2006-2012 Honda TRX90 / TRX90EX / TRX90X Service Manual
Complete Honda TRX90 service manual covering engine (85.8cc single-cylinder OHC), transmission, clutch system with PB5FB carburetor specifications and torque values for all major components including valve clearance (0.05mm), spark plug gap (0.60-0.70mm), and Pro Honda GN4 10W-30 oil requirements.
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Models Covered & Key Technical Specifications
Honda TRX90, TRX90EX, TRX90X (61HNP06) — 2006–2012 Engineered Mechanical Specification Packet | TRX90 Series Repository.
- Engineered Weight Data: 85.8 cm³ (5.23 cu in) is configured at the engine cylinder displacement Architecture.
- Measured Net Mass: For optimal displacement performance, 47.0 × 49.5 mm (1.85 × 1.95 in) produces the crankshaft bore and stroke Sequences.
- Standard Output Density: 9.2:1 — maintains the compression chamber pressure requirement Baseline.
- Principal Capacity Limits: The fuel tank requires 7.5 liters (1.98 US gal, 1.65 Imp gal) system capacity Requirements.
- Advanced Energy Draw: 0.7 liter (0.74 US qt, 0.62 Imp qt) is set to engine oil drainage volume Threshold.
- Primary Angular Speed: Idle speed reaches 1,600 ± 100 rpm (min⁻¹) parameter configuration Mapping.
Professional Workshop Service Manual & Technical Specifications
Comprehensive Service Manual: Honda TRX90 TRX90EX/X (2006–2012) Maintenance-Registry
Specification-Class: Honda TRX90 Series (2006–2012) // Unit-Designations: Engine System / Powertrain Logic // Maintenance-Category: Complete technical documentation with OEM specifications.
| Component System | Reference | Documentation |
|---|---|---|
| Engine & Drivetrain | Sections 4–11 | Lubrication, fuel, ignition, and transmission systems fully documented |
| Suspension & Steering | Sections 12–13 | Front and rear wheel assemblies with brake specifications |
| Electrical Systems | Sections 14–16 | Battery, charging, starter, and ignition control module data |
Diagnostic procedures address engine removal and installation, cylinder head and valve service, clutch and gearshift linkage maintenance, alternator and starter clutch operations, crankcase transmission and crankshaft assembly, front and rear brake systems, suspension articulation, and electrical component troubleshooting. The manual documents service rules, model identification procedures, and cable and harness routing configurations with emission control system requirements for EPA and CARB compliance.
Structured Protocol
Technical specifications are provided for the single-cylinder, air-cooled engine featuring 85.8 cm³ displacement with a chain-driven overhead camshaft architecture. The carburetor identification (PB5FB) uses specified main jet (#82) and slow jet (#40) configurations with documented idle speed parameters. Engine rebuild procedures are documented for piston pin and connecting rod assembly, cylinder bore and hoist clearance verification, and crankshaft bearing inspection and replacement methodologies.
Diagnostic Topology
Factory specifications are documented for the forced-pressure wet sump lubrication system requiring Pro Honda GN4 10W-30 engine oil with drainage and refill capacities clearly outlined. The DC-CDI ignition framework utilizes NGK CR7HSA spark plugs with specific gap requirements and timing advance specifications. Drive chain specifications address slack measurements, sprocket inspection protocols, master link replacement procedures, and lubrication requirements for O-ring chains, preventing common wear patterns.
Technical Threshold
Drivetrain specifications are addressed in the transmission section, covering the four-speed constant mesh gearbox with specific gear ratios, shift drum operations, and transmission bearing service limits. Centrifugal and manual clutch systems are documented with wear limits for clutch discs, plates, weight assemblies, and one-way clutch components. The manual documents torque specifications for the swingarm pivot nut (88 Nm), axle outer lock nut (127 Nm), and cylinder head cover cap nut (14 Nm) to ensure proper fastener fatigue prevention.
Systematic Methodology
Reassembly procedures are specified for brake drum bearing replacement, featuring distance collar installation, dust seal application techniques, and hub nut torque sequences with cotter pin alignment requirements. Front and rear brake panel assembly includes felt seal lubrication, indicator plate positioning, brake shoe installation, and cable connection protocols documented with hydraulic measurement standards. The manual provides comprehensive wiring diagram coverage addressing battery, charging system, ignition control module, starter motor, neutral indicator, and gear position switch circuit configurations.
Core Nexus
Engine specifications table includes compression ratio (9.2:1), valve timing data (intake opens 5° BTDC, closes 15° ABDC; exhaust opens 35° BBDC, closes 7.5° BTDC), and complete dimensional specifications for piston, cylinder, and ring assemblies with measurable service limits. Maintenance schedule recommendations detail service intervals for air cleaner inspection, spark plug replacement, valve clearance adjustment, engine oil changes, battery testing, and brake system verification. The document provides complete torque value tables covering engine fasteners, frame components, electrical mounting hardware, and suspension pivot points with application notes for locking agents, engine oil, and grease requirements.
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