litar (0.72 US qt, 0.60 Imp qt) After disassembly 0.80 litar (0.8B US qt, 0.70 Irnp qt) Recommended transmission.oil Pro Honda GN44-stroke oil (U.S.A. and Canada) or equivalent motor oil API service.classification SG or Higher JASO'T 903 standard MA Viscosity SAE 10W-30 Oil pump rotor Tip clearance 0.15 (0.006) Body clearance o.1s o.21 o.oos o.ooze Side clearance (04 - 05) 0.05 0.1.3 (0..002 0.005) Side clearance (After05) 0.04 0.1.3 (0.002 0.005) 0.20 (.0.008)
Transmis- 04 - 05 After draining 0.55 liter (0.SB US qt 0.48 Imp qt.) sion.oil After disassembly 0.65 liter.(0.69 Us qt 0.57.Imp qt) p'' After 05 After draining 0.68 litar (0.72 US qt, 0.60 Imp qt) After disassembly 0.80 litar (0.8B US qt, 0.70 Irnp qt) Recommended transmission.oil Pro Honda GN44-stroke oil (U.S.A. and Canada) or equivalent motor oil API service.classification SG or Higher JASO'T 903 standard MA Viscosity SAE 10W-30 Oil pump rotor Tip clearance 0.15 (0.006) Body clearance o.1s o.21 o.oos o.ooze Side clearance (04 - 05) 0.05 0.1.3 (0..002 0.005) Side clearance (After05) 0.04 0.1.3 (0.002 0.005)
Transmis- 04 - 05 After draining 0.55 liter (0.SB US qt 0.48 Imp qt.) sion.oil After disassembly 0.65 liter.(0.69 Us qt 0.57.Imp qt) p'' After 05 After draining 0.68 litar (0.72 US qt, 0.60 Imp qt) After disassembly 0.80 litar (0.8B US qt, 0.70 Irnp qt) Recommended transmission.oil Pro Honda GN44-stroke oil (U.S.A. and Canada) or equivalent motor oil API service.classification SG or Higher JASO'T 903 standard MA Viscosity SAE 10W-30 Oil pump rotor Tip clearance 0.15 (0.006) Body clearance o.1s o.21 o.oos o.ooze Side clearance (04 - 05) 0.05 0.1.3 (0..002 0.005) Side clearance (After05) 0.04 0.1.3 (0.002 0.005)
Transmis- 04 - 05 After draining 0.55 liter (0.SB US qt 0.48 Imp qt.) sion.oil After disassembly 0.65 liter.(0.69 Us qt 0.57.Imp qt) p'' After 05 After draining 0.68 litar (0.72 US qt, 0.60 Imp qt) After disassembly 0.80 litar (0.8B US qt, 0.70 Irnp qt) Recommended transmission.oil Pro Honda GN44-stroke oil (U.S.A. and Canada) or equivalent motor oil API service.classification SG or Higher JASO'T 903 standard MA Viscosity SAE 10W-30 Oil pump rotor Tip clearance 0.15 (0.006) Body clearance o.1s o.21 o.oos o.ooze Side clearance (04 - 05) 0.05 0.1.3 (0..002 0.005) Side clearance (After05) 0.04 0.1.3 (0.002 0.005)
FUEL SYSTEM SPECIFICATIONS (04 - 05)
fTEM Carburetor identification number 6PECIFICATIONG
fTEM Carburetor identification number DA16A
Main jet SIOw jet Main jet SIOw jet 118 48 118 48
Pilot screw opening Float level " Pilot screw opening Float level " See page 7-23. See page 7-23.
