Honda TRX250TE/TM Fourtrax ATV Service Manual 1997-2004 (P/N 61TX400)
378 Pages • 45.58 MB • Instant, Printable PDF
Honda Models Covered & Key Technical Specifications
Models: Honda TRX250TE, Honda TRX250TM, Fourtrax Recon
Sub-models / Variants: TE (Electric Shift Program), TM (Manual shift), 1997-2001 (pre-update), After 2001 (post-update)
Trade Names: Fourtrax, Recon
Model Years: 1997–2004
Technical Data:
- Engine: Single-cylinder, 229 cc, 4-stroke, air-cooled
- Transmission: 5-speed with reverse, automatic clutch
- Fuel System: Piston valve carburetor, 20 mm throttle bore
- Starter: Recoil and electric starter
- Ignition: AC-CDI system
- Final Drive: Chain drive, 3.692 reduction ratio
- Max Operational Temperature: 80 C (176 F)
- Battery Capacity: 12V 10AH
Honda Manual Features & Content Preview
- Covers 1997–2004 Honda TRX250TE and TRX250TM Fourtrax Recon ATVs, including electric-shift and manual transmission configurations
- Official 378-page Honda publication 61TX400, providing factory-authorized technical documentation for the Recon series
- Includes 23 detailed sections covering maintenance, engine, chassis, and electrical systems with factory torque specifications
- Contains comprehensive wiring schematics for both 1997–2001 and post-2001 models to ensure accurate electrical system diagnostics
- The 2004-dated edition documents the transition of the TE electric shift program and updated engine specifications, making it the definitive reference for this eight-year production range
Component and Maintenance Documentation
This manual outlines the exact technical specifications for the entire Fourtrax Recon lineup. Whether you are evaluating transmission gear ratios, pulling an engine, or inspecting chassis components, having the correct factory data is essential. Routine maintenance intervals are clearly laid out to keep the air-cooled engine running efficiently. Working on ATVs carries inherent risks; utilizing the exact factory tolerances provided here ensures you can safely and accurately assess component wear.
Technical chapters break down fuel system tuning, detailing jet needle positions and pilot screw adjustments across different model years. You will find all critical fluid capacities, including the 1.5–1.6 liter engine oil requirement and the 80 cm3 final drive oil capacity. For electrical diagnostics, the text provides pinout identification and fuse ratings for the 15A main fuse system. Torque reference tables are grouped systematically by fastener diameter, covering everything from 5 mm screws up to 32 mm axle nuts.
Technical Specifications Preview
Engine compression is documented at 1,275 kPa (185 psi) at 800 rpm. Intake and exhaust valve clearances must measure 0.13 mm (0.005 in) cold. The oil pump rotor tip clearance service limit is set at 0.20 mm, while front and rear tire cold pressure sits at 20 kPa (2.9 psi) for standard operation. This document serves strictly as a comprehensive reference guide to the manual's contents, providing technical data without step-by-step repair instructions.
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