Honda TRX250ex 2005 Service manual

Honda TRX250ex · 2005 · service manual · 306 pages

Honda TRX250ex
2005
Service manual
306 pages
ATV

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Oil drain-bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 14
Spark plug	18 N·m	1.8 kgf·m · 13 ft·lb	p. 14
Timing hole cap	10 N·m	1 kgf·m · 7 ft·lb	p. 14
Valve adjusting hole cap	20 N·m	2 kgf·m · 14 ft·lb	p. 14
Valve adjusting screw lock-nut	17 N·m	1.7 kgf·m · 12 ft·lb	p. 14
Carburetor insulator stud bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 14
Cylinder head cover bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 14
Cylinder head flange nut	30 N·m	3.1 kgf·m · 22 ft·lb	p. 14
Cam chain tensioner arm pivot bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 14
Front crankcase stud bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 14
Rear crankcase stud bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 14
Centrifugal clutch-drum lock nut	88 N·m	9 kgf·m · 65 ft·lb	p. 14
Change clutch center lock nut	79 N·m	8.1 kgf·m · 59 ft·lb	p. 14
Change clutch lifter plate bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 14
Gearshift return spring pin bolt	22 N·m	2.2 kgf·m · 16 ft·lb	p. 14
Gearshift cam plate bolt	16 N·m	1.6 kgf·m · 12 ft·lb	p. 14
Gearshift A arm bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 14
Gearshift drum stopper arm bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 14
Flywheel bolt	74 N·m	7.5 kgf·m · 54 ft·lb	p. 14
Starter one-way clutch outer Torx bolt	16 N·m	1.6 kgf·m · 12 ft·lb	p. 14
Ignition pulse generator bolt	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 14
Neutral switch rotor socket-bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 14
Neutral switch and reverse switch	13 N·m	1.3 kgf·m · 9 ft·lb	p. 14
Footpeg mounting nut	32 N·m	3.3 kgf·m · 24 ft·lb	p. 15
Skid plate bolt	32 N·m	3.3 kgf·m · 24 ft·lb	p. 15
Muffler band bolt	23 N·m	2.3 kgf·m · 17 ft·lb	p. 15
Spark arrester bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 15
Engine mounting nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 15
Cylinder head mounting rubber bolt	32 N·m	3.3 kgf·m · 24 ft·lb	p. 15
Gearshift pedal pinch bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 15
Handlebar lower holder nut	39 N·m	4 kgf·m · 29 ft·lb	p. 15
Steering shaft end nut	108 N·m	11 kgf·m · 80 ft·lb	p. 15
Tie-rod ball joint nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 15
Tie-rod lock nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 15
Steering shaft holder bolt	32 N·m	3.3 kgf·m · 24 ft·lb	p. 15
Upper arm pivot nut	30 N·m	3.1 kgf·m · 22 ft·lb	p. 15
Lower arm pivot nut	30 N·m	3.1 kgf·m · 22 ft·lb	p. 15
Knuckle ball joint nut	32 N·m	3.3 kgf·m · 24 ft·lb	p. 15
Shock absorber upper mounting nut	30 N·m	3.1 kgf·m · 22 ft·lb	p. 15
Shock absorber lower mounting nut	30 N·m	3.1 kgf·m · 22 ft·lb	p. 15
Front wheel hub nut	69 N·m	7 kgf·m · 51 ft·lb	p. 15
Front wheel nut	64 N·m	6.5 kgf·m · 47 ft·lb	p. 15
Throttle case cover screw	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 15
Shock absorber upper mounting nut	44 N·m	4.5 kgf·m · 33 ft·lb	p. 15
Shock absorber lower mounting bolt	44 N·m	4.5 kgf·m · 33 ft·lb	p. 15
Rear axle nut	39 N·m	4 kgf·m · 29 ft·lb	p. 15
Rear axle nut lock nut	127 N·m	13 kgf·m · 94 ft·lb	p. 15
Rear wheel hub nut	147 N·m	15 kgf·m · 108 ft·lb	p. 15
Rear wheel nut	64 N·m	6.5 kgf·m · 47 ft·lb	p. 15
