Honda Rincon 650 Service Manual Repair 2003-2005 TRX650

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This manual covers the Rincon 650 (TRX650 / TRX650FA) models produced between 2003 and 2005. As a premium utility ATV, the Rincon 650 is recognized for its pioneering Dual Clutch...

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Tipo: Atv

Proveedor:

SKU: 136300

Etiquetas: 2003 2004 2005 ATV Honda Powersports Rincon 650 Rincon Series TRX650

Variantes de producto

Descripción

This manual covers the Rincon 650 (TRX650 / TRX650FA) models produced between 2003 and 2005. As a premium utility ATV, the Rincon 650 is recognized for its pioneering Dual Clutch Transmission (DCT), the first automatic transmission offered in an ATV, alongside its powerful 650cc liquid-cooled engine, independent rear suspension, and robust Programmed Fuel Injection (PGM-FI) system. These features set it apart in the competitive utility ATV segment, delivering exceptional off-road capability and performance. This comprehensive service and repair manual, totaling 529 pages in English, provides detailed guidance for owners and technicians. It covers complete tear-downs and rebuilds, routine maintenance, troubleshooting, and repair procedures for all major systems, including the engine, fuel system, ignition, transmission, drivetrain, suspension, brakes, and electrical systems. With numerous diagrams and illustrations, this manual is an essential resource for ensuring the optimal performance, reliability, and longevity of your Rincon 650.

🏷️ Basic Information

Identification

Make:

Honda

Model:

Rincon 650 (TRX650 / TRX650FA)

Model Designation:

TRX650 / TRX650FA

Product Type:

Service & Repair Manual

Generation

Covered Years:

2003, 2004, 2005

Codes

Chassis Code:

TRX650 / TRX650FA

👋 Introduction

Market Position

Category:

High-performance utility ATV

Segment:

Premium Utility ATV

Competitive Analysis

Competitors:

Yamaha Grizzly, Kawasaki Brute Force, Polaris Sportsman, Suzuki KingQuad.

Key Features

Unique Selling Points:

First ATV with automatic transmission (Dual Clutch Transmission), independent rear suspension, powerful 650cc liquid-cooled engine, robust PGM-FI system.

📋 Manual Details

Coverage Areas

General Coverage:

Complete tear down and rebuild, maintenance, troubleshooting, electrical systems, engine, chassis, driveline, suspension, brakes, bodywork.

Page Count

Total Pages:

Manual Type

Type:

Comprehensive Service and Repair Manual

Language

Language:

English

Format

File Format:

Searchable:

Printable:

Save Options:

Yes (no restrictions on saving/burning to disc)

📖 Manual Coverage

Systems Covered

Engine:

Internal engine components, cylinder head, piston, conrod, crankshaft, cams, valves, lubrication system, cooling system, PGM-FI fuel injection system.

Fuel System:

PGM-FI (Programmed Fuel Injection), fuel pump, injectors, throttle body, fuel tank, fuel lines.

Ignition System:

CDI (Capacitor Discharge Ignition), ignition coil, spark plug, magneto, stator, charging system.

Transmission:

Automatic Dual Clutch Transmission (DCT) operation, primary reduction gear, gearshift mechanism, maintenance.

Drivetrain:

Front driveshaft, rear driveshaft, drive shafts, CV joints, final drive unit, driveshaft boots.

Suspension:

Front independent double A-arm suspension, rear swingarm, shock absorbers, springs, linkage, bushings, steering system, triple clamps.

Brakes:

Front hydraulic disc brakes, rear hydraulic disc brake, brake pads, brake rotors, brake lines, brake fluid, brake lever, brake pedal.

Electrical System:

Battery, starter motor, rectifier/regulator, lighting system (headlights, taillight, brake lights), switches, wiring harnesses, ECU (Engine Control Unit).

Bodywork:

Fenders, plastics, seat, handlebars, frame, exhaust system, muffler.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, coolant checks and changes, spark plug service, chain adjustment (if applicable), lubrication points.

Troubleshooting:

Diagnostic procedures, error code interpretation (for EFI), common problems and solutions (e.g., no spark, starting issues, rough running).

Repair:

Complete engine rebuild, transmission overhaul, suspension repair, brake system service, electrical component replacement, body panel repair/replacement.

Installation:

Component installation and removal (e.g., engine, transmission, suspension components, electrical parts).

Specifications:

Torque specifications for all fasteners, engine specifications, dimension specifications, fluid capacities.

Technical Depth

Depth:

Comprehensive, from basic checks to complete engine and transmission rebuilds.

Illustrations:

Numerous diagrams and pictures.

Diagnostic Tools:

Information for utilizing diagnostic capabilities of the PGM-FI system.

📊 Manual Specifications

File Format

Quality:

High-resolution PDF, ensuring clarity of text and images.

