2004-2012 Honda TRX450R / TRX450ER Service Manual
Covers TRX450R and TRX450ER with procedures for engine removal and rebuilding, transmission and clutch service, complete cooling system diagnostics. Documents 548 pages of technical specifications and repair procedures.
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Sample pages from the 2004-2012 Honda TRX450R / TRX450ER Service Manual manual
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Models Covered & Key Technical Specifications
Honda TRX450R, TRX450ER — 2004–2012 Technical Service Sourcebook | TRX450 Series Collection.
- Calibrated Displacement Data: 449.4 cm³ (27.42 cu-in) is rated at the engine cylinder volume Architecture.
- Advanced Compression Ratio: The cylinder head requires 12.0:1 for standard combustion chamber pressure Logic.
- Operational Fuel Capacity: Tank volume reaches 11.7 liters (3.09 US gal, 2.57 Imp gal) Parameters.
- Measured Coolant Specification: 1.5 liters (1.6 US qt, 1.3 Imp qt) — establishes the radiator reserve capacity Framework.
- Core Engine Oil Capacity: 0.69 liter (0.73 US qt) after draining provides the lubrication volume Bounds.
- Nominal Transmission Oil: 0.68 liter (0.72 US qt) after draining achieves the gearbox fluid reserve Standards.
Professional Workshop Service Manual & Technical Specifications
Factory-Level Technical Repair Manual: ATV Thorough Maintenance & Repair Guide: Honda TRX450R/ER (2004-2012) Documentation-Framework
Application-Range: TRX450R, TRX450ER (2004-2012) // Asset-ID: Service Documentation, System Overhaul Reference, Multi-System Coverage // Component-Focus: Engine management, transmission systems, hydraulic systems, electrical circuits.
| Component | Baseline | Validation-Data |
|---|---|---|
| Engine Management | OHC Single Cam Architecture | Complete specifications provided |
| Transmission Control | 5-Speed Constant Mesh | Service procedures documented |
| Brake Systems | Dual Hydraulic Circuit | DOT 4 fluid requirements specified |
| Cooling Architecture | Liquid-Cooled Radiator | Thermostat operating parameters included |
| Electrical Integration | AC-CDI Ignition, Alternator Charging | Wiring diagram reference included |
The documentation provides guidance on integrated engine service, transmission procedures, hydraulic brake operation, and cooling system maintenance. Maintenance information covers fuel system architecture, lubrication routing, and component identification for both 2004-2005 and post-2005 model variants. Reference data includes crankcase, transmission, and crankshaft specifications alongside bearing and seal point locations throughout the vehicle.
Comprehensive Methodology
Transmission service information covers the constant-mesh 5-speed gearbox with detailed shift drum and fork assembly orientation. Cooling system procedures are included for radiator inspection, thermostat replacement, and water pump mechanical seal assessment. The manual documents engine oil circulation, transmission lubrication requirements, and bearing lubrication sequences with specific material recommendations for each application.
Diagnostic Parameters
Torque specifications are documented for the cylinder head nuts, crankshaft fasteners, and transmission component assembly to ensure proper mechanical engagement. Parts identification is covered for the fuel carburetor (QA16A), air cleaner housing foam element, and crankcase breather system routing. Removal procedures are documented for the balancer shaft, primary drive gear, and complete engine assembly from the frame structure.
Comprehensive Sequences
Detailed service sequences address front suspension inspection, rear suspension bearing replacement, and swingarm pivot maintenance with dust seal installation specifications. Brake fluid replacement procedures include air bleeding methodology for both hydraulic circuits with step-by-step caliper piston removal and seal installation. Valve clearance adjustment data references intake and exhaust valve positions with shim selection guidance across seventy-three available thickness intervals.
Operational Nexus
The manual documents torque specifications for the clutch center lock nut, gearshift drum assembly, and engine hanger fasteners to ensure structural integrity. Electrical system inspection covers the alternator stator bolt, ignition pulse generator positioning, and cooling fan motor circuit operation. Frame-mounted component service includes front brake master cylinder holder installation, steering shaft bearing replacement, and handlebar grip cement application guidance.
Structured Interface
Wiring diagram routing references address throttle cable path, clutch cable positioning, and brake hose orientation throughout the chassis. The document includes emission control system overview covering crankcase ventilation pathways and fuel system architecture. Cable and harness routing illustrations specify alternator wire paths, spark plug connections, and main wire harness clamp locations for organized electrical management.
The manual documents torque specifications for the frame mounting points to ensure proper oscillation integrity.
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