2004-2009 Honda TRX450R Service Manual

Diagnostic procedures and component service for the Honda TRX450R. Covers paper handling and control panel diagnostics. PN 07757-0010000.

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Document Details

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Document Number / Seller:
29500 / Carol Thomas
File Size:
42.88 MB
File Type:
PDF
Language:
English
Pages:
522
Printable:
Yes
Category:
ATV
Last updated / verified
May 31, 2025

Models Covered & Key Technical Specifications

Essential Instructional Manual: ATV Factory Service Protocols: Honda TRX450R (2004-2009) Procedure-Library

Functional Functional Archive | Series Archive. Design: Valve clearance: 0.16 mm sets the intake valve clearance Specification. Advanced: Containment Volume: 12.0 L represents the total engine oil capacity Boundary. Technical: Running Clearance: 5.475 mm ensures the valve stem O.D. tolerance Framework. Standard: Heat Tolerance: 1.1-1.3 mm indicates the free length of the valve spring Margin. Principal: Weight Data: 34.7 kg is the operational weight of the engine Matrix. Key: Threaded Fastener Data: 54 N-m provides the torque specification for the upper engine hanger nut Protocol.

Professional Workshop Service Manual & Technical Specifications

Essential Instructional Manual: ATV Factory Service Protocols: Honda TRX450R (2004-2009) Procedure-Library

Application-Range: 2004-2009 // Repair-Classification: Service Manual // Serial-Range: TRX450R

Engine and Chassis Specifications Table

Metric System-Path Validation-Data
Cylinder Arrangement Single Cylinder Transversely Installed
Fuel Tank Capacity 12.0 Liters 3.17 US Gal
Engine Oil Capacity 34.7 kg 76.8 lbs
Front Brake Hydraulic Disc 5.87° Caster Angle
Rear Brake Hydraulic/Mechanical Disc 0° Camber Angle

Repair procedures are structured around

Comprehensive coverage of the TRX450R's fuel system, including detailed diagrams and specifications for the carburetor, jets, and float levels. This manual documents critical adjustments for optimal performance and fuel efficiency, ensuring your ATV runs smoothly.

The manual provides in-depth information on the cooling system, covering radiator and fan assembly, coolant replacement procedures, and thermostat testing. It details maintenance for ensuring optimal engine temperature and preventing overheating.

Essential guidance for the lubrication system, detailing oil types, capacities, and procedures for oil and filter changes. It includes specifications for the oil pump and cooler, ensuring proper lubrication and engine longevity.

Detailed instructions for the ignition system and electrical components, covering spark plug specifications, ignition timing, and troubleshooting for electrical issues. This section ensures reliable starting and operation.

Covers the frame, body panels, and exhaust system, with procedures for removal and installation of components like fenders, guards, and the exhaust pipe. It ensures proper fitment and integrity of the ATV's external structure.

FAQ

What **designated** tools are required for valve clearance adjustment? keyboard_arrow_down

Valve clearance adjustment requires a valve spring compressor (07757-0010000), a driver (07749-0010000), and a pilot (07746-0040500) for precise measurement and adjustment.

Identify the **critical** pressure specifications for the radiator cap. keyboard_arrow_down

The radiator cap relief pressure must be between 108 - 137 kPa (1.1 - 1.4 kgf/cm², 16 - 20 psi) to ensure the cooling system operates correctly.

What **required** procedures are there for replacing the starter motor cable? keyboard_arrow_down

Starter motor cable replacement involves removing the rubber cap from the starter motor terminal, removing the terminal nut, and disconnecting the starter motor cable. Ensure the battery ground cable is also disconnected and tightened properly.

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The troubleshooting guide is incredibly helpful. Support responded quickly to my questions about the download. Great service!
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As a beginner, I found the explanations clear and helpful. Plus, the email support was fantastic and very responsive!
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This manual is a lifesaver! The step-by-step guides made my maintenance tasks so much easier. Quick download process too!
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I love how detailed this manual is. The electrical systems section was particularly useful. Download was smooth and quick!