1984-2011 Honda TRX70 - TRX90 - TRX125 - TRX200 - TRX250 - TRX300 - TRX350 - TRX400 - TRX420 - TRX450 - TRX500 - TRX650 - TRX680 - TRX700 Electric Starter & service manual download links for 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 & 2011 TRX models.


1984-2011 Honda TRX Electric Starter Service & Repair

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Choose a service manual from the list below and download it straight to your computer in just seconds! These manuals contain the same exact information Honda service technicians use to service and repair you Honda TRX off-road-vehicle. The contain everything you will ever need to know to fix anything on your Honda TRX. Want to see a sample of what a TRX service manual looks like? SAMPLE MANUAL

SERVICE MANUAL

DOWNLOAD LINKS



 


TRX70 MANUALS


1986-1987 TRX 70, TRX70


TRX90 MANUALS

1993-2005 TRX 90, TRX90

2006-2009 TRX 90, TRX 90EX, TRX 90X

TRX125 MANUALS

1985-1986 TRX 125, TRX 125

1987-1988 TRX 125, TRX125

TRX200 MANUALS

1984 TRX 200, TRX200

1986-1988 TRX 200SX, TRX200 SX

1990-1991 TRX 200 91-97 TRX 200D Type II

TRX250 MANUALS

1985-1987 FourTrax (Four Trax) 250, TRX250

1987-1988 TRX 250X, TRX250X, TRX250 X

1986-1989 TRX 250R, TRX250R, TRX250 R

1991-1992 TRX 250X, TRX250 X

1997-2004 Honda Recon TRX250 TRX250 TE/TM 250 Service Manual Repair


2001-2005 TRX 250EX, TRX250 EX


2005-2012 Recon TRX250, TRX250TM, TRX250TE


2006-2011 TRX 250 EX, TRX 250X


TRX300 MANUALS

1988-1994 FourTrax 300 (TRX 300, TRX 300 FW)

1993-2000 TRX 300EX

1995-2000 Honda TRX300 (TRX 300), TRX300FW Fourtrax ATV

2001-2006 TRX 300EX, TRX300 EX

2007-2009 TRX 300EX & TRX 300X

TRX350 MANUALS

1986-1987 FourTrax TRX350 4x4

1986-1989 Foreman TRX 350D, TRX350D, TRX350 D

2000-2003 Rancher TRX350FM, TRX350TM, TRX350FE, and TRX350TE

2004-2006 Rancher TRX350TE, TRX350TM, TRX350FE, TRX350FM

TRX400 MANUALS

1995-2003 Foreman TRX400FW TRX 400

1999-2003 TRX 400EX, TRX400 EX

2004-2005 Rancher TRX400FA TRX400FGA TRX400

2006-2007 Rancher TRX400FA, TRX400FGA, TRX400

2005-2009 TRX 400EX, TRX 400X

TRX420 MANUALS

2007-2010 Rancher TRX420,FE,FM,TE, TRX420TM, TRX420FPE, TRX420FPM

2009-2012 Rancher AT TRX420FA, TRX420FPA, TRX420

TRX450 MANUALS

1998-2004 Foreman trx450 TRX450S, TRX450FM, TRX450ES, TRX450FE

2004-2012 TRX 450R, TRX 450ER, TRX450 E

TRX500 MANUALS

2001-2004 Foreman Rubicon 500 TRX500FA, TRX500 FA

2005-2011 TRX500FE TRX500FM TM FPM FPE Fourtrax Forman

2005-2012 Foreman Rubicon TRX500 FA, TRX500 FGA

TRX650 MANUALS

2003-2005 Rincon TRX650FA

TRX680 MANUALS

2006-2009 Honda TRX680, TRX680FA, TRX680FGA Rincon

TRX700 MANUALS

2008-2009 Honda TRX700 X X (TRX 700 XX, TRX700XX)



ELECTRIC STARTER

SERVICE INFORMATION

STARTER RELAY SWITCH

TROUBLESHOOTING

CLUTCH

STARTER MOTOR

DIODE

TROUBLESHOOTING

 

TROUBLESHOOTING

Starter motor will not turn

* Check for a blown fuse (15 A).
* Check that the battery is fully charged and in good condition.
* Check for loose or poorly connected battery cable and open circuit in battery cable.
* Check for loose or poorly connected starter relay switch terminals and connectors.
* Check for loose or poorly connected starter t motor cable. and oDen circuit in starter motor cable.
* With the ignition switch ON, push the starter switch and check for a "Click" sound from the starter relay switch.
* Check the starter relay coil ground line.
* Check the starter relay voltage.
* Check the starter relay switch operation.

