Market Position:
The Honda TRX250X was a popular sport ATV known for its performance and reliability. This manual targets owners and technicians who perform maintenance, repairs, and overhauls on these specific models.
Competitive Analysis:
This manual provides a direct competitor to OEM service manuals and other aftermarket repair guides, offering a comprehensive and user-friendly digital format.
Key Features:
Instant download, searchable PDF, clickable chapters, detailed diagrams, torque specs, troubleshooting guides, and free replacement offer.
Applicable Years:
1991, 1992
Coverage Areas:
Complete teardown and rebuild, engine, drivetrain, chassis, electrical system, bodywork, suspension, brakes, fuel system, cooling system, maintenance, troubleshooting, specifications.
Manual Type:
Service and Repair Manual
Engine Systems:
Engine overhaul, cylinder head, piston, conrod, crankshaft, valve clearance, camshaft, timing, lubrication, cooling, starting system, ignition system, charging system.
Drivetrain Systems:
Transmission, clutch, primary reduction gear, reverse gear, drive shaft, propeller shaft, rear axle, differentials (if applicable).
Chassis Systems:
Frame, suspension (front forks, rear swingarm, struts), steering, brakes (front and rear), wheels, tires.
Electrical Systems:
Battery, magneto, stator, rectifier, regulator, lighting, ignition coil, starter motor, fuses, wiring diagrams, troubleshooting for no spark or charging issues.
Fuel System:
Carburetor (including main jet, pilot jet, mixture screw adjustments), fuel tank, fuel lines, fuel pump (if applicable).
Bodywork And Plastics:
Fenders, plastics, seat, body panels, handle bars.
Repair Procedures:
Complete engine rebuild, carburetor overhaul, transmission rebuild, clutch replacement, suspension servicing, brake system repair, electrical component testing and replacement.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacement, spark plug replacement, valve adjustment, chain maintenance, lubrication, coolant flush.
Troubleshooting:
Diagnostic procedures for common problems such as starting issues, engine performance problems, electrical faults (no spark, charging issues), and clutch/transmission issues.
Installation Procedures:
Instructions for installation of various components and parts.
Technical Depth:
Comprehensive. Covers everything from routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and torque specifications.
Diagrams And Illustrations:
Includes detailed part diagrams and step-by-step illustrations for major procedures.
Torque Specifications:
Extensive list of torque specifications for critical engine, chassis, and transmission fasteners.
Schematics:
Includes electrical system schematics and wiring diagrams.
Engine Type:
Four-stroke, SOHC, air-cooled, 2-valve
Bore X Stroke:
68.5 mm x 67.0 mm
Fuel Delivery:
Carburetor (likely a Keihin CV-type, model may vary by specific year/region, e.g., PD10C or similar)
Ignition:
CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK CR6HSA or equivalent
Valve Clearance Intake Cold:
0.05 mm (0.002 in)
Valve Clearance Exhaust Cold:
0.07 mm (0.003 in)
Engine Oil Capacity With Filter Change:
Approximately 1.7 L (1.8 US qt)
Recommended Engine Oil Viscosity:
SAE 10W-30 API SE or SG, or SAE 10W-40 API SE or SG
Horsepower:
Approximately 17-19 HP (figures vary slightly by source and test conditions)
Torque:
Specific torque figures are detailed within the manual for various components.
Transmission Type:
Automatic Clutch with 5-speed Manual Transmission and Reverse
Clutch Type:
Automatic centrifugal clutch
Gear Selection:
Foot shifter with neutral, 1st through 5th gears, and reverse.
Transmission Oil Capacity:
Approximately 0.75 L (0.79 US qt)
Transmission Oil Type:
Honda HP Transmission Oil or equivalent SAE 10W-30 API SE or SG
Engine Oil Change Interval:
Every 1000 km (600 miles) or 6 months, whichever comes first (or per specific hours of operation as detailed in the manual).
Transmission Oil Change Interval:
Every 1000 km (600 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Inspect every 500 km (300 miles), clean as needed. Replace if damaged.
Spark Plug Replacement:
Recommended at 4000 km (2500 miles) or if fouled or worn.
Valve Clearance Check:
Every 2000 km (1200 miles).
Brake Fluid Flush Replacement:
Recommended every 2 years.
Engine Oil Type:
SAE 10W-30 API SE or SG, or SAE 10W-40 API SE or SG
Transmission Oil Type:
Honda HP Transmission Oil or equivalent SAE 10W-30 API SE or SG
Coolant Type:
Permanent type antifreeze coolant (Honda recommends a mixture of 50% coolant and 50% distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Known Issues:
Common issues can include carburetor gumming due to infrequent use or stale fuel, occasional clutch wear (though generally robust), and potential for electrical component failure over time (e.g., rectifier/regulator). Valve adjustments are critical for optimal performance and longevity.
Brand Heritage:
Honda has a long and storied history in powersports, particularly with its All-Terrain Vehicles (ATVs), known for engineering excellence and durability.
Model Evolution:
The TRX250X, part of Honda's 'X' series sport ATVs, represented a step forward in performance and handling for recreational riders, building on previous TRX models. It offered a balance of power and maneuverability, often compared to its more race-oriented siblings like the TRX250R.
Production Period:
1986-1992 (First Generation)
Manufacturing Location:
Japan
