2005-2013 Honda TRX250TM, TRX250TE Service & Repair Manual (P/N 61LW030)

• Covers the 2005–2013 Honda Recon TRX250TM (manual foot-shift) and TRX250TE (Electric Shift Program) ATVs.
• Official OEM technical publication (P/N 61LW030).
• Documents the 61LW030 series build with over 375 pages of factory specifications, tolerances, and wiring schematics.

Technical Details and Data

Engineers and mechanics working on the Honda Recon series need accurate factory numbers to get the job done right. This original Honda publication delivers exactly that for the shop floor. It outlines the 229.2 cm3 air-cooled engine, detailing the 9.2:1 compression ratio and valve clearances set at a strict 0.13 mm for both intake and exhaust. Need to know the final gear case oil capacity? It holds exactly 80 cm3 after draining. The transmission section covers the 5-speed constant-mesh gearbox with reverse. You will also find electrical baselines, such as the 0.8–0.9 mm spark plug gap and complete testing protocols for the AC-CDI ignition system.

Maintenance and Component Highlights

Beyond the engine block, this book breaks down chassis and suspension geometries. It maps out the double-cradle frame and front double wishbone suspension, alongside exact specifications for the hydraulic drum brakes. For example, the front brake drum has a standard inner diameter of 130.0 mm, bottoming out at a service limit of 131.0 mm. Fuel system tuning gets highly specific, noting the initial pilot screw setting for the PDC1F carburetor at 1-1/2 turns out. Proper torque is essential when buttoning up these machines. You'll find specific bolt-tightening values throughout the documentation, like 25 N-m for the oil drain plug and 23 N-m for the exhaust muffler band bolt.

Keep in mind that working on ATVs involves heavy machinery, moving parts, and combustible fluids. Always refer directly to the detailed factory procedures inside this original documentation to ensure safe, reliable repairs.