Honda TRX250TE FourTrax Recon ES ATV Owner's Manual 2003–2004 (P/N 31HM8820)

This Honda owner's manual (P/N 31HM8820) covers safe operation and routine maintenance for the 2004 Honda TRX250TE FourTrax Recon ES ATV.

Finding Information in the PDF

Contents and index: Use the printed table of contents and index to locate topics. Text search and embedded PDF bookmarks are unavailable.

The download is one printable, 234-page PDF in English. The total includes 220 numbered pages, four of which carry only a page number and section footer, plus nine front-matter pages, four Quick Reference pages, and the back cover.

Riding Controls, Routine Service, and Trail Troubleshooting

These selected topics show what the manual covers. It also explains how to transport the ATV and prepare it for extended storage.

• Pre-ride checks and loading: Inspection points for tires, controls, and cargo, plus guidance on rack loads, trailer weight, and the combined tongue and rear cargo limit.

• Starting and shifting: Starting and warm-up procedures for different air temperatures, flooded-engine clearing, recoil starting, gear position indicators, and reverse selector operation.

• Engine and air cleaner service: Step-by-step engine oil changes, spark plug inspection and replacement, spark arrester purging, and foam filter cleaning and oiling.

• Throttle, clutch, and final drive: Throttle freeplay and choke cable checks, wet multiplate clutch and reverse lock adjustments, and hypoid gear oil changes.

• Drum brakes: Front hydraulic and rear mechanical brake inspections, front shoe clearance adjustment, and rear lever and pedal freeplay adjustment.

• Battery and fuses: Battery removal, installation, storage, and trickle charging, with an illustration identifying the main and shift-control motor fuse holders.

• Trail troubleshooting: Starting and poor-running symptom charts, checks for unresponsive shift switches, emergency gear selection, and flat-tire guidance with wheel removal and installation.

Owners can use the manual for riding guidance and, with basic mechanical skills and the tools supplied with the ATV, for many routine maintenance tasks.

Starting Problems and Emergency Shifting

The starting charts distinguish a starter that does not turn, an engine that cranks without starting, and an engine that starts but runs poorly. Owners can use those distinctions to narrow down the complaint before arranging a repair.

Honda limits manual gear selection with the supplied gear change tool to emergencies. Continued or abusive manual shifting can damage the gear change mechanism. The manual also explains when recoil starting is possible with a dead battery.

Scheduled Service and Inspection Points

The maintenance schedule flags jobs that require additional service data, tools, or dealer attention. Reference tables list fuel and lubricant requirements, fluid capacities, and selected fastener torques.

The air cleaner section identifies the filter, body, and clamp and covers servicing the housing drain tube. Honda warns that wringing the foam can tear it and that a poor filter seal can let dirt into the engine. Throttle cable checks cover routing, condition, and tension through the steering range.

The front drums have inspection holes for checking lining thickness. The rear drum has an external wear indicator. Honda refers brake bleeding to a dealer and provides the wheel removal procedure for emergency service. The maintenance precautions cover secure support for wheel work and ventilation when the engine must run.

Valve Clearance and High-Altitude Carburetion

The owner's manual lists valve clearance and explains why high-altitude riding can require a different carburetor jet. Honda directs readers to the separate Service Manual for valve adjustment and jet installation. Internal engine and transmission repairs also fall outside the owner's manual's scope.

Sample Throttle and Tire Specifications

The throttle inspection calls for 1/8–5/16 in (3–8 mm) of freeplay at the throttle lever. The accompanying illustration identifies the lever and cable adjuster.

The tire table gives a recommended cold pressure of 2.9 psi (20 kPa) for both front and rear tires, with or without cargo.