Pilot screw opening Float level " Pilot screw opening Float level " 15.9 mm (0.63 in) 15.9 mm (0.63 in)
Idle speed Idle speed 1,600 t 100 rpm 1,600 t 100 rpm
Throttle grip freeplay Throttle grip freeplay 3 8 mm (1/8 5/16 in) 3 8 mm (1/8 5/16 in)
Hot starter lever freeplay Hot starter lever freeplay 2 3 mm (1/16 1/8 in) 2 3 mm (1/16 1/8 in)
1-11
16
GENERAL INFORMATION FUEL SYSTEM SPECIFICATIONS
(Aker 05)
ITEM ITEM ITEM SPECIFICATIONS
Carburetor ioentification number 06 model I HX450ER FCR 10A
Carburetor ioentification number 06 model TR x450R FCh11A
Carburetor ioentification number 07 model TR X450ER FCR10B
Carburetor ioentification number 07 model TRX450R FCRIIB
Carburetor ioentification number After '07 I i-tX450ER FCf410C
Carburetor ioentification number After '07 TRX450R FCR11C
Main jet Main jet 06 07 120
Main jet Main jet Afir '07 122
Slow et Slow et 42
Starter jet Starter jet /5
Jet needle Jet needle 06 model NHHU
Jet needle Jet needle After 06 NJBU
Pilot screw initial openi ng Pilot screw initial openi ng 06 07 2-3/8 turns out
Pilot screw initial openi ng Pilot screw initial openi ng After 07 2 turns out
Float level Float level Float level 8.0 mm (0.31 in)
Idle speed Idle speed Idle speed ,700 100 rpm
Throttle grip freeplay Throttle grip freeplay Throttle grip freeplay 5 10 mm (7.32 3/8 in)
Hot starter lever freeplay ITRX450R) Hot starter lever freeplay ITRX450R) Hot starter lever freeplay ITRX450R) 2 - 2 mm (1/1d 1/8 in)
COOLING SYSTEM SPECIFICATIONS
ITEM ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 1.5 liters (1.6 US qt, 1.3 Imp qt
Coolant capacity Reserve lank 0.34 liter (0.36 US qt, 0.30 Imp qt)
Radiator Cap relief pressure Radiator Cap relief pressure 108 - 137 kPa (1.1 1.4 kgf/cm, 16 20 psi)
Thermostat Beg in to open 80 84'C (176 - 183F)
Thermostat Fully open 95C (203F)
Thermostat Valve lift 8 mm (0.3 i n) minimum
Recommended antlfreeze Recommended antlfreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibilors
Standard coolant concentraiion Standard coolant concentraiion 11 mixture with distilled water
1-12
17
GENERAL INFORMATION CYLINDER HEAD/VALVE/CAMSHAFT
SPECIFICATIONS (04 - 05)
Unit mm (iñ SERVICE MMIT
ITEM
STANDARD 745 kPa (.7.6 kgf/cm, 108 psig
Cylindar compress Valve clearance
IN EX
I 0.16 0.03 t0.006 0.001.) 0.28.10.03.10.011 0
001)
Decompressor clearance
""
Ri.ght side exhaust valve clearancs
0.15 z 0.02 mm I0,OO6 0.001 in) 5.475 -5.490
(0.2156 -0.2161)
IN EX
Valve, Valve stern O.D. valye guïde Valve guide
I.D. Stern-to-guide clesrance
5.46 \0.215) 5.44(0.214)
5.455 - 5.470 (0.2148 0.2154) 5.5005.512
(0.21.65 -0.2\70)
INDEX
552 (0.2171 0.12 (0.005)
IN EX
0.010 0.037 (0.00040.0015) 0.030 0.057 (0.0012
0.0022)
0.14 (0.006)
Valve guide projection above IN cytinde head

16.8 J7.2(0.660.68) " )T.9- l8.3D.70-0.72)
-
Valve seat width
2.0 (0.08)
1.1 1.3 (0.043 0.051) 1.3 1.6 (0.051 0.0S9)
2.0 (0.08) 39.7 (1.56)
Valve spring
Free length
Ï IN EX
40.68 (1.602J 43.16 ft.699)
42.2 (1.66) 1.2.05 (0.474)
Exhaust rocker arm
Arm I.D. Shaft O.D.
