Market Position:
The Honda TRX650FA Rincon 650 was positioned as a premium, large-displacement, utility-focused ATV, known for its comfortable ride, independent rear suspension, and user-friendly features like its automatic transmission. It competed with other high-end utility ATVs from brands like Yamaha, Polaris, and Can-Am.
Competitive Analysis:
Competed against models like the Yamaha Grizzly 660, Polaris Sportsman 700. Differentiated itself with its shaft drive, IRS, and a more car-like automatic transmission compared to the CVT-based systems of some rivals.
Key Features:
649cc liquid-cooled OHC 4-stroke engine, Honda's patented torque-sensing, variable-assist power steering (on FA models), Independent Rear Suspension (IRS), five-speed automatic transmission with three forward gears and one reverse, shaft drive, selectable 2WD/4WD with front differential lock, comfortable rider ergonomics, robust chassis.
Coverage Areas:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Cooling System, Exhaust System, Chassis, Bodywork, Maintenance, Troubleshooting, Diagnostics, Specifications, Wiring Diagrams
Page Count:
Estimated 400-600 pages (typical for comprehensive service manuals of this era)
Manual Type:
Service Repair Manual
Systems Covered:
Engine (internal components, lubrication, cooling, fuel delivery, ignition), Transmission (automatic transmission, clutch, drive shaft), Drivetrain (4WD system, differentials, axles), Suspension (front and rear), Steering, Braking System (hydraulic, front and rear), Electrical System (charging, starting, lighting, ignition, ECU, sensors), Fuel System (injection, pump, lines), Cooling System (radiator, fan, coolant flow), Exhaust System, Frame and Bodywork (panels, mounts).
Suspension Details:
Front: Independent double-wishbone with adjustable spring preload. Rear: Independent trailing-arm with adjustable spring preload and shock absorber. Includes specifications for alignment and shock settings.
Procedures Included:
Routine Maintenance (oil changes, filter replacements, spark plug service, air filter cleaning/replacement), Component Removal and Installation (engine, transmission, suspension components, brakes, electrical units), Engine Tuning and Adjustment, Carburetor/Fuel Injection System Diagnosis and Repair, Electrical System Troubleshooting, Brake System Bleeding and Pad Replacement, Suspension Alignment and Adjustment, Drivetrain Service, Bearing and Seal Replacement, Wiring Harness Repair, Diagnostic Procedures, Overhaul and Rebuild Procedures for Major Components.
Troubleshooting Guide:
Detailed troubleshooting section with symptom-based diagnostics and step-by-step repair procedures for common problems.
Technical Depth:
Comprehensive. Covers everything from basic routine maintenance to advanced diagnostics and complete engine/transmission rebuilds. Includes detailed torque specifications, clearances, timing information, and diagnostic flowcharts.
Diagnostic Tools:
Includes procedures for using basic diagnostic tools and understanding sensor data (where applicable, such as for fuel injection system).
Primary Engine:
649cc, liquid-cooled, SOHC, 4-stroke, 3-valve, single-cylinder
Valve Train:
SOHC, 3 valves per cylinder (2 intake, 1 exhaust)
Bore X Stroke:
100.0 mm x 82.6 mm
Horsepower:
Approximately 40-45 HP (estimated, as official figures are not always provided for ATVs)
Torque:
Approximately 40-45 lb-ft (estimated)
Fuel System:
PGM-FI (Programmed Fuel Injection) with 36mm throttle body
Ignition:
Digital CDI with electronic advance
Cooling System:
Liquid-cooled, with radiator and fan
Transmission Type:
Automatic Transmission (AT)
Gear Selection:
Hydraulic automatic clutch with electronic shift control. Three forward gears, Neutral, Reverse.
Drive System:
Shaft drive, selectable 2WD/4WD with front differential lock.
Torque Converter:
Torque converter for smooth engagement and power delivery.
Transmission Fluid Type:
Honda ATV High-Performance PSF (Honda Genuine Fluid) or equivalent API SG, SAE 10W-40
Transmission Fluid Capacity:
2.3 US qt (2.2 L) (Refer to manual for exact capacity)
Gear Ratios:
Specific gear ratios for 1st, 2nd, 3rd, and Reverse are detailed within the manual for performance analysis and troubleshooting.
Safety Ratings:
N/A (ATVs are not typically assigned NCAP or IIHS ratings)
Active Features:
Torque-sensing, variable-assist power steering (on FA model), powerful hydraulic disc brakes, engine braking (inherent in automatic transmission).
Passive Features:
Integrated floorboards with heel guards, comfortable seating position for rider control, strong frame construction.
Infotainment:
N/A (Focus is on utility and performance, not infotainment systems).
Driver Assistance:
Torque-sensing, variable-assist power steering significantly reduces rider fatigue and improves control, especially at low speeds and over rough terrain.
Engine Management:
PGM-FI (Programmed Fuel Injection) ensures optimal fuel delivery, throttle response, and emissions control across varying altitudes and temperatures.
Initial Service:
20-hour or 1-month service (check oil, clean air filter, inspect brakes, check tire pressure)
Regular Maintenance:
Every 6 months or 100 hours (whichever comes first): Engine oil change, oil filter replacement, spark plug check/replacement, air filter service, gear oil change (engine and transmission), rear differential oil change, brake fluid check, chassis lubrication, drive belt inspection, valve clearance check.
Spark Plug Replacement Interval:
Check every 6 months/100 hours, replace as needed. Specific plug type: NGK CR7EH-9 or equivalent.
Engine Oil Type:
API SG, SAE 10W-40 (Honda GN4 or equivalent)
Engine Oil Capacity:
2.6 US qt (2.5 L) (Refer to manual for exact capacity)
Gear Oil Type:
Honda Hypoid Gear Oil (or API GL-4, SAE 80) for rear differential; Honda ATV High-Performance PSF or equivalent for transmission.
Brake Fluid Type:
DOT 3 or DOT 4 Honda Brake Fluid
Common Issues:
Potential for premature wear on rear differential bearings (due to heavy loads/abuse), occasional issues with the automatic transmission shifting mechanism (though generally robust), potential for overheating if cooling system is not maintained, starter solenoid failures (common on many ATVs of this era).
Maintenance Recommendations:
Regularly inspect and clean the radiator and cooling fins, ensure proper coolant levels, change transmission and differential fluid more frequently than specified if operating in extreme conditions, inspect the starter solenoid and battery terminals.
Brand Heritage:
Honda has a long and storied history in motorsports and powersports, known for its engineering prowess, reliability, and innovative technologies. The 'Rincon' nameplate signifies Honda's flagship, large-displacement ATV.
Model Evolution:
The TRX650FA Rincon was introduced for the 2003 model year, replacing the TRX500FA Foreman Rubicon as Honda's largest-displacement utility ATV. It set a new benchmark for comfort and capability with its IRS and automatic transmission. It was produced from 2003 to 2005 before being replaced by the TRX680FA Rincon.
Production Years:
2003-2005
Manufacturing Location:
Japan (primarily)
