HONDA TRX650 RINCON 650 2003 Service Manual

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HONDA TRX650FA RINCON 650 2003 Service Manual

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VIEW SOME SNAPS OF THIS MANUAL !!

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FULL MANUAL AT 500 PLUS PAGES 55 PLUS MB !!

28 CHAPTERS LISTED:

GENERAL INFORMATION 1
FRAME/BODY PANELS/EXHAUST
MAINTENANCE 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
COOLING SYSTEM 6
ENGINE REMOVAL INSTALLATION 7
CYLINDER HEAD VALVE/CAMSHAFT 8
CYLINDER/PISTON 9
ALTERNATOR/STARTER CLUTCH 10
SUB-TRANSMISSION/GEARSHIFT LINKAGE 11
AUTOMATIC TRANSMISSION 12
CRANKCASE/CRANKSHAFT/BALANCER 13
FRONT WHEEL SUSPENSION/STEERING 14
REAR WHEEL SUSPENSION 15
BRAKE SYSTEM 16
FRONT DRIVING MECHANISM 17
REAR DRIVING MECHANISM 18
BATTERY/CHARGING SYSTEM 19
IGNITION SYSTEM 20
ELECTRIC STARTER 21
LIGHTS/METERS/SWITCHES 22
SELECTABLE 4WD SYSTEM 23
AUTOMATIC TRANSMISSION SYSTEM 24
WIRING DIAGRAM 25
TECHNICAL FEATURE 26
TROUBLESHOOTING 27
INDEX 28
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28 CHAPTERS IN DETAIL:

1. GENERAL INFORMATION

SERVICE RULES 1-2 BRAKE SYSTEM SPECIFICATIONS 1-10
MODEL IDENTIFICATION 1-2 FRONT DRIVING MECHANISM
SPECIFICATIONS 1-10
GENERAL SPECIFICATIONS 1-5
REAR DRIVING MECHANISM
LUBRICATION SYSTEM SPECIFICATIONS 1-7 SPECIFICATIONS 1-10
FUEL SYSTEM SPECIFICATIONS 1-7 BATTERY/CHARGING SYSTEM
SPECIFICATIONS 1-10
COOLING SYSTEM SPECIFICATIONS 1-7
IGNITION SYSTEM SPECIFICATIONS 1-11
CYLINDER HEAD/VALVE/CAMSHAFT
SPECIFICATIONS 1-8 ELECTRIC STARTER SPECIFICATIONS 1-11
CYLINDER/PISTON SPECIFICATIONS 1-8 LIGHTS/METERS/SWITCHES
SPECIFICATIONS 1-11
ALTERNATOR/STARTER CLUTCH
SPECIFICATIONS 1-8 STANDARD TORQUE VALUES 1-12
SUB-TRANSMISSION/GEARSHIFT ENGINE & FRAME TORQUE VALUES 1-12
LINKAGE SPECIFICATIONS 1-9
TOOLS 1-16
AUTOMATIC TRANSMISSION SPECIFICA-
TIONS 1-9 LUBRICATION & SEAL POINTS 1-18
CRANKCASE/CRANKSHAFT/BALANCER CABLE & HARNESS ROUTING 1-21
SPECIFICATIONS 1-9
EMISSION CONTROL SYSTEMS 1-35
FRONT WHEEL/SUSPENSION/STEERING
SPECIFICATIONS 1-9 EMISSION CONTROL INFORMATION
LABEL (U.S.A. only) 1-36
REAR WHEEL/SUSPENSION
SPECIFICATIONS 1-9

2. FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION 2-2 FRONT CARRY PIPE 2-10
TROUBLESHOOTING 2-2 FRONT CARRIER 2-11
BODY PANEL LOCATIONS2-3 FRONT FENDER 2-11
SEAT 2-4 MUFFLER PROTECTOR 2-12
RIGHT SIDE COVER 2-4 REAR CARRIER/MUD GUARD 2-13
STEERING COVER 2-5 REAR FENDER 2-14
FUEL TANK COVER 2-5 OUTER FENDER 2-15
FUEL TANK SIDE COVER 2-6 ENGINE GUARD 2-16
CENTER MUD GUARD 2-7 ENGINE SIDE COVER 2-17
FRONT MUD GUARD 2-8 METER COVER 2-18
INNER FENDER 2-9 EXHAUST SYSTEM 2-19
FRONT GRILLE 2-10

3: MAINTAINANCE

SERVICE INFORMATION 3-2 DRIVE SHAFT BOOTS 3-14
MAINTENANCE SCHEDULE 3-3 REAR FINAL GEAR CASE OIL AND
DIFFERENTIAL OIL 3-15
FUEL LINE 3-4
BRAKE FLUID 3-17
THROTTLE OPERATION 3-4
BRAKE SHOES WEAR 3-18
CARBURETOR CHOKE 3-5
BRAKE PADS WEAR 3-18
AIR CLEANER 3-5
BRAKE SYSTEM 3-19
AIR CLEANER HOUSING DRAIN HOSE 3-7
SKID PLATE, ENGINE GUARD 3-20
SPARK PLUG 3-7
SUSPENSION 3-21
VALVE CLEARANCE 3-8
SPARK ARRESTER 3-21
ENGINE OIL 3-10
NUTS, BOLTS, FASTENERS 3-22
ENGINE OIL FILTER 3-12
WHEELS/TIRES 3-22
ENGINE IDLE SPEED 3-12
STEERING SHAFT HOLDER BEARING 3-22
RADIATOR COOLANT 3-13
STEERING SYSTEM 3-22
COOLING SYSTEM 3-13

