1984-2011 Honda TRX70 - TRX90 - TRX125 - TRX200 - TRX250 - TRX300 - TRX350 - TRX400 - TRX420 - TRX450 - TRX500 - TRX650 - TRX680 - TRX700 Ignition System General Information, Service, Repair, Specs, Specifications, Troubleshooting and service manual download links.


Honda TRX Ignition & Ignition System

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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.

All manuals contain pictures, illustrations, diagrams, specifications, special tools, solvents & step-by-step procedures!

These Factory Service Manuals 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

(Sample manual restricted to one page)

COMPLETE SERVICE MANUAL

DOWNLOAD LINKS BELOW

 


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)


IGNITION SYSTEM

SERVICE INFORMATION
TROUBLESHOOTING
IGNITION SYSTEM INSPECTION
IGNITION COIL
IGNITION TIMING

SERVICE INFORMATION - GENERAL

Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. When servicing the ignition system, always follow the steps in the troubleshooting on page. The ignition timing cannot be adjusted since the ignition control module (ICM) is factory preset. The ICM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may damage the ICM. Always turn off the ignition switch before servicing. A faulty ignition system is often related to poor connections. Check those connections before proceeding. Use a spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine. For ignition switch and engine stop switch inspection. For ignition pulse generator (alternator stator) removal/installation.

SPECIFICATIONS

  • Spark plug Standard - DPR7EA-9 (NGK) X22EPR-U9 (DENSO)
  • For cold climate (below 5°C/41°F) - DPR6EA-9 (NGK) X20EPR-U9 (DENSO)
  • Spark plug gap - 0.8 0.9 mm(0.03 0.04 in)
  • Ignition coil primary peak voltage - 100 V minimum
  • Ignition pulse generator peak voltage - 0.7 V minimum
  • Ignition timing (‘‘F’’ mark) - 11° BTDC at idle

TORQUE:Timing hole cap - 10 N·m (1.0 kgf·m , 7 lbf·ft)

IGNITION SYSTEM - TROUBLESHOOTING

Inspect the following before diagnosing the system:

  • Faulty spark plug
  • Loose spark plug cap or spark plug wire connections
  • Water got into the spark plug cap (Leaking the ignition coil secondary voltage)

Ignition coil primary voltage: Low peak voltage.

Incorrect peak voltage adaptor connections. (System is normal if measured voltage is over the specifications with reverse connections.)

  • The multimeter impedance is too low; below 10M / DCV.
  • Cranking speed is too low. (Battery is undercharged.)
  • The sampling timing of the tester and measured pulse were not synchronized. (System is normal if measured voltage is over the standard voltage at least once.)
  • Poorly connected connectors or an open circuit in ignition system.
  • Faulty gear position switch.
  • An open circuit or loose connection in No. 6 related circuit (light green/red wire).
  • Faulty ignition coil.
  • Faulty ignition control module (ICM). (when above No. 1 through 8 are normal.)

No peak voltage:

  • Incorrect peak voltage adaptor connections. (System is normal if measured voltage is over the specifications with reverse connections.)
  • Battery is undercharged. (Voltage drops largely when the engine is started.)
  • Faulty ignition switch or engine stop switch.
  • Loose or poorly connected ICM connector.
  • No voltage at the black/white wire of the ICM.
  • Open circuit or poor connection in ground (green) wire of the ICM.
  • Faulty gear position switch.
  • An open circuit or loose connection in No. 7 related circuit (light green/red wire).
  • Faulty peak voltage adaptor.
  • Faulty ignition pulse generator. (Measure peak voltage.)
  • Faulty ICM. (when above No. 1 through 10 are normal.)

Peak voltage is normal, but no spark jumps at plug:

  • Faulty spark plug or leaking ignition coil secondary current ampere.
  • Faulty ignition coil.

