Honda Trx300ex 2009 Service manual

Honda Trx300ex · 2009 · service manual · 366 pages

Honda Trx300ex
2009
Service manual
366 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
6mm screw	9 N·m	0.9 kgf·m · 6.6 ft·lb	p. 15
Valve adjuster lock nut	18 N·m	1.8 kgf·m · 13 ft·lb	p. 15
Timing hole cap	10 N·m	1 kgf·m · 7 ft·lb	p. 15
Oil drain bolt	24 N·m	2.4 kgf·m · 18 ft·lb	p. 15
Oil filter cover bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 15
Oil pipe bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 15
Relief valve cap	19 N·m	1.9 kgf·m · 14 ft·lb	p. 15
Fuel valve nut	23 N·m	2.3 kgf·m · 17 ft·lb	p. 15
Insulator/connecting hose band	4 N·m	0.4 kgf·m · 3 ft·lb	p. 15
Float chamber screws	2.1 N·m	0.2 kgf·m · 1.5 ft·lb	p. 15
Accelerator pump cover screws	2.1 N·m	0.2 kgf·m · 1.5 ft·lb	p. 15
Throttle valve screws	0.9 N·m	0.1 kgf·m · 0.7 ft·lb	p. 15
Throttle valve arm screw	2.1 N·m	0.2 kgf·m · 1.5 ft·lb	p. 15
Top cover screws 3	2.1 N·m	0.2 kgf·m · 1.5 ft·lb	p. 15
Cylinder head cover bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Cylinder head cover SH bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 16
Oil pass pipe bolt	14 N·m	1.4 kgf·m · 10 ft·lb	p. 16
Cylinder head bolt	39 N·m	4 kgf·m · 29 ft·lb	p. 16
Cylinder head cap nut	39 N·m	4 kgf·m · 29 ft·lb	p. 16
Cam sprocket bolt	20 N·m	2 kgf·m · 15 ft·lb	p. 16
Cylinder SH flange bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 16
Right crankcase cover bolt 72	10 N·m	1 kgf·m · 7 ft·lb	p. 16
Neutral switch	13 N·m	1.3 kgf·m · 10 ft·lb	p. 16
Reverse switch 1	13 N·m	1.3 kgf·m · 10 ft·lb	p. 16
Primary drive gear bolt	68 N·m	6.9 kgf·m · 50 ft·lb	p. 16
Clutch center lock nut	108 N·m	11 kgf·m · 80 ft·lb	p. 16
Clutch spring bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Gearshift stopper arm bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Gearshift drum center bolt	22 N·m	2.2 kgf·m · 16 ft·lb	p. 16
Left crankcase cover bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 16
Stator bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 16
Flywheel bolt	108 N·m	11 kgf·m · 80 ft·lb	p. 16
Ignition pulse generator bolt	6 N·m	0.6 kgf·m · 4.4 ft·lb	p. 16
Starter gear cover bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 16
Starter one-way clutch bolt	16 N·m	1.6 kgf·m · 12 ft·lb	p. 16
Gearshift pedal pinch bolt 1	16 N·m	1.6 kgf·m · 12 ft·lb	p. 16
Breather plate bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Cam chain slider bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 16
Rear wheel nut	64 N·m	6.5 kgf·m · 47 ft·lb	p. 18
Driven sprocket nut	59 N·m	6 kgf·m · 44 ft·lb	p. 18
Rear wheel hub nut	147 N·m	15 kgf·m · 108 ft·lb	p. 18
Axle outer lock nut	88 N·m	9 kgf·m · 65 ft·lb	p. 18
Axle inner lock nut	128 N·m	13.1 kgf·m · 94 ft·lb	p. 18
Brake disc nut	26 N·m	2.7 kgf·m · 19 ft·lb	p. 18
Axle bearing holder stopper bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 18
Axle bearing holder pinch bolt	22 N·m	2.2 kgf·m · 16 ft·lb	p. 18
Swingarm pivot nut	108 N·m	11 kgf·m · 80 ft·lb	p. 18
Front brake caliper bracket bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 18
Front brake hose oil bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 18
Lad Brake pipe joint	17 N·m	1.7 kgf·m · 13 ft·lb	p. 18