4: LUBRICATION

LUBRICATION SYSTEM DIAGRAM 4-2 OIL PRESSURE CHECK 4-5
SERVICE INFORMATION 4-3 OIL PUMP 4-5
TROUBLE SHOOTING 4-4 OIL COOLER 4-12

5. FUEL SYSTEM

SYSTEM COMPONENTS 5-2 CARBURETOR ASSEMBLY 5-13
SERVICE INFORMATION 5-3 CARBURETOR INSTALLATION 5-19
TROUBLESHOOTING 5-4 PILOT SCREW ADJUSTMENT 5-20
AIR CLEANER HOUSING 5-5 HIGH ALTITUDE ADJUSTMENT 5-21
CARBURETOR REMOVAL 5-6 FUEL TANK 5-22
CARBURETOR DISASSEMBLY/ INSPECTION 5-7

6. COOLING SYSTEM

SYSTEM FLOW PATTERN 6-2 THERMOSTAT 6-8
SERVICE INFORMATION 6-3 RADIATOR RESERVE TANK 6-10
TROUBLESHOOTING 6-4 RADIATOR/COOLING FAN 6-10
SYSTEM TESTING 6-5 WATER PUMP 6-14
COOLANT REPLACEMENT 6-6

7. ENGINE REMOVAL/INSTALLATION

SYSTEM COMPONENTS 7-2 ENGINE REMOVAL 7-4I
SERVICE INFORMATION 7-3 ENGINE INSTALLATION 7-7

8. CYLINDER HEAD/VALVE/CAMSHAFT

SYSTEM COMPONENTS 8-2 VALVE GUIDE REPLACEMENT 8-11
SERVICE INFORMATION 8-3 VALVE SEAT INSPECTION/REFACING 8-12
TROUBLESHOOTING 8-4 CAMSHAFT REMOVAL 8-14
CYLINDER COMPRESSION 8-5 CAMSHAFT INSTALLATION 8-16
CYLINDER HEAD COVER REMOVAL/ CYLINDER HEAD ASSEMBLY 8-17
DISASSEMBLY 8-5
CYLINDER HEAD INSTALLATION 8-18
CYLINDER HEAD REMOVAL 8-8
CYLINDER HEAD COVER ASSEMBLY/
CYLINDER HEAD DISASSEMBLY 8-9 INSTALLATION 8-20

9. CYLINDER/PISTON

SYSTEM COMPONENTS 9-2 CYLINDER/PISTON REMOVAL 9-4
SERVICE INFORMATION 9-3 CYLINDER/PISTON INSTALLATION 9-8
TROUBLESHOOTING 9-3

10. ALTERNATOR/STARTER CLUTCH

SYSTEM COMPONENTS 10-2 RECOIL STARTER 10-4
SERVICE INFORMATION 10-3 ALTERNATOR STATOR/STARTER
REDUCTION GEARS 10-7
TROUBLESHOOTING 10-3
FLYWHEEL/STARTER CLUTCH 10-12

11. SUB-TRANSMISSION/GEARSHIFT LINKAGE

SYSTEM COMPONENTS 11-2 REAR CRANKCASE COVER 11-5
SERVICE INFORMATION 11-3 SUB-TRANSMISSION 11-9
TROUBLESHOOTING 11-4 GEAR SELECTOR LEVER LINKAGE 11-14

12. AUTOMATIC TRANSMISSION

SYSTEM COMPONENTS 12-2 FRONT CRANKCASE COVER 12-18
SERVICE INFORMATION 12-4 TORQUE CONVERTER REMOVAL 12-24
TROUBLESHOOTING 12-5 SHIFT CLUTCH/MAINSHAFT
DISASSEMBLY 12-26
OIL PRESSURE CHECK 12-9
SHIFT CLUTCH/MAINSHAFT ASSEMBLY12-31
SHIFT VALVE BODY 12-11
TORQUE CONVERTER INSTALLATION -12-37

13. CRANKCASE/CRANKSHAFT/BALANCER

SYSTEM COMPONENTS 13-2 CRANKSHAFT 13-5
SERVICE INFORMATION 13-3 CRANKCASE BEARING REPLACEMENT-13-9
TROUBLESHOOTING 13-3 CRANKCASE ASSEMBLY 13-11
CRANKCASE SEPARATION 13-4

14. FRONT WHEEL/SUSPENSION/STEERING

SYSTEM COMPONENTS 14-2 TIRES 14-9
SERVICE INFORMATION 14-3 WHEEL HUB/KNUCKLE 14-13
TROUBLESHOOTING 14-4 FRONT SHOCK ABSORBER 14-17
HANDLEBAR 14-5 SUSPENSION ARM 14-18
THROTTLE HOUSING 14-8 STEERING SHAFT 14-23
FRONT WHEEL 14-9 TIE-ROD 14-29

