Honda Fourtrax 300 Manual Free

3
How to Use This Manual
3
Contents
4
General Information
4
General Safety
4
Service Rules
5
Model Identification
7
Specifications
10
Torque Values
10
Engine
11
Frame
12
Standard Torque Values
13
Tools
13
Special
14
Common
15
Cable & Harness Routing
16
Trx300
18
Trx300fw
21
Emission Control System (After '97)
22
Emission Control Information Label (After '97 California Type Only)
23
Lubrication Diagram
24
Lubrication
24
Service Information
26
Engine Oil Level
26
Engine Oil & Filter Change
27
Oil Filter Screen
27
Front Differential (Trx300fw)/rear Final Drive Oil
27
Oil Change
28
Front Gear Case Oil (TRX300FW)
28
Level Check
29
Lubrication Points
29
Control Cables
30
Maintenance
32
Maintenance Schedule
32
Trx300 ('95-'97)
33
Trx300fw ('95-'97)
34
TRX300 (After '97)
35
TRX300FW (After '97)
36
Fuel Line
36
Fuel Strainer Screen
36
Throttle Operation
37
Carburetor Choke
37
Air Cleaner Element
38
Air Cleaner Housing Drain Tube
38
Spark Plug
39
Valve Clearance
40
Engine Idle Speed
41
Cylinder Compression
41
Brake Fluid
41
Brake Shoe Wear
41
Front Brake
42
Rear Brake
42
Brake System
43
Reverse Lock System
44
Skid Plates
44
Clutch System
44
Suspension
45
Swingarm Bearings
45
Spark Arrester Cleaning
46
Wheels/Tires
46
Steering Shaft Holder Bearing
46
Steering System
46
Toe-In
47
Headlight Aim
47
Nuts, Bolts, Fasteners
49
Fuel System View
50
Fuel System
52
Fuel Tank
52
Removal
52
Installation
53
Air Cleaner Housing
54
Carburetor Removal
55
Carburetor Disassembly
55
Starting Enrichment (SE) Valve
56
Float and Jets
57
Primer Knob
57
Diaphragm/Vaccum Piston
59
Carburetor Assembly
61
Float Level Inspection
62
Carburetor Installation
64
Pilot Screw Adjustment
66
High Altitude Adjustment
67
Engine Removal/Installation View
70
Engine Removal
71
Engine Installation
73
Cylinder Head/Valves View
74
Cylinder Head/Valves
76
Cylinder Head Cover Removal
76
Disassembly
78
Camshaft/Cam Chain Tensioner Lifter Removal
79
Cylinder Head Removal
82
Valve Guide Replacement
83
Valve Seat Inspection/Refacing
84
Valve Seat Cutters
84
Valve Seat Refacing
86
Cylinder Head Assembly
87
Cylinder Head Installation
87
Camshaft/Cam Chain Tensioner Lifter Installation
90
Cylinder Head Cover Assembly/Installation
93
Cylinder/Piston View
94
Cylinder/Piston
98
Cylinder/Piston Installation
101
Clutch/Oil Pump/Kick Starter View
102
Clutch/Oil Pump/Kick Starter
104
Right Crankcase Cover Removal
105
Bearing Replacement
105
Centrifugal Clutch/Primary Drive Gear
105
Centrifugal Clutch Removal
107
Primary Drive Gear Removal
109
Primary Drive Gear Installation
110
Centrifugal Clutch Weight Assembly
111
Centrifugal Clutch Installation
113
Change Clutch
118
Reverse Lock Mechanism
119
Oil Pump
119
Removal/Disassembly
122
Kick Starter
124
Right Crankcase Cover Installation
127
Alternator/Starter Clutch/Gearshift Linkage View
128
Alternator/Starter Clutch/Gearshift Linkage
129
Starter Reduction Gear
131
Left Crankcase Cover Removal
132
Alternator-Ignition Pulse Generator Replacement
134
Flywheels/Starter Clutch
134
Flywheels Removal
134
Starter Clutch Inspection/Disassembly
135
Starter Clutch Assembly
136
Flywheel Installation
137
Gearshift Linkage
141
Left Crankcase Cover Installation
143
Crankcase/Crankshaft/Transmission View
144
Crankcase/Crankshaft/Transmission
147
Crankcase Separation
148
Transmission
153
Assembly/Installation
156
Crankshaft/Balancer
159
Output Gear
160
Backlash Inspection
161
Gear Tooth Contact Pattern Check
162
Output Shaft Disassembly
163
Output Shaft Bearing Replacement
164
Countershaft Disassembly
165
Gear Case Bearing/Oil Seal Replacement
165
Countershaft/Output Shaft Assembly
169
Crankcase Assembly
172
Font Wheel/Suspension/Steering View
173
Font Wheel/Suspension/Steering
175
Handlebar
177