" " 12.000 12/018 (0,.4724 04731)
11.967 11.975 (0.4711 0.47.15) 0.025 -.0.051
(0.0010 0.0020)
1J..92 \0.469) 0.10 (0.004)
Arm-to-shaft clearance
CamshaC
Cam lobe height
IN EX
36.63.0 - 36.790 (1.442Î 1.44B4I
/fi.48 (1.436)
I
34.753 - 34.913 \1.3682 1.3745) " 25.978
25.993 \1.0228 J.0233)
34.60 (1.362) 2597 (1.022)
Valve lifter O.D.
Valve lifter bore I.D. 26010 - 26.026 (1.0240
1.0246.1
26.04 (1/025.) 0.05 IÖ.002)
Cylinder head warpage
CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS (AHer
05)
Unit mm (in SERVICE LIMIT
ITEM Cylinder cömpression
STANDARD -a82 kPa 3.5 3.9 kgf/cm, 343
441.kPa (3 4 5 kgf c ,
T 45I?EFI
06 07
After 07
TRX450R
961 1000 kPa (9.8 10.2 kgf/cm, 139 145
psi) 0.16 0.03 (0.006 0.001)
IN EX
Valve clearance
0.28 O.03 IO.OII 0.0O1) Right s.ide exha.u.st
vaive clearanc.e

Decompressor clearance (TRX460R and 06 07
TRXô50ER)
025 0.02 mm (0.010 -L 0.001 In) 5.475
5.490 (0.2156 0.2161)
IN EX
21 ) 4.96 (0.195) Si.52 (0.217)
Valve stern O.D,
Valve, valve güide
4965 - 4.980 0.1955 0.1961) 5.500 S.512
10.2165 0.2170)
IN EX
Valve guide I,D.
5.000 5.012 (0196S 0.1973) 0.0t.0
0.037(0.0004 0.00.15)
5.052 10.1989) 0.12 (0.0051
Stem-to-guide " clearance
IN EX
0..020 - 0.047 CO.0008 0.0019) 16.1 16.3
(0.63 0.64)
0.13 (0.005)
Valve guide projection above
IN EX
cylinder head Valve sest width

17.9 18/1 (0.70 0.71) 1.1 1.3 (.0.043 0.05t
I
IN
2.0 (0.08)
EX
2.0 t0.08)
1.3. 15 0.051 0.059) IN 406B T1,602)
Free length
Valve spring. Exhaust
39.7 \1.56)
EX
42.82 1.686) 12.000 12.018 (0.4724 0.4731)
" 42.2.(1.66) 12.05 (0.474)
Arm I.D. .shaft O.D.
rocker
11.sg7 1t.875 (0.4711 0,4715) .0.025 0.051
(0.0010 0.0020)
11.92 0.469) 0.1Ô (0.004)
i
Arm-to-shaft clearance
Camshaft Cam lobe height
IN EX
35.040 35.2B0 (1.3795 1.3890) 34.214 34.454
11.3470 1.35651
' 34.89 II.374) 34.06 (1.341)
25.978 25.993 \1.0228 1.0233) 26.010 26.026
(1.D240 1.O24ô)
25.97 (1.022) 26.04 (1.025)
Valve lifter O.D.