Cap screw Front master cylinder holder bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 18
Front brake lever pivot bolt	1 N·m	0.1 kgf·m · 0.7 ft·lb	p. 18
Front brake lever pivot nut	5.9 N·m	0.6 kgf·m · 4.4 ft·lb	p. 18
Front brake caliper slide pin	22 N·m	2.2 kgf·m · 16 ft·lb	p. 18
Front and rear brake caliper	5.4 N·m	0.6 kgf·m · 4 ft·lb	p. 18
Bleed valve Rear brake caliper bracket bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 18
Nut Parking brake adjusting bolt lock	17 N·m	1.8 kgf·m · 13 ft·lb	p. 18
Nut Parking brake base bolt	22 N·m	2.2 kgf·m · 16 ft·lb	p. 18
Rear brake caliper slide pin	22 N·m	2.2 kgf·m · 16 ft·lb	p. 18
Footpeg	49 N·m	5 kgf·m · 36 ft·lb	p. 35
Mounting bolts and washer	12 N·m	1.2 kgf·m · 9 ft·lb	p. 39
Muffler mounting bolts	54 N·m	5.5 kgf·m · 40 ft·lb	p. 40
Muffler mounting bolts	74 N·m	7.5 kgf·m · 55 ft·lb	p. 40
Exhaust pipe band bolt	23 N·m	2.3 kgf·m · 17 ft·lb	p. 40
Drive chain roller bolt	18 N·m	1.8 kgf·m · 13 ft·lb	p. 42
Drive chain roller bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 42
Pinch bolts	22 N·m	2.2 kgf·m · 16 ft·lb	p. 54
Linkage cover screws	23 N·m	2.3 kgf·m · 17 ft·lb	p. 81
Connecting hose band screws	4 N·m	0.4 kgf·m · 3 ft·lb	p. 85
We BAFFLE THROTTLE STOP SCREW STAY SCREW FLOAT	4.9 N·m	0.5 kgf·m · 3.6 ft·lb	p. 93
Lock nut	1.8 N·m	0.2 kgf·m · 1.3 ft·lb	p. 94
Front upper engine hanger nut	59 N·m	6 kgf·m · 44 ft·lb	p. 107
Front lower engine hanger nut	59 N·m	6 kgf·m · 44 ft·lb	p. 107
Rear upper engine hanger nut	74 N·m	7.5 kgf·m · 55 ft·lb	p. 107
Rear lower engine hanger nut	59 N·m	6 kgf·m · 44 ft·lb	p. 107
Crankshaft	20 N·m	2 kgf·m · 15 ft·lb	p. 136
Cam chain tensioner lifter sealing bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 143
Tensioner lifter bolts	10 N·m	1 kgf·m · 7 ft·lb	p. 151
Right crankcase cover bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 155
Gearshift return spring pin	21 N·m	2.1 kgf·m · 15 ft·lb	p. 179
Gearshift pedal pinch bolt	16 N·m	1.6 kgf·m · 12 ft·lb	p. 187
Mainshaft bearing setting plate bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 203
Brake disc bolt	26 N·m	2.7 kgf·m · 19 ft·lb	p. 227
Pin hole	69 N·m	7 kgf·m · 51 ft·lb	p. 244
Pin hole	54 N·m	5.5 kgf·m · 40 ft·lb	p. 251
Bolts alternately	27 N·m	2.8 kgf·m · 20 ft·lb	p. 256
Shock absorber upper and lower nut	108 N·m	11 kgf·m · 80 ft·lb	p. 263
Cotter pin holes	147 N·m	15 kgf·m · 108 ft·lb	p. 276
Mounting nuts	108 N·m	11 kgf·m · 80 ft·lb	p. 278
Parking brake base bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 286
Parking brake base bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 286
Parking brake base bolt	17 N·m	1.7 kgf·m · 13 ft·lb	p. 286
Bleed valve	5.4 N·m	0.6 kgf·m · 4 ft·lb	p. 289
RUBBER CAP Zier PIN	22 N·m	2.2 kgf·m · 16 ft·lb	p. 301
Joint lock nut	17 N·m	1.8 kgf·m · 13 ft·lb	p. 305
Ym suide PIN	22 N·m	2.2 kgf·m · 16 ft·lb	p. 308

Spark plugs

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

Item	Value	PDF page
DR8ES-L	0.6–0.7 mm	p. 13
P12	—	p. 15
O7KMA	—	p. 102
DR8ES-L	—	p. 325

Service intervals

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

Item	Value	Also	PDF page
Drive chain service	300 miles		p. 44

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