1997–2004 Honda TRX250TE/TM Fourtrax Recon ATV Service Manual (P/N 61TX400)

This Honda service manual covers 1997–2004 TRX250TE and TRX250TM Fourtrax Recon ATVs, including TE electric-shift and TM foot-shift configurations.

The download is a 378-page scanned PDF without searchable page text.

• Engine repair: Engine removal and installation, cylinder head and piston inspection, valve guide replacement, valve seat refacing, and camshaft and cam chain service.

• Fuel and lubrication: Carburetor disassembly and adjustment, high-altitude settings, oil pump inspection, centrifugal oil filter cleaning, and oil cooler service.

• Clutch and transmission: Centrifugal and change clutch repair, gearshift linkage inspection, crankcase separation, crankshaft measurement, and transmission disassembly and reassembly.

• Rear final drive: Axle and drive shaft removal, pinion and ring gear bearing replacement, gear backlash measurement, and tooth-contact pattern checks.

• Brakes and chassis: Hydraulic front drum-brake repair and bleeding, mechanical rear brake service, swingarm bearings, steering shaft inspection, and ball joint replacement.

• Electrical and ESP: Charging and ignition tests, starter motor repair, Electric Shift Program fault diagnosis, connector identification, and wiring diagrams.

Honda wrote this manual for readers with basic maintenance knowledge of its motorcycles, scooters or ATVs; standard workshop procedures are assumed.

Engine Repair and Lubrication

The engine sections distinguish work possible with the engine in the frame from jobs requiring removal. Cylinder head, piston, camshaft and clutch service are covered in-frame; crankshaft and transmission repair require engine removal and crankcase separation.

Cylinder compression testing, cold valve clearance checks and inspection limits support diagnosis of low compression, smoke and top-end noise. Separate cylinder head procedures cover the earlier rocker arm holder and the later head cover arrangement.

The maintenance schedule covers routine service, including the oil strainer and centrifugal filter. Oil pump rotor clearance inspection and the Lubrication System Diagram explain the lubrication system; the after-2001 material adds oil cooler removal, inspection and installation.

Carburetor Repair and Adjustment

Technical chapters break down fuel system tuning, detailing jet needle positions and pilot screw adjustments across different model years. Carburetor identification tables distinguish PDC1B, PDC1C and PDC1E units, including the California configuration.

The fuel chapter covers the air cutoff valve, float valve inspection and high-altitude adjustment. Float level inspection uses gauge 07401-0010000; the float itself is not adjustable. Carburetor repair cautions address pilot screw seat damage from overtightening.

Transmission and Rear Final Drive

Transmission gear ratios and exploded mainshaft/countershaft views identify changes between 1997–2001 and later assemblies. The Crankcase Bearing Locations drawing supports internal bearing identification, while clutch sections include disc, plate, spring and one-way clutch inspection.

Special tool references include clutch puller 07GMC-HB30100 and U.S. alternative 07933-HB3000A.

Rear-drive procedures go beyond oil changes to pinion removal, spacer selection and Gear Tooth Contact Pattern Check illustrations. The chapter also warns that torch heating can warp the final-drive gear case.

Brake, Steering and Chassis Service

Front-brake coverage includes the master cylinder, wheel cylinders, shoe adjusters and waterproof seals. Rear-brake procedures cover the drum, brake cam, pedal and cable adjustments.

Chassis sections address tie rods, toe adjustment and suspension-bearing replacement. The Frame Cover Removal Chart identifies body panel access requirements. Brake service and running-engine tests require the manual's precautions for brake dust, fuel and exhaust gases.

ESP Diagnosis and Wiring Diagrams

The TE-specific Electric Shift Program section contains a diagnosis table and circuit checks for the angle sensor, gear-position switch, shift-control motor and speed sensor. Gear-indicator blink codes lead to targeted checks, helping distinguish sensor, switch and wiring faults before replacing components.

Motor and reduction-gear service, reverse-shift switch testing and code clearing are also documented. The ESP system diagram distinguishes the main fuse circuit from the separate shift-system fuse.

Charging-system flowcharts, ignition peak-voltage tests and starter-relay checks support electrical fault tracing. Wiring diagrams cover the earlier and later configurations, including the TE shift-control circuit, with wire-color codes and switch connection tables.

Service Specifications and PDF Details

Torque tables are organized by fastener size and component. Reference data includes engine and final-drive oil capacities, wear limits, electrical test values and cold tire pressures.

The 23 numbered sections include general troubleshooting and an index. PDF bookmarks cover those sections and the contents page.

The total page count includes one cover, 12 blank pages and three repeated seller-agreement pages. Wiring diagrams are scanned as paired page halves; small wire codes and ECU labels require zooming and remain somewhat soft in the densest areas.