Valve.lifter bore I.D. Cylinder head warpage
-
0.05 (0.002)
1-13
18
GENERAL INFORMATION CYLINDER/PIGTON
SPECIFICATIONS (04.- 05)
Unit mm in Unit mm in Unit mm in Unit mm in Unit mm in
ITEM ITEM ITEM GTANDAI3D SERVICE LIMIT
CylindBr l.D. l.D. 94,000 94.015 (3..7008 - 3.7Ò14) 94.05 (3.703)
CylindBr Out-of-round Out-of-round 0.05 (0002)
CylindBr Taper Taper 0.05 10.002)
CylindBr 0.05 10.002)
Piston, piston pin, p' B Piston O.D. at 20 10.81 from bottom Piston O.D. at 20 10.81 from bottom 93.960 -93.990(.3.6992 -3.7004) 93.86 (3.695)
Piston, piston pin, p' B Piston pin hola I.O. Piston pin hola I.O. 21.002 -21.008 t0.8268 - 0.8271) 21.03 (0.828)
Piston, piston pin, p' B Piston pin O.D. Piston pin O.D. 20.994 - 21.000 (0.8265 0.8268) 20.ss io.a2gi
Piston, piston pin, p' B Piston-to-piston pin clearance Piston-to-piston pin clearance 0.002 - 0.014 (0.0001 0.0006) 0.04 (0.002)
Piston, piston pin, p' B Piston ring end Tog gap Second Piston ring end Tog gap Second 0.20 - 0.35 (0.008 0.0.14) 0.35 0.50(0.0J4 0.020) 0.50 10.020) 0.65 (0,026)
Piston, piston pin, p' B I oii hae cii o.zo -o.jo la.oos o.ons 0.9.(0.04)
Piston, piston pin, p' B Piston ring-to-ring groovo elaarsnce Top 0.065 - 0.100 (0.0026 - 00039) 0.115 (0.0045)
Piston, piston pin, p' B Piston ring-to-ring groovo elaarsnce Second 0.030 0.080. f0.0012 0.0024) 0.075 (0.0030)
Cylinder-to-piston clearance Cylinder-to-piston clearance Cylinder-to-piston clearance 0.010 0.055 IO.0004 0.0022 0.19 t0.0071
Connecting rod small end I.D. Connecting rod small end I.D. Connecting rod small end I.D. 21.016 21.034.(0.8274 0.8281) 21.04 (0.828)
Connecting rod-to-piston pin clearance Connecting rod-to-piston pin clearance Connecting rod-to-piston pin clearance .0.018 0.040 (0.0006 - 0 6) 0.06 (0.002)
CYLINDER/PISTON SPECIFICATIONS (Afier 05)
.Unit mm. (in)
ITM ITM ITM tsrANDARD SERVICE MMIT SERVICE MMIT
Cylinder I.D. I.D. 96.000 - 96.0J5 (3.7795 - 3.7801) 96.05 t3.781) 96.05 t3.781)
Cylinder Out-of-round Out-of-round 0,05 (0.002) 0,05 (0.002)
Cylinder Taper Taper 0.05 (0.002) 0.05 (0.002)
Cylinder Warpaga Warpaga 005 (0.002) 005 (0.002)
Piston, Piston O.D. at1O 10.4) from boxom Piston O.D. at1O 10.4) from boxom 95.970 -95.580 13.77833.7787) 95.87 13.7741
pistoFl piFl, piston ring Piston pin hole I.D. Piston pin hole I.D. 19.002 19.008 10.74B1 ò.7483) 19.03 (0,7491 "
pistoFl piFl, piston ring pju di O.D. pju di O.D. 8.994 19.000 (0.7478 0,7480 18.SB 10.747) 18.SB 10.747)
pistoFl piFl, piston ring Piston-to-piston pin clearance.. Piston-to-piston pin clearance.. 0002 - 0.014 (0.0001 - 0.0006) 0.04 (0.Ò0/) 0.04 (0.Ò0/)
pistoFl piFl, piston ring Piston ring end aaP Top 0.25 - 0.31 (0.010 - 0.012) 0.4E (0.018) 0.4E (0.018)
pistoFl piFl, piston ring Piston ring end aaP Second 0.23 - 0.33 10.009 -0.013) 0.48 (0.0191 0.48 (0.0191
pistoFl piFl, piston ring Piston ring end aaP Oil Aside rail) 0.20 0.70 (0.008 0.028s 0.90 t0.035) 0.90 t0.035)
