Honda TRX680FA / TRX680FGA 2006–2011 Service & Repair Manual (P/N 61TXC00)

• Covers 2006–2011 Honda TRX680FA and TRX680FGA ATVs, including GPS-equipped variants, standard 4WD, and ESP-shift models
• Original OEM publication (P/N 61TXC00)
• Contains 567 pages of technical specifications, exploded-view diagrams, electrical schematics, and system-specific data
• Documents transmission logic, PGM-FI diagnostics, and detailed torque values
• Delivers the exact engineering baselines and electronic fuel injection tuning requirements unique to the 674.9 cc engine platform
• Features essential wiring diagrams, comprehensive troubleshooting guides, routine maintenance schedules, and complete repair procedures within the PDF
• Outlines the sub-transmission, front driving mechanism, rear driving mechanism, steering, suspension, and brake system

Manual Contents Overview

This document breaks down the core mechanical and electronic systems of the 2006–2011 Honda TRX680 series. The contents are structured heavily around technical features, general shop information, and procedural data. Having the exact oil pressure testing sequences and DTC blink code indices directly at the workbench accelerates diagnostic procedures and prevents costly misjudging of transmission slipping versus shift solenoid failures, directly increasing daily shop throughput.

Expect detailed component breakdowns covering frame and body panels, the liquid-cooled engine, and piston assemblies. It thoroughly maps out the complex A/T system—including torque converter and shift clutch management—while providing dedicated electrical chapters for charging systems, wiring layouts, and ignition timing. The structural breakdowns are supported by specific visual aids, including cable and harness routing views, lubrication system diagrams, gear tooth contact patterns, and component location drawings.

The documentation allows technicians to keep complex jobs in-house by providing step-by-step instructions for tasks that typically require expensive dealer intervention. These include retrieving and clearing PGM-FI trouble codes manually, conducting automatic transmission hydraulic oil pressure tests, and bleeding the hydraulic brake system.

When servicing the TRX680FA transmission, a common diagnostic trap involves utilizing engine oils with molybdenum additives that cause the wet shift clutches to slip, mimicking a major mechanical failure. Furthermore, understanding how to manually activate the internal emergency valve can restore limited mobility if the A/T clutch pressure control solenoid becomes mechanically stuck.

Engineering & Specification Highlights

Having the right numbers on hand prevents costly teardowns. The manual details critical tolerances for engine assembly and drivetrain work.

For example, primary torque specifications dictate 55 Nm for the cylinder head cover cap nut and 108 Nm for the primary driven gear lock nut. Documented fluid capacities include 2.0 liters of coolant and 78 cm³ of final gear case oil. It also defines strict operating parameters like a cylinder compression of 550 kPa, with valve clearances set tightly at 0.15 mm (intake) and 0.33 mm (exhaust).

Working on high-compression ATV engines involves heavy components and inherent physical risks. Because precision is critical for safe vehicle operation, always verify these sample baselines against the complete manual data before applying torque to any fasteners in your bay.