Print Quality

Printability:

Designed for easy printing of individual pages or sections.

Binding Type

Binding:

Digital (PDF) - no physical binding.

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Type:

649.4cc liquid-cooled, SOHC, 3-valve, single-cylinder

Bore X Stroke:

96.0 mm x 91.1 mm

Compression Ratio:

9.5:1

Carburetor Efi:

PGM-FI (Programmed Fuel Injection)

Performance

Horsepower Estimate:

Approximately 46 hp @ 6500 rpm (estimated, not officially published)

Torque Estimate:

Approximately 40 lb-ft @ 5000 rpm (estimated, not officially published)

Fuel System

Fuel Delivery:

Electronic Fuel Injection with 40mm throttle body, 12-hole injectors

Fuel Type:

Unleaded gasoline (87 octane recommended)

Fuel Tank Capacity:

4.0 US gallons (including 1.1-gallon reserve)

Lubrication

Oil Type:

SAE 10W-40 SJ or higher (API classification)

Oil Capacity:

2.5 US qt (2.4 L) with filter change

Cooling System

Cooling Method:

Liquid-cooled

Coolant Type:

Honda HP Coolant (or equivalent 50/50 antifreeze/water mixture)

Coolant Capacity:

1.8 US qt (1.7 L)

🔧 Transmission

Standard

Type:

5-Speed Automatic Dual Clutch Transmission (DCT)

Drive Modes:

Automatic, manual-shift (via thumb shifter)

Transmission Fluid Type:

Honda MTF (Manual Transmission Fluid) or equivalent DEXRON-III compatible fluid (check manual for specific recommendations).

Features

Traction Control:

Locking Differential:

No (Torque-sensing front differential)

📐 Dimensions

Exterior

Length:

82.3 in (2090 mm)

Width:

46.5 in (1180 mm)

Height:

44.4 in (1128 mm)

Wheelbase:

50.2 in (1275 mm)

Ground Clearance:

7.1 in (180 mm)

Weights

Dry Weight:

628 lbs (285 kg)

Curb Weight:

661 lbs (300 kg)

Tongue Weight Capacity:

N/A (ATV does not typically come with a hitch receiver for towing rated loads)

Towing Capacity:

N/A (Not rated for towing)

Rack Capacity Front:

33 lbs (15 kg)

Rack Capacity Rear:

110 lbs (50 kg)

🛡️ Safety Features

Ratings

Safety Certifications:

Meets applicable EPA emissions standards.

Active Features

Braking System:

Front and rear hydraulic disc brakes, sealed system.

Lighting:

Dual 35W headlights, 10W taillight/brakelight.

Passive Features

Frame Construction:

Steel frame, designed for stability and durability.

Ergonomics:

Comfortable seating position, intuitive controls.

💡 Technology Features

Infotainment

Features:

N/A (Focus on utility and performance, not typically equipped with infotainment features).

Driver Assistance

Features:

N/A (No electronic driver assistance systems like ABS or traction control in the traditional sense beyond the PGM-FI system's management).

Connectivity

Features:

N/A (No integrated connectivity features).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 600 miles (1,000 km) or 6 months.

Air Filter Cleaning:

Every 300 miles (500 km) or as needed, depending on conditions.

Spark Plug Inspection:

Every 600 miles (1,000 km).

Coolant Change:

Every 12 months.

Valve Clearance Check:

Every 1,200 miles (2,000 km) or 12 months.

Fluid Specifications

Engine Oil Viscosity:

SAE 10W-40

Engine Oil API:

SJ or higher

Brake Fluid Type:

DOT 4

Transmission Fluid Type:

Honda MTF or DEXRON-III compatible

Known Issues

Common Problems:

Occasional issues with the automatic transmission shifting can sometimes occur if maintenance is neglected. Some owners report premature wear on certain suspension bushings. Fuel pump reliability can be a concern if poor fuel quality is used.

Maintenance Tips:

Regular cleaning of the air filter and proper maintenance of the PGM-FI system are crucial for optimal performance and longevity. Use high-quality fuel and replace fuel filters as recommended.

📚 Vehicle History

Brand Heritage

Manufacturer:

Honda Motor Co., Ltd.

Reputation:

Renowned for reliability, innovation, and quality engineering in motorcycles and ATVs.

Model Evolution

Introduction Year:

Key Innovations:

Introduction of the first fully automatic transmission (DCT) in an ATV.

Production

Production Period:

2003-2005 (for the 650cc model)

Production Location:

Japan

🏆 Awards & Recognition

Recognitions

Industry Impact:

Revolutionized the ATV market with its innovative automatic transmission.

Ratings

Consumer Reviews:

Generally positive for its unique transmission, comfort, and off-road capability, though some found the initial DCT technology complex.