pistoFl piFl, piston ring Ptston ring-to-ring groove clearanC0 Top a.ogs o.loo \o.0026 0.0039) 01'I5 (0.00451 01'I5 (0.00451
pistoFl piFl, piston ring Ptston ring-to-ring groove clearanC0 Second 0.065 0.100 t0.0026 0.0039) 0.115 10.0045) 0.115 10.0045)
Cylinder-to-piston clearance Cylinder-to-piston clearance Cylinder-to-piston clearance 0020 0.045 (0.0008 0.0018) 0.8 (0.007) 0.8 (0.007)
Conneming rod smBII end I.D. Conneming rod smBII end I.D. Conneming rod smBII end I.D. 19.016 19.034 (0.7487 0.7494) 19-04 (0.750) 19-04 (0.750)
Connecting rod-to-piston pin. clearance Connecting rod-to-piston pin. clearance Connecting rod-to-piston pin. clearance 0.01.6 0.040 (0,0006 00016) 0.06 t0.002) 0.06 t0.002)
L4TCH KICKSTARTER/GEARSHIFT LINKAGE SPECIFICATIONS
Unit. mm (in) 6ERVIDE MMIT
ITEM Lever freeplay Spring free length Disc A
thickness Disc B thickness Plate warpage Pinion
gear I.D. Spindle O.D. Idle gear I.D. Idle gear
bushing
STANDARD
Clutch
10 20 (3/8 3/4)
45.7 (1.80) 2.92 - 3.08 (0115 0.121) 3.22
-3.38(EU 27 - 0.133)
64.7 (1.76) 2.85 10.112) 3.15 (0.124) 0.15
(0.006) 22.05 (0B68) 21.95 (DI.864) 2107
(0.830) 17.04 (0.671) 20.96 0.B25) 18.95 (0.667)
Kickstarter
22.007 .22.028 (0.86640,8672) 21.959 -21.9B0
(0.8645 - 0.8654) 2.1.020 - 21.041 (0.8276 -
0.8284) 17.000 170fB (0.689306700) 20.97921.0
00 (0.8259 -0g268) 16.966 - 16.984 (0.6680 -
0.6687)
0
I.D. O.D,
Countershafi O.D. at kickstarter idIe.gear
1-14
19
GENERAL INFORMATION CLUTCH/STARTER
CLUTCH/KlCKSTARTER/GEARSHIFT LINKAGE SPECIFICATION
S (Afier 05)
Unit mm (in Unit mm (in Unit mm (in Unit mm (in Unit mm (in
t I z-M t I z-M t I z-M gt IANDARD SERVICE LIMIT
Clutch Lever freeplay Lever freeplay 1O 20 (3/8 Z/4)
Clutch Spring free length Spring free length 45.7 (1.BD) 44.7 (1.76)
Clutch Disc A thickness Disc A thickness 2.92 3.08 (0.115 0.121) 2.85 (0.112)
Clutch Disc B thickness Disc B thickness 3.22 3.38 (O.127 0.133) 3.J 5 (0.124)
Clutch Plate warpage Plate warpage 0.15 (0.006)
Driven gear boss (TRX450ER) Driven gear boss (TRX450ER) I.D. 36.00936.034(1.41// 1.4189) 36.034 (1.4189)
Driven gear boss (TRX450ER) Driven gear boss (TRX450ER) O.D. 45.660 45.673 (1.7976 1.7981) 45.660 (1.797g)
Reduction aear A I.D. (TRX450ER) Reduction aear A I.D. (TRX450ER) Reduction aear A I.D. (TRX450ER) J2.010 12.050 (0.4728 0.4744) 12.050 (0.4744)
Reduction gear 8 I.D. (TRX450ER) Reduction gear 8 I.D. (TRX450ER) Reduction gear 8 I.D. (TRX450ER) 10,045 - 10.085 (0.3955 - 0.3970) 10.085 (0.3970)
Idle gear I.O. tTRX450ER Idle gear I.O. tTRX450ER Idle gear I.O. tTRX450ER 12010 - 12050 \0.4728 - 14744) t2.050 0.4744T
Gear holdsr shafts O.D. TRX450ERI Gear holdsr shafts O.D. TRX450ERI Gear holdsr shafts O.D. TRX450ERI 11.989 12.000 (0.4720 0.4724) 11.989 (0.4720)
Reduction gear shaft O.D. (TRX450ER) Reduction gear shaft O.D. (TRX450ER) Reduction gear shaft O.D. (TRX450ER) 9.980 9.s9s o.a zs o.3g3si 9.980 CO.3929)
