2006-2011 Honda TRX250EX / TRX250X Service Manual
Troubleshooting, parts diagrams, and service data for engine, transmission, clutch, brakes, suspension, and final drive systems. 371-page comprehensive technical reference.
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Models Covered & Key Technical Specifications
Honda TRX250EX, TRX250X — 2006–2011 Consolidated Mechanical Primer | TRX250 Series Kit.
- Calibrated Mass Specs: 172 kg (379 lbs) is specified as the vehicle curb weight Standard.
- Measured Gross Dimensions: For complete capacity, 229.2 cc (14 cu in) governs the engine displacement Norms.
- Advanced Torque Data: The crankshaft requires 9.2:1 compression ratio for combustion chamber operation Bounds.
- Standard Containment Volume: Fuel tank reaches 10.2 L (2.7 US gal) for TRX250EX models Topology.
- Principal Current Rating: Cylinder compression is rated at 1,275 kPa (185 psi) at 800 rpm Matrix.
- Key Rotation Data: Maximum idle speed sets the engine to 1,400 ± 100 rpm Standards.
Professional Workshop Service Manual & Technical Specifications
Specialized Factory Wiring Manual: Honda TRX250EX, TRX250X Service Manual (2006-2011) - Comprehensive Repair Guide Parts-Reference
Equipment-Series: TRX250EX (2006-2011), TRX250X (2006-2011) // Coverage-Scope: Single Cylinder OHV Engine Systems / Centrifugal and Change Clutch Logic // Unit-Designations: 371-page professional documentation covering complete powertrain and electrical reference data.
| Performance-Element | Technical-Path | Validation-Data |
|---|---|---|
| Engine & Transmission | Displacement 229.2 cm³ with constant mesh 5-speed transmission | Complete specifications provided |
| Lubrication Systems | Forced pressure and wet sump with trochoid oil pump | Documented clearances and thresholds |
| Brake Systems | Hydraulic front disc, mechanical rear drum architecture | See Chapters 15-16 |
| Electrical Charging | Single phase output alternator with SCA rectification | Charging voltage specifications included |
| Suspension & Steering | Double wish-bone front, swingarm rear with dampers | Component service procedures included |
Factory procedures are documented for frame and body panel service, then advance to lubrication system inspection, proceed through fuel system assembly protocols, and conclude with comprehensive electrical system verification. The manual specifies service intervals following EPA and CARB emission standards throughout its reference section.
Systematic Nexus
Quality checks are addressed for general maintenance procedures, valve clearance adjustment, and carburetor fuel-air mixture calibration. The document includes detailed specifications across all powertrain subsystems, with particular rigor applied to torque application data for critical fasteners. Component identification numbers, service limits, and replacement part cross-references are systematically organized by assembly location.
Structured Interface
The troubleshooting chapter addresses compression diagnostics, ignition system peak voltage testing, and transmission operational verification. Cooling system maintenance is addressed in the lubrication and oil cooler sections with explicit flow requirements. Test procedures for starter motor continuity, charging system output, and brake system hydraulic pressure are provided with reference voltage ranges and resistance measurements.
Structured Methodology
Testing requirements are specified for cylinder head valve timing, spark plug electrode gap verification, and clutch lever freeplay adjustment. The manual documents systematic disassembly and inspection protocols for all major subsystems, including crankcase separation procedures, transmission gear evaluation, and bearing clearance measurement techniques. Detailed component location diagrams supplement text-based service procedures throughout.
The service manual documents torque specifications for engine fasteners to ensure proper load distribution and vibration dampening.
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