Ignition pulse generator: Low peak voltage

  • The multimeter impedance is too low; 10M /DCV.
  • Cranking speed is too slow. (Battery is undercharged.)
  • The sampling timing of the tester and measured pulse were not synchronized. (System is normal if measured voltage is over the standard voltage at least once.)
  • Faulty ignition pulse generator. (when above No. 1 through 3 are normal).

No peak voltage:

  • Faulty peak voltage adaptor.
  • Faulty ignition pulse generator.

If the result of the troubleshooting was likely to malfunction the ‘‘ICM’’, check as follows. Disconnect the sub-ICM connectors and connect the main harness side 8P (gray) connector to the ICM and perform the spark test. If the plug is no spark, faulty ICM. If the plug is sparks, faulty sub-ICM.

IGNITION SYSTEM INSPECTION

If not spark jumps at the plug, check all connections for loose or poor contact before measuring each peak voltage. Use recommended digital multimeter or a commercially available digital multimeter (impedance 10 M /DCV minimum). The display value differs depending internal impedance of the multimeter. Connect the peak voltage adaptor to the digital multimeter, or use the peak voltage tester.

IGNITION PRIMARY PEAK VOLTAGE

Check all system connections before this inspection. Poor connected connectors can cause incorrect readings. Check the cylinder compression and check that the spark plug is installed correctly in the cylinder. Disconnect the spark plug cap from the spark plug. Connect known good spark plug to the spark plug cap and ground the spark plug to the cylinder head as done in a spark test. With the connector connected, connect the peak voltage tester or adaptor probes to the ignition coil primary terminal and body ground.

CONNECTION: Black/yellow (-)-Body ground (+)

Turn the ignition switch ON. Crank the engine with the starter motor and read the ignition coil primary voltage.

PEAK VOLTAGE: 100 V minimum

If the peak voltage is lower than the standard value, follow the checks described in the troubleshooting in your service manual.

IGNITION PULSE GENERATOR PEAK VOLTAGE

Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Disconnect the ignition control module (ICM) 8P (gray) connector. Connect the peak voltage tester or adaptor probes to the connector terminals of the wire harness side.

CONNECTION: Blue/yellow (+) Green/white (-)

Turn the ignition switch ON. Crank the engine with the starter motor and read the peak voltage.

PEAK VOLTAGE: 0.7 V minimum

If the voltage measured at ICM connector is abnormal, measure the peak voltage at the alternator connector. Disconnect the alternator 5P (white) connector and connect the peak voltage tester or adaptor probes to the Blue/yellow wire terminal of the alternator side connector and ground. In the same manner as at the ICM connector, measure the peak voltage and compare it to the voltage measured at the ICM connector.

If the peak voltage measured at the ICM connector is abnormal and the one measured at the alternator connector is normal, the Blue/yellow wire has an open or short circuit, or loose connections. If both peak voltages are abnormal, follow the checks described in the troubleshooting in your service manaul and see your service manual for stator/ignition pulse generator assembly replacement.

IGNITION COIL - REPLACEMENT

Remove the left side cover. Release the spark plug wire fromthe clip. Remove the spark plug cap from the plug. Disconnect the connectors and remove the ignition coil from the stay of the frame. Install a new ignition coil in the reverse order of removal.

IGNITION TIMING

Remove the recoil starter cover. Start the engine and warm it up operating temperature. Stop the engine and remove the timing hole cap. Connect the timing light and tachometer. Start the engine, let it idle (1,400 rpm) and check the ignition timing. The ignition timing is correct if the F mark on the flywheel aligns with the index mark on the rear crankcase cover at idle. Increase the engine speed and make sure the F mark begins to move. Coat a new O-ring with engine oil and install it onto the timing hole cap. Install the timing hole cap and tighten it.

TORQUE: 10 N·m (1.0 kgf·m , 7 lbf·ft)

Install the recoil starter cover.

FUSE BOX - (FUSE 15A/30A AND DIODE)
STARTER RELAY SWITCH
GEAR POSITION SWITCH
STARTER MOTOR
IGNITION SWITCH
STARTER SWITCH
BATTERY


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