Kickstarter Pinion gear I.D, Pinion gear I.D, 22.007 22.028 (0.8664 D.B672) 22.05 \0.868)
(TRX 0_at_) Spndle O.D. (TRX 0_at_) Spndle O.D. (TRX 0_at_) Spndle O.D. 21.959 21.980 (0.8645 0.8654) 21.95 (0.864)
idle gear I.D. idle gear I.D. 21.020 21.041 (0.8276 0.8284) 21.07 (0.830)
Idle gear bushing I.D. 17.000 170J8 0.6693 0.6700) 17.04 (0.671)
Idle gear bushing O.D. 20.979 21.000 (0.8259 0.8268) 20.96 (0.825)
Countershaft O.D. at k ckstarter idle gear (TRX450R) Countershaft O.D. at k ckstarter idle gear (TRX450R) Countershaft O.D. at k ckstarter idle gear (TRX450R) 16.966 16.984 (0.6680 0.6687) 6.95 (0.6671
CRANKCASE/TRANSMISSlON/CRANKSHAFT
SPECIFICATIONS (04 - 05)
Unit mm (in Unit mm (in Unit mm (in Unit mm (in Unit mm (in
ITEM ITEM ITEM STANDARD SERVICE LIMIT
Shift fork, shaft Forkl.D. Left, right 12.003 12.024 (0.4Y26 0.4733) 12.04 (0.474)
Shift fork, shaft Forkl.D. Center 11.003 J1.024 10.4332 0.4340) 11.04 (0.435)
Shift fork, shaft Shaft 0. D. Left/right 11.983 11.994 (0.4718 0.4722) 11.97 (0.471)
Shift fork, shaft Shaft 0. D. Center 10.983 10.994 (0.d324 0.4328) 10.97 (0.432)
Shift fork, shaft Fork claw thickness 4.93 5.00 (0.194 0.197) 4.8 (0.19)
Transmssion Gear I.D. M4 28.007 28.028 (1.1026 1.1035) 28.05 (1.104)
Transmssion Gear I.D. MS 28.020 28.033 (1.1031 1.1037) 28.06 (1.105)
Transmssion Gear I.D. CI 22.0Z0 22.041 0.86g9 0.867B) 22.07 (0.869)
Transmssion Gear I.D. C2 30.020 30.041 (1.1819 1.1827) 30.07 (1.184)
Transmssion Gear I.D. C3 28.020 28.041 (1.1031 1.1040) 28.07 (1.105)
Transmssion Gear bushing O.D. M4, M5 27.959 27.980 (1. t007 1.1016) 27.94 (1.100)
Transmssion Gear bushing O.D. C1 21.959 21.980 (0.B645 0.8654) 21.94 10.B64)
Transmssion Gear bushing O.D. C2 29.959 29.980 (1.1795 t.1803) 29.94 (1.179)
Transmssion Gear bushing O.D. C3 27.959 27.980 (1.1007 1.101g) 27.94 (1.100)
Transmssion Gear bushing I.D. MS 25.020 - 25.04 0.985O 0.9859) 25.06 (0.987)
Transmssion Gear bushing I.D. C1 19.020 19.041 (0.7488 0.749g) 19.06 (0.750)
Transmssion Gear bushing I.D. CZ 27.020 27.041 (1.0638 1.0646) 2706 (1.065)
Transmssion Gear bushing I.D. C3 25.020 25.041 (0.9B50 0.9859) 25.06 (0.987)
Transmssion Mainshaft O.D. at M5 24.967 24.980 0.9830 0.9835) 24.95 (0.982)
Transmssion Countershaft O.D. at C1 18.95918.980 (0.7464 0.7472) 18.94 (0.746)
Transmssion Countershaft O.D. at C2 26.ss9 26.gso 1.0614 1.0622) 26.94 (1.061)
Transmssion Countershaft O.D. at C3 24.959 24.980 (0.9826 0.9835) 24.94 (0.982)
Crankshaft Runout Left 0.05 (0.002)
Crankshaft Runout RBht o.oa \o.oo1I
Crankshaft s end side ctearance s end side ctearance 0.05 0.60 tO.002 0.024) ß.XS IO.ß3ß)
Crankshaft Big end radial clearance Big end radial clearance 0.006 0.018 (0.O0O2 0.0007) 0.o5 (0.002)
1-15
20
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21
GENERAL INFORMATION CRANKCASE/TRANSMISSION/CRANKSH
AFT SPECIFICATIONS (After 05)
Unit mm (in SERVICE MMir
szANDARD
iTzfyi Fork I.O.