15. REAR WHEEL/SUSPENSION

SYSTEM COMPONENTS 15-2 REAR WHEEL 15-5
SERVICE INFORMATION 15-3 WHEEL HUB/KNUCKLE 15-5
TROUBLESHOOTING 15-4 REAR SHOCK ABSORBER/SUSPENSION
ARM 15-9

16. BRAKE SYSTEM

SYSTEM COMPONENTS 16-2 REAR BRAKE MASTER CYLINDER/BRAKE
PEDAL 16-15
SERVICE INFORMATION 16-4
FRONT BRAKE SHOES/DRUM 16-21
TROUBLESHOOTING 16-5
FRONT WHEEL CYLINDER/BRAKE
BRAKE FLUID REPLACEMENT/ PANEL 16-24
AIR BLEEDING 16-6
REAR BRAKE CALIPER 16-29
REAR BRAKE PAD/DISC 16-9
REAR BRAKE DISC 16-36
FRONT BRAKE MASTER CYLINDER 16-11

17. FRONT DRIVING MECHANISM

SYSTEM COMPONENTS 17-2 DIFFERENTIAL DISASSEMBLY/
INSPECTION 17-14
SERVICE INFORMATION 17-3
CASE BEARING REPLACEMENT 17-21
TROUBLESHOOTING 17-4
DIFFERENTIAL ASSEMBLY 17-24
FRONT DRIVE SHAFT 17-5
DIFFERENTIAL INSTALLATION 17-29
DIFFERENTIAL REMOVAL 17-11

18. REAR DRIVING MECHANISM

SYSTEM COMPONENTS 18-2 FINAL DRIVE DISASSEMBLY/
INSPECTION 18-14
SERVICE INFORMATION 18-3
CASE BEARING REPLACEMENT 18-19
TROUBLESHOOTING 18-4
FINAL DRIVE ASSEMBLY 18-21
REAR DRIVE SHAFT 18-5
FINAL DRIVE INSTALLATION 18-24
FINAL DRIVE REMOVAL 18-11

19. BATTERY/CHARGING SYSTEM

COMPONENT LOCATION 19-2 BATTERY 19-5
SYSTEM DIAGRAM 19-2 CHARGING SYSTEM INSPECTION 19-7
SERVICE INFORMATION 19-3 ALTERNATOR CHARGING COIL 19-8
TROUBLESHOOTING 19-4 REGULATOR/RECTIFIER 19-9

20. IGNITION SYSTEM

COMPONENT LOCATION 20-2 IGNITION SYSTEM INSPECTION 20-5
SYSTEM DIAGRAM 20-2 IGNITION COIL 20-7
SERVICE INFORMATION 20-3 IGNITION TIMING 20-8
TROUBLESHOOTING 20-4

21. ELECTRIC STARTER

COMPONENT LOCATION 21-2 STARTER MOTOR 21-6
SYSTEM DIAGRAM 21-2 STARTER RELAY SWITCH 21-11
SERVICE INFORMATION 21-3 DIODE 21-12
TROUBLESHOOTING 21-4

22. LIGHTS/METERS/SWITCHES

COMPONENT LOCATION 22-2 CARBURETOR HEATER/AIR
TEMPERATURE SWITCH 22-8
SERVICE INFORMATION 22-3
COMBINATION METER/REAR VEHICLE
HEADLIGHT 22-4 SPEED SENSOR (VSS) 22-9
TAILLIGHT 22-4 FUEL GAUGE/FUEL LEVEL SENSOR 22-11
ACCESSORY SOCKET 22-5 TEMPERATURE INDICATOR/
TEMPERATURE SENSOR 22-14
IGNITION SWITCH 22-6
BRAKE LIGHT SWITCH 22-17
HANDLEBAR SWITCH 22-7
FRONT BRAKE SWITCH 22-18

23. SELECTABLE 4WD SYSTEM

COMPONENT LOCATION 23-2 SERVICE INFORMATION 23-3
SYSTEM DIAGRAM 23-2 TROUBLESHOOTING 23-4

24. AUTOMATIC TRANSMISSION SYSTEM

COMPONENT LOCATION 24-2 DIAGNOSTIC TROUBLESHOOTING 24-13
SERVICE INFOMATION 24-3 GEAR POSITION SWITCH 24-39
CONNECTOR LOCATION 24-4 GEARSHIFT SWITCH 24-40
SYSTEM DIAGRAM 24-6 DRIVE MODE SELECT SWITCH 24-41
BEFORE STARTING
TROUBLESHOOTING 24-7 THROTTLE POSITION (TP) SENSOR 24-42
TROUBLESHOOTING CHART 24-12

25. WIRING DIAGRAM

WIRING DIAGRAM 25-3

27. TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT LOW AND
TO START 27-2 IDLE SPEED 27-5
ENGINE LACKS POWER 27-3 POOR PERFORMANCE AT HIGH SPEED 27-6
POOR HANDLING 27-6

28. INDEX

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