Starter motor turns slowly
* Weak battery Poorly connected battery cable
* Poorly connected starter motor cable
* Faulty starter motor

Starter motor turns, but engine does not turn Faulty starter clutch
* Faulty starter clutch

Starter relay switch "clicks", but engine does not turn over
* Crankshaft does not turn due to engine problem
* Faulty starter reduction gear
* Faulty starter idle gear

STARTER MOTOR REMOVAL

Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. Remove the rubber cap, terminal nut and starter motor cable. Remove the two mounting bolts, cable guide and the starter motor from the crankcase and left crankcase cover. Remove the O-ring from the starter motor.

DISASSEMBLY/INSPECTION

Remove the starter motor case bolts. Remove the front cover, thrust washer and seal ring. Remove the rear cover, shims and seal ring. Remove the armature from the motor case. Check the bearing and oil seal in the front cover for wear or damage. Check the commutator bars of the armature for discoloration.

NOTE: Do not use emery or sand paper on the commutator. Check for continuity between pairs of commutator bars. There should be continuity.

Check for continuity between each commutator ba and the armature shaft. There should be no continuity. Check for continuity between the insulated brush and cable terminal. There should be continuity. Check for continuity between the cable terminal and motor case. There should be no continuity.

Remove the following:
- nut
- washer
- insulator washers
- O-ring
- brush holder assembly


Remove the brushes from the brush holder and measure the brush length. Install the brushes into the brush holder. Install the brush holder assembly into the rear cover by aligning the tab of the holder with the groove in the rear cover.

Install the following:
- new O-ring
- insulator washers
- washer
- nut

Install the armature into the motor case while holding the armature tightly to keep the magnet of the case from pulling the armature against it.

CAUTION: The coil may be damaged if the magnet pulls the armature asainst the case.

Install the same number of shims in the same locations as noted during disassembly. Install a new seal ring. Install the rear cover by aligning the brush holder tab with the motor case groove.
Install the thrust washer and a new seal ring. Apply grease to the oil seal lip in the front cover. Install the front cover. Align the index lines on the front cover and motor case. Install the set plates and new O-rings onto the motor case bolts. Install and tighten the motor case bolts.

INSTALLATION

Coat a new O-ring with oil and install it into the starter motor groove. Install the starter motor into the left crankcase cover and onto the crankcase. Install the cable guide and mounting bolts, and tighten the bolts securely. Install the starter motor cable and terminal nut onto the motor terminal and tighten the nut securely. Install the rubber cap over the motor terminal securely.

STARTER RELAY SWITCH INSPECTION

Shift the transmission into neutral. Turn the ignition switch ON. Push the starter switch. The coil is normal if the starter relay switch clicks. If you don't hear the switch "CLICK". inspect the
relay switch using the procedure below. Remove the seathear fender.

GROUND LINE

Disconnect the yellowlgreen wire connector of the starter relay switch. Check for continuity between the wire harness side connector terminal and ground. If there is continuity when the transmission is in neutral or when the clutch is disengaged, the ground circuit is normal. (In neutral, there is a slight resistance due to the diode.)

STARTER RELAY VOLTAGE

Disconnect the yellowlred wire connector of the starter relay switch. Measure the voltage between the wire harness side connector terminal (+) and ground (-). If the battery voltage appears only when the starter switch is pushed with the ignition switch ON, the circuit is normal.

OPERATION CHECK

Disconnect the starter relay switch connectors and cables. Connect the fully charged 12 V battery positive terminal to the relay switch yellow/red wire connector terminal and negative terminal to the yellowlgreen wire connector terminal. There should be continuity between the large terminals while the battery is connected, and no continuity when the battery is disconnected.

CLUTCH DIODE INSPECTION

Remove the seathear fender  Disconnect the starter relay switch (Yellow/green) and neutral switch (Light green) connectors. Check for continuity between the wire harness side connector terminals.
If there is continuity in one direction, the diode is normal. When there is continuity, a small resistance value will register.


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