Shift fork, ahaft
t2.036 12.058 0.4738 0.47d6) 12.07
(0.476a
Left Right
12.003 12.024 (0.4726 - 0.4734) 1t.003 11.024
(0.a332 0.4340)
12.04 (0.474) 1J.04 (0.435)
Center LefUright
Shaft O.D.
IN.966 11.984 (0.4711 - 0.4718) JO.969 - 10.980
(0.43t9 - 0.4322)
11.950 (0.4700)
Center
10.969 (0,4319)
Fact clew thiCknese Gear I.D.
4.93 - 5.00 O. f9 0.is7) 28.007 -28.028 U.1026
J.J035)
I 4.8 (o.i9) 28.05 (1.104)
Tr8nsmlssion
M4 M5
28.020 - 28.033 (1.J031 J.1037) 22.020 - 22.04J
(0.8669 0.8878)
28.06 (1.1Ò5) 22.07 (0.869)
C1 C2
30.07 (1.184)
30.020 - 30.041 (1.J819 1.1827) 28.020 28.041
(1.1031 l.1040)
Z8.07(11051 27.9411.100T
Gear bushing O.D.
M4, M5 C1
27.959 -2Z980 t1.1007 1.1016) 21.069 21.980
(0.8645 0.B654)
21.94(086d)
C2 C3
29.959 2s.980 II.17s5 1.1803) 27.959 27.980
(1.1007 1.10161
29.94(1.179)
27.94(1.100)
Gear bushlng I.D.
M5. C1
25.020 25.04t 10.9850 ó.98591
25.06 t0.987)
19.020 - 19.041 (0.74S8 0.74961 27.020 27.041
(1.0638 1.0646)
19.06 t0.750)
C2 C3
I
27.06(1.065)
25.02O -25.041 (o.9850 - 0.9859 24.967 - 24.980
(0.9830 0.9836)
I 25.06(0.9871 I
Mainaheft O.D. CounterBhaft O.D.
at M5 at C1
24.95(0.9821
1d.959 - 18.980 (0.746d 0.74721 26.959 -26.980
(1.0614 - 1.0622)
1.8.94 t0.746)
at C2 at C3
26.94(1.061)
24.959 24.980 (0.9826 0.9835)
24.94 (0.9821
Crankshaft
Runout
Left Right
0.05 (0.002). 0.03 (0.0011
Big end sida claarance
0.30 0.75 0.012 0.030) 0.006 0.018 t0.0002
0.0007)
0.75 t0.030) 0.0s tò.002) "
Big end radial clearance
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit mm (inl SERVICE UMfT 4.0 (0.16)
STANDARD 27.5 kPa (0.275 kgf/cm , 4,0 psi) 23.5
kPa (0.235 kgf/cm , 3.4psi) 31.5 kPa 0.315 kgf/cm
, 4.6 psi) 27.5 kPs fO.275 kgf/cm , 4.0 psi) 25.0
kPa 10.250 kgf/cm, 3.6psi)
Minlmum tire trsad depth Cold tlrs pressure 04 -
05
Standard Minimum Maximum Standard Minimum
DB-'07
-
Maximum
ZO.0 kPa (0.300 kgf/cmm, 4 pal)
i fter 07
27.5 kPa (0.275 kst/ , 4.0 psil I -
Compression darnping adjuster ctan- dard position
04 0S 06 07
1-7/8 turns out from full in 1/2 I- 1/8 turns out
from full in
After 07 04 05
1-7/8 t 1/8 turns out from full in 1-3/8 turns
out from full in
Rebound demping adjuster standard gO8ÏtÍOrI
7/8 t 118 turns out from full In
06 0.7
After O7
1 -L 1/8 turns out from full in
409/5 (16.12) -
Tie-rod distance between the ball "o4 05
Joints ARer 05
39B0 t15.67) Toe-in t1.4 t 15 (0.45 z
0.6) Toe-in \4 15 10.6 0.6)
Toe
After 05
1-16
22
GENERAL INFORMATION REAR WHEEL/SUSPENSION
SPECIFICATIONS
Unh mrn (iri) 6ERVICE MM!T
iTEM GTANDARD
Minimum tire tread dapth Cold tire pressure
4.0 (0.16).