Throttle Housing
178
Front Wheel
179
Tie-Rod/Knuckle Removal (TRX300)
182
Ball Joint Replacement
183
Front Arm (TRX300)
185
Tie-Rod/Knuckle Installation (TRX300)
186
Tie-Rod Assembly
188
Tie-Rod/Knuckle Removal (TRX300FW)
192
Knuckle Bearing Inspection/Replacement (TRX300FW)
193
Front Arm (TRX300FW)
196
Tie-Rod/Knuckle Installation (TRX300FW)
198
Steering Shaft
201
Front Shock Absorber
205
Brakes View
207
Brakes
209
Brake Fluid Replacement/Air Bleeding
209
Brake Fluid Draining
209
Brake Fluid Filling
210
Brake Bleeding
210
Brake Hose/Brake Pipe/Breather Tube Inspection
211
Master Cylinder
213
Brake Shoes/Wheel Cylinder/Adjuster
215
Brake Drum Bearing Replacement (TRX300)
216
Disassembly (TRX300FW)
218
Wheel Cylinder/Adjuster Inspection (TRX300)
219
Wheel Cylinder/Adjuster Inspection (TRX300FW)
219
Front Brake Panel Inspection (TRX300)
220
Front Brake Waterproof Seal Inspection
220
Front Brake Waterproof Seal Replacement
222
Assembly (TRX300)
225
Assembly (TRX300FW)
234
Rear Brake Pedal
237
Rear Wheel/Suspension View
238
Rear Wheel/Suspension
240
Rear Wheel
240
Tires
242
Tire Repair
244
Rear Shock Absorber
246
Swingarm
248
Pivot Bearing Replacement
251
Front Driving Mechanism (TRX300FW) View
252
Front Driving Mechanism (TRX300FW)
254
Front Drive Shaft
256
Front Differential
258
Differential Case Disassembly
261
Differential Assembly Inspection
262
Differential Disassembly
263
Differential Inspection
264
Drive Pinion Removal
265
Drive Pinion Disassembly/Assembly
266
Case Bearing Replacement
267
Drive Pinion Installation
268
Differential Assembly
270
Differential Case Assembly
272
Front Drive Shaft Installation
276
Front Drive Side Shaft Removal
276
Front Gear Case
278
Gear and Shaft
278
Bearing Removal
278
Case Bearing
279
Cover Bearing
279
Bearing Installation
282
Front Drive Side Shaft Installation
283
Rear Driving Mechanism View
284
Rear Driving Mechanism
286
Rear Axle Removal
287
Rear Final Drive Removal
293
Bearing/Oil Seal Replacement
295
Rear Drive Shaft
296
Rear Final Drive Installation
298
Rear Axle Installation
300
Bumper/Carriers/Fenders/Muffler
300
Front Bumper/Carrier/Fender
301
Installation (TRX300)
302
Installation (TRX300FW)
303
Rear Carrier/Rear Fender
306
Exhaust Muffler
307
Ignition System
307
System Diagram
310
Ignition Control Module (ICM) System Inspection
310
Ignition Coil
311
Ignition Pulse Generator
312
Alternator
312
AC Sensor Line Inspection
312
Ignition Timing
313
Peak Voltage Testing
317
Battery/Charging System Diagram
318
Battery/Charging System
321
Voltage Inspection
321
Battery Testing
322
Battery Charging
323
Charging System
324
Leakage Inspection
324
Regulated Voltage/Amperage Inspection
325
Alternator Charging Coil
325
Regulator/Rectifier
325
Regulator/Rectifier Inspection
327
Starter System View
328
Starter System
330
Starter Motor
334
Starter Relay Switch
334
Operation Inspection
334
Continuity Inspection
335
Diode
337
Lights/Switches View
337
Oil Warning System Diagram
338
Lights/Switches
339
Oil Warning System
340
Headlight
340
Bulb Replacement
340
Case Removal/Installation
341
Taillight
341
Indicator Lamp
342
Ignition Switch
342
Handlebar Switches
343
Neutral Switch/Reverse Switch
343
Oil Temperature Sensor
344
Alarm Unit
346
Wiring Diagram
346
'95-'97
347
After '97
348
Troubleshooting
348
Engine Does Not Start or Is Hard to Start
349
Engine Lacks Power
350
Poor Performance at Low and Idle Speeds
351
Poor Performance at High Speeds
351
Poor Handling
352
Index

Honda Fourtrax 300 Owners Manual Free

Honda TRX300/FOURTRAX 300 and TRX300FW/FOURTRAX 300 4x4 manual. Clymer ATV repair manuals are written specifically for the do-it-yourself enthusiast. From basic maintenance to troubleshooting to complete overhaul, Clymer manuals provide the information you need.

