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Honda TRX250 Repair Manual 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

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TRANSMISSION GEARSHIFT LINKAGE ADJUSTMENT/INSPECTION

If shifting problems are encountered, the transmission linkagemay require adjustment.

Visually check for contact of shift lever to shifter opening in the front fender. Ensure shift linkage or shift lever is not contacting the frame or exhaust components.

Tighten shift linkage rod end jam nuts properly after adjustment. You should be able to rotate the linkage rod between 1/8 and 1/4 turn after both jam nuts are tight.

The transmission shift linkage should be periodically inspected for wear and parts replaced as required to remove excess play from shift linkage.

SHIFT LINKAGE ADJUSTMENT

1. Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged.
2. Place gear selector in neutral.
3. Loosen rod end adjuster jam nuts (A) on both ends of linkage rod. NOTE: The jam nut closest to the knurled end is Left Hand thread.
4. Turn linkage rod (A) to shorten or lengthen rod until the shift lever is centered on hole in the fender.
5. Hold rod end parallel to mounting surface and tighten jam nuts securely.

THROTTLE OPERATION

Check for smooth throttle opening and closing in all
handlebar positions. Throttle lever operation should
be smooth and lever must return freely without
binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition. If cable is routed properly and in good condition, repeat adjustment procedure.
5. Replace the throttle cable if worn, kinked, or damaged.

CHOKE (ENRICHER) ADJUSTMENT

If the choke knob does not stay out when pulled, adjust the choke tension by tightening the tensioner located under the rubber boot between the choke knob and nut. Firmly grasp the rubber boot and tighten until the choke slides freely but stays out when pulled. Verify free play of 1/16--3/16” (1.6--4.76 mm) and smooth operation of choke cable. If smooth choke operation is not obtainable, inspect choke cable for kinks or sharp bends in routing.

PILOT SCREW

The pilot systemsupplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into themain bore through the pilot outlet.

PILOT SCREW ADJUSTMENT

1. Start engine and warm it up to operating temperature (about 10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns. NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged.
3. Connect an accurate tachometer that will read inincrements of + or -- 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN 8712500).
4. Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.
5. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss.
6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop.
7. Center the pilot screw between the points in Step 5 and 6.
8. Re adjust idle speed if not within specification.


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