04 05
4.7 psii
Štandard. 22.5 kPa (0,325 kgf Minimum "

.28.5 kPa (0.285 kgf/cm 4.1 psi) 36.5 kPa
(0.365 kgf/cm, 5.3 psi)
Maximum

.06 - 07
32.5 kPa (0.325 _at_ crn 7 p )
Standsrd. Minimum

2l.0 kPa (0.300 kgf/cm 4.3 psi)
"
"
Maximum

35.0 kPa (0.350 kgf/cm, 5.1 psi) 32.5 kPa (0.325
kgf/cm 4..7 psi)
After 07
Axle runout Drive chain
3.0(0.12)
Slack
25 35 (1 - 1-7/16)
IO520VB/'94
DID RK
Size/link. (04 05) Size/link
I
RK520SMOZ10S/94 OID520V6/96
DID RK.
(06 07) Size/link
RK520SMDZ10S/90 DID520V/98
DID RK
(After 07)
R.K520SMOZ10S/96 26 -t 1 clicks out from full
in
Compression damping adjuster standard position
04 05 os oz
z icks out from full in
After .07 .0I 05
26.6 1..clicks out frOM full fn 1-3/4 turns out
from full in

Rebound damping adjuster standard P ltl
06 07 After .07
1-1/8 1/8 turns out from NII in 1-3/4.4.1/8
turn.s out from full in
_
HYDRAULIC BRAKE SPECIFICATIONS
Uriit.mm (in)
ITEM ITEM STANDARD STANDARD STANDARD STANDARD SERVICE MMiT
Recommended brake fluid Recommended brake fluid DOT 4 brake fluid DOT 4 brake fluid DOT 4 brake fluid DOT 4 brake fluid
I Front brake i Eiisc thickness I Front brake i Eiisc thickness 2.8 3.2 (0.11 0.13) 2.8 3.2 (0.11 0.13) 2.8 3.2 (0.11 0.13) 2.8 3.2 (0.11 0.13) 2.5 (.0.10) 0.30 (0.0121
i Disc runout 2.5 (.0.10) 0.30 (0.0121
i M e iin e I Caliper cylifider I.D. 12.7 (0.55) 25.4 (1.00) 12.7 (0.55) 25.4 (1.00) 2.5 (.0.10) 0.30 (0.0121
i M e iin e I Caliper cylifider I.D. 12.7 (0.55) 25.4 (1.00) 12.7 (0.55) 25.4 (1.00)
Rear brake Disc thickness Disc runout. filaster cylinder .D. Caliper cylinder I.D. Rear brake Disc thickness Disc runout. filaster cylinder .D. Caliper cylinder I.D. 3.8 4.2 (0.15 0.17) 3.8 4.2 (0.15 0.17) 3.8 4.2 (0.15 0.17) 3.8 4.2 (0.15 0.17) 3.5 (0.14)
Rear brake Disc thickness Disc runout. filaster cylinder .D. Caliper cylinder I.D. Rear brake Disc thickness Disc runout. filaster cylinder .D. Caliper cylinder I.D. 12.7 (0.55) 0.30 (0..01.2)
Rear brake Disc thickness Disc runout. filaster cylinder .D. Caliper cylinder I.D. Rear brake Disc thickness Disc runout. filaster cylinder .D. Caliper cylinder I.D. 12.7 (0.55)
Rear brake Disc thickness Disc runout. filaster cylinder .D. Caliper cylinder I.D. Rear brake Disc thickness Disc runout. filaster cylinder .D. Caliper cylinder I.D. 32.0 11.26) 32.0 11.26) 32.0 11.26) 32.0 11.26)
1-17
23
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