Swingarm right pivot bolt	112 N·m	11.4 kgf·m · 82 ft·lb	p. 15
Swingarm left pivot adjusting bolt	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 15
Swingarm left pivot lock nut	112 N·m	11.4 kgf·m · 82 ft·lb	p. 15
Rear brake arm nut	12 N·m	1.2 kgf·m · 9 ft·lb	p. 15
Rear brake panel drain bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 15
Brake disc cover bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 15
Brake disc bolt	42 N·m	4.3 kgf·m · 31 ft·lb	p. 15
Master cylinder reservoir cap screw	1.5 N·m	0.15 kgf·m · 1.1 ft·lb	p. 15
Brake hose oil bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 15
Brake pipe bolt	17 N·m	1.7 kgf·m · 12 ft·lb	p. 15
Brake caliper/bracket mounting bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 15
Brake caliper bleed valve	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 15
Brake caliper pad pin plug	3 N·m	0.3 kgf·m · 2.2 ft·lb	p. 15
Brake caliper pad pin	18 N·m	1.8 kgf·m · 13 ft·lb	p. 15
Brake lever pivot bolt	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 15
Brake lever pivot lock nut	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 15
Brake caliper slide pin bolt	22 N·m	2.2 kgf·m · 16 ft·lb	p. 15
Brake caliper bracket pin bolt	18 N·m	1.8 kgf·m · 13 ft·lb	p. 15
Final gear case mounting bolt	54 N·m	5.5 kgf·m · 40 ft·lb	p. 16
Pinion bearing lock nut	98 N·m	10 kgf·m · 72 ft·lb	p. 16
Final gear case drain-bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Final gear case oil check bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Final gear case oil cap	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Headlight aim adjusting screw 1	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 16
Valve adjusting wrench	25 N·m	2.5 kgf·m · 18 ft·lb	p. 38
Valve adjusting wrench	18 N·m	1.8 kgf·m · 13 ft·lb	p. 38
Valve adjusting wrench	10 N·m	1 kgf·m · 7 ft·lb	p. 38
Gear case oil cap groove	12 N·m	1.2 kgf·m · 9 ft·lb	p. 49
Lock nut	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 52
Tie-rod lock nuts	54 N·m	5.5 kgf·m · 40 ft·lb	p. 55
Pilot screw wrench	10 N·m	1 kgf·m · 7 ft·lb	p. 65
Oil drain bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 79
Engine mounting nuts	54 N·m	5.5 kgf·m · 40 ft·lb	p. 84
Carburetor insulator mounting bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 89
Change clutch center lock nut	88 N·m	9 kgf·m · 65 ft·lb	p. 121
Gearshift Aarm bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 142
Brake caliper/bracket mounting bolt	39.3 N·m	29 ft·lb	p. 179
Brake caliper/bracket mounting bolt	108 N·m	11 kgf·m · 80 ft·lb	p. 179
Brake caliper/bracket mounting bolt	54 N·m	5.5 kgf·m · 40 ft·lb	p. 179
Joint nuts	32 N·m	3.3 kgf·m · 24 ft·lb	p. 195
Holder bolts	32 N·m	3.3 kgf·m · 24 ft·lb	p. 201
Joint stud flat surfaces	54 N·m	5.5 kgf·m · 40 ft·lb	p. 202
We Brake disc cover bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 227
Reservoir cap screws	1.5 N·m	0.15 kgf·m · 1.1 ft·lb	p. 230
Final gear case drain bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 241
Ee Spark plug	18 N·m	1.8 kgf·m · 13 ft·lb	p. 271
Neutral switch	12 N·m	1.2 kgf·m · 9 ft·lb	p. 291
Reverse switch	12 N·m	1.2 kgf·m · 9 ft·lb	p. 291
Headlight aim adjusting screw	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 291

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	PDF page
DPR8EA	0.8–0.9 mm	p. 13
AT22	—	p. 38
HN6	—	p. 105
DPR8EA	—	p. 271

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