1989 Honda Fourtrax 300 Manual Free

2
Preface
3
Contents
5
Fourtrax Safety
10
Warning Information
12
Product View
14
Parts Location and Operation
14
Handlebars, From Rider's Point of View
15
Right Side of Fourtrax
16
Left Side of Fourtrax
17
Parts Operation
17
Power Controls
17
Ignition Switch
18
Engine Stop Switch
19
Choke Lever
20
Starting Primer Knob
20
Starter Button
21
Kick Starter
23
Throttle Lever
24
Lights
24
Headlight and Dimmer Switches
24
Oil High Temperature Indicator Lamp
26
Reverse and Neutral Indicator Lamps
27
Gearshift Controls
27
Gearshift Pedal
27
Gearshifting Sequence
28
Reverse Selector Knob
29
Brake Controls
29
Front Brakes
29
Rear Brake
29
Parking Brake
30
Fuel Tank Controls
30
Fuel Fill Cap
30
Fuel Valve
30
Off
31
On
31
Res
32
Engine Oil
32
Oil Filler Cap/Dipstick
33
Additional Features
33
Helmet Holder
34
Flag Pole Bracket
34
Trailer Hitch
35
Storage Compartment
36
12 V DC Power Supply
36
To Wire the Special DC Plug to an Accessory
38
Riding Your Fourtrax
38
Before Riding
38
Rider Preparation
38
Age Recommendation
40
Rider Training
40
Vehicle Preparation
40
Pre-Ride Inspection
42
Tires
43
Load Limits
44
Loading and Operational Guidelines
46
Accessories
48
No Modifications
48
Safe Riding Rules
48
Protective Apparel
50
No Passengers
51
No Alcohol or Drugs
52
Off-Road Only
54
For Off-Road Use Only
55
Keep Hands and Feet On Controls
56
Control Speed
57
No Stunts
58
Use Care On Unfamiliar Terrain
60
Riding
61
Starting the Engine
62
Flooded Engine
63
Shifting Gears
64
Riding in Reverse
66
Making Turns
69
Riding Up Hills
76
Riding Down Hills
78
Crossing Slopes
79
Making Turns On Slopes
80
Riding Over Obstacles
81
Riding Through Water
82
Parking
83
Maintenance and Repairs
83
Maintenance Schedule
84
Maintenance Precautions
86
Tool Kit
88
Fuel System
88
Refueling
90
Fuel Recommendations
91
Oxygenated Fuels
92
Fuel Strainer Screen
92
To Clean the Fuel Strainer Screen
94
Throttle Cable and Lever
94
To Adjust Throttle Free Play
95
To Clean the Air Cleaner Filter
98
Air Cleaner Case Drain Tube
98
To Clean the Drain Tube
99
Carburetor
99
Choke Cable and Lever
99
Adjusting Idle Speed and Air-Fuel Mixture
101
High Altitude Adjustment
102
Lubrication
102
Checking Engine Oil Level and Adding Oil
103
Engine Oil Recommendations
104
Changing the Engine Oil and Oil Filter
107
Rear Final Gear Case Oil
108
To Check and Change the Spark Plug
109
Valves
110
Clutch Adjustment
111
Reverse Lock System
111
Other Checks
112
Electrical System
112
Battery
113
Battery Removal
115
To Replace a Fuse
117
To Check Lever Free Play and Shoe Lining Clearance
119
To Adjust the Brake Lining Clearance
121
To Check the Brake Fluid Level
123
To Check and Adjust Brake Pedal Free Play
125
To Check and Adjust Brake Lever Free Play
126
To Check Rear Brake Shoe Wear
127
Draining Water From Brakes
128
Wheels and Tires
128
Wheel Removal
129
Tire Pressure
131
Tire Tread Condition
132
Repairing a Flat Tire
133
Seat Removal
134
Skid Plates
136
Spark Arrester
138
Transporting Your Fourtrax
141
Storing Your Fourtrax
144
Specifications
146
Wiring Diagram
147
Consumer Information (USA Only)
147
Noise Emission Control System
148
Warranty Service
149
Serial Numbers
150
Index