Honda Trx650 Rincon 650 2003 Service Manual (PS004235)

Honda Trx650 Rincon 650 2003 Service Manual (PS004235)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• HONDA TRX650FA RINCON 650 2003 Service Manual

  PLEASE USE THE PREVIEW AT THE TOP LEFT OF THIS PAGE TO
  
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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
  
  _________________
  
  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