2004-2009 Honda TRX450R Service Manual (P/N 07757-0010000)

• Covers 2004–2009 Honda TRX450R and TRX450ER sport ATVs, including both kick-start and electric-start variants
• Original OEM publication, P/N 07757-0010000
• Contains 522 pages of technical specifications, maintenance schedules, and mechanical layout illustrations
• Serves as the primary reference for servicing the 2004–2009 TRX450 series Unicam-equipped engines

What the Manual Documents

This OEM service publication delivers detailed mechanical breakdowns for the twin-sump lubrication system and the Unicam SOHC valve train. It organizes each major assembly by chassis and engine systems, providing the exact factory parameters for removal, inspection, and assembly across the 2004–2009 model years. Maintenance protocols clearly outline regular service intervals for the drivetrain, suspension, and braking components, helping you keep the vehicle performing at strict factory standards. Working on high-performance ATV engines and suspension setups involves inherent risks. Always verify your work against these factory limits before heading out to the track or trail to ensure mechanical integrity and rider safety.

Specification Highlights

Technical reference tables provide precise clearance data. For instance, intake valve clearance is set at 0.16 mm ± 0.03 mm. The engine lubrication data confirms the crankcase oil capacity at 1.20 liters following a total teardown. You will also find torque specifications for critical fasteners, such as the upper engine hanger nut listed at 54 Nm, ensuring accurate final assembly.