Honda Recon TRX250TM / TRX250TE Service Manual, 2005–2011 (P/N 61HM855)

Honda’s factory service manual (P/N 61HM855) covers the 2005–2011 Recon TRX250TM with foot shift and TRX250TE with the Electric Shift Program (ESP).

PDF Bookmarks and Wiring Diagram Readability

Navigation and diagram detail: Bookmarks open the chapters, index, and individual TM and TE wiring diagrams. Text search is unavailable. Zoom in to read small wiring labels. Some connector and wire-color codes remain faint even when enlarged.

The manual comes as one printable, English-language PDF with 410 pages, including the cover, two introductory pages, a safety information page, 13 memo pages, and one blank numbered page.

Engine, Drivetrain, and Electric Shift Service

This selection of workshop topics highlights the repair and diagnostic coverage. Other examples include muffler removal and oil cooler inspection.

• Engine and fuel system: Engine removal and installation, cylinder-head and valve repair, piston and camshaft inspection, oil-pump service, and carburetor overhaul.
• Clutches and rear drive: Centrifugal and change clutch service, reverse linkage repair, crankcase separation, transmission and crankshaft inspection, and rear final-drive overhaul.
• Steering, suspension, and brakes: Wheel and hub service, tie rods, knuckles, control arms, shocks, swingarm service, front hydraulic drum brake repair, and rear mechanical drum brake service.
• TRX250TE shift diagnosis: ESP blink-code retrieval and erasure, symptom flowcharts, ECU circuit checks, and tests for the shift motor, sensors, and switches.
• Electrical testing and wiring: Battery, charging, ignition, and starting-system diagnosis, with separate TM and TE wiring diagrams, system schematics, and harness routing.
• Factory service references: Exploded views, component torque tables, fluid and lubrication specifications, wear limits, electrical test values, and special tools identified by part number.

Honda wrote this manual for qualified service technicians familiar with shop safety, special tools, and test equipment. Follow the manual’s precautions when handling fuel, servicing hydraulic brakes or spring-loaded parts, and working on a raised ATV.

Maintenance, Carburetor, and Engine Work

The maintenance schedule covers valve clearance, engine oil, rear final-drive oil, clutch adjustment, brake and steering inspections, and spark-arrester cleaning. It refers to the separate owner’s manual for the pre-ride inspection. The carburetor chapter covers disassembly, inspection, reassembly, pilot-screw adjustment, high-altitude setup, and fuel tank service.

Engine-in-frame service: The cylinder head, valves, cylinder, piston, camshaft, clutches, recoil starter, alternator, starter clutch, carburetor, and oil pump can be serviced with the engine installed. Crankshaft and transmission service require engine removal, as does gearshift linkage service apart from gearshift plate mounting bolt adjustments.

The top-end chapters cover compression testing, rocker arm and piston ring inspection, valve guide replacement, valve seat refacing, and cam chain tensioner service. Tool callouts include the valve spring compressor (07757-0010000), valve guide driver (07742-0010100), and rotor puller (07733-0010000). The centrifugal clutch locknut has left-hand threads.

Chassis, Drum Brakes, and Rear Final Drive

The chassis chapters cover steering shaft bearings, toe adjustment, and front and rear suspension work. The front hydraulic drum brake procedures include fluid replacement, bleeding, and master and wheel cylinder repair. The rear mechanical drum brake coverage includes shoes, cables, and the pedal.

The rear drive chapter covers axle inspection, driveshaft service, and bearing and seal replacement. It also explains when to check ring gear tooth contact and backlash after replacing final-drive components.

ESP and Electrical Fault Finding

On the TRX250TE, the ESP flowcharts use first-gear indicator blink codes and a manual shift check to help trace a no-shift complaint to the mechanical linkage, transmission, or electrical controls. The chapter includes wiring continuity checks and tests for the angle sensor, shift motor and reduction gears, gear-position and reverse switches, vehicle-speed sensor, and handlebar shift switches. It also warns that disconnecting a powered ESP connector can damage the ECU.

Other electrical chapters cover battery current leakage, charging voltage, the alternator charging coil and regulator/rectifier, ignition timing and the pulse generator, and starter motor, relay, and diode checks. Lights, indicators, and switches have their own chapter. The general troubleshooting charts cover hard starting, loss of power, poor running at low or high speed, and handling faults.

Clutch Spring and Rear Gear Specifications at a Glance

The change clutch inspection lists a standard spring free length of 35.2 mm for the TRX250TM and 37.0 mm for the TRX250TE.

For the rear final drive on both models, the manual gives a standard gear backlash of 0.05–0.25 mm for dial-indicator inspection. It specifies 0.30–0.60 mm of clearance between the ring gear and stop pin for checking shim fit during assembly.