2005–2012 Honda TRX250TE/TM Service Manual (P/N 18747-112-000)

• Covers 2005–2012 Honda TRX250TE and TRX250TM Recon models, detailing both manual foot-shift and Electric Shift Program (ESP) configurations
• Original OEM publication (P/N 18747-112-000) supporting the 229.2 cc longitudinal engine platform
• Contains 412 pages of mechanical data, torque specifications, wiring diagrams, lubrication charts, and exploded-view illustrations
• Provides the factory-authorized reference essential for deep diagnostic and system verification work
• Delivers step-by-step repair instructions for carburetor rebuilds, valve clearance adjustments, and brake bleeding to avoid expensive dealership visits
• Explores vital assemblies including the fuel system, rear driving mechanism, crankcase, alternator, starter clutch, and gearshift linkage

Mechanical and Electrical Documentation

This official PDF manual delivers precise technical baseline data for the entire Recon platform, providing a significant advantage for daily shop operations by minimizing diagnostic times. Detailed sections break down the engine top-end, transmission, clutch, and drive train. Technicians will find specialized chapters dedicated to troubleshooting the ESP system in TE variants, supplying exact resistance values for the angle sensor and shift control motor to prevent time-consuming multimeter trial-and-error. The documentation outlines exact specifications for cylinder head components, piston clearances, and valve train setup. Electrical coverage encompasses the charging system, ignition timing, and complete wiring diagrams for the 12V 10Ah battery configuration. Visual references are abundant; alongside the electrical schematics, the text provides cable and harness routing drawings, emission control routing diagrams, troubleshooting flowcharts, lubrication system diagrams, and gear tooth contact pattern views to accelerate any complex repair. Furthermore, chassis sections detail front and rear suspension, brake system adjustments, and steering geometry. As with any ATV maintenance procedure, always stabilize the vehicle properly and verify equipment load ratings before beginning diagnostic work to prevent injury or component damage.

Specification and Data Preview

Technical content includes the precision metrics vital for professional-grade maintenance and any major repair. For example, the text lists a 30 N·m cylinder head nut torque and a 1.5-liter crankcase oil capacity. Cylinder compression is documented at 1,275 kPa at 800 rpm. According to the cylinder head specification table, intake valve clearance is tightly regulated at 0.13 mm. Ignition timing is specified at 14° BTDC at idle. When tackling intricate tasks, knowing platform-specific pitfalls prevents catastrophic component failure. For instance, mechanics can easily strip the crankshaft by forgetting that the centrifugal clutch center lock nut utilizes left-hand threads. Furthermore, applying a direct torch flame to the final drive gear case cover to remove the ring gear bearing will cause irreversible aluminum warpage; the reference strictly dictates using an oven or hot plate to reach exactly 80°C (176°F) for safe extraction. Having these exact factory figures readily available streamlines the workflow and ensures accuracy in any busy shop or home garage.