Only Honda's own shop data settles how the automatic transmission on this ATV comes apart, and this 565-page Honda TRX680FA, TRX680FGA service manual PDF puts that data in one file for both variants. The drive train chapter, one of the largest in the book, walks through shift valve body service and torque converter removal, while the lubrication system diagram traces oil from the pump through the cooler. Wiring diagrams for both models sit at the back beside symptom charts that run hard starting, low power, and rough idle down to a cause. Refill with 2.9 liters (3.1 US qt) after a drain and filter change, and torque the upper and lower engine hanger fasteners to 54 N·m (40 lbf·ft) when the engine goes back in. One wrong guess inside a torque converter buys you a second teardown. Bookmarked chapters and a searchable text layer take you straight to the brake caliper or starter relay you are working on.
What's Inside This Honda TRX680FA, TRX680FGA Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 3-42 | Service Rules, Model Identification, General Specifications |
| Technical Features | 43-56 | PCM Powertrain Control Module, Pgm-Fi System, Automatic Transmission System |
| Frame/Body Panels/Exhaust System | 57-77 | Body Panel Locations, Front Carrier, Exhaust System |
| Maintenance | 78-101 | Maintenance Schedule, Air Cleaner, Steering System |
| Lubrication System | 102-114 | Lubrication System Diagram, Oil Pump, Oil Cooler |
| Fuel System | 115-171 | Pgm-Fi System Location, Fuel Line Inspection, Sub Fuel Tank/Fuel Pump |
| Cooling System | 172-187 | System Testing, Radiator/Cooling Fan, Water Pump |
| Engine Removal/Installation | 188-200 | Engine Removal, Engine Installation |
| Cylinder Head/Valve/Camshaft | 201-224 | Cylinder Head Removal, Cylinder Head Inspection, Camshaft |
| Cylinder/Piston | 225-234 | Cylinder/Piston Removal, Cylinder/Piston Inspection, Cylinder/Piston Installation |
| Alternator/Starter Clutch | 235-250 | Recoil Starter, Alternator Stator/Starter Reduction Gears, Flywheel/Starter Clutch |
| Sub-Transmission/Gearshift Linkage | 251-266 | Sub-Transmission, Gear Selector Lever Linkage, Selector Cable Adjustment |
| Crankcase/Crankshaft/Balancer | 267-280 | Crankcase Separation, Crankshaft, Crankcase Bearing Replacement |
| Drive Train System | 281-354 | Drivetrain System Location, Shift Valve Body, Torque Converter Removal |
| Front Wheel/Suspension/Steering | 355-388 | Front Wheel, Wheel Hub and Knuckle, Steering Shaft |
| Rear Wheel/Suspension | 389-405 | Rear Wheel, Rear Shock Absorber/Suspension Arm |
| Brake System | 406-442 | Brake Fluid Replacement/Air Bleeding, Front Master Cylinder, Rear Brake Caliper |
| Front Driving Mechanism | 443-474 | Front Drive Shaft, Differential Removal, Differential Disassembly/Inspection |
| Rear Driving Mechanism | 475-503 | Rear Drive Shaft, Final Drive Removal, Final Drive Installation |
| Battery/Charging System | 504-512 | Battery, Charging System Inspection, Alternator Charging Coil |
| Ignition System | 513-520 | Ignition System Inspection, Ignition Coil, Ignition Timing |
| Electric Starter | 521-534 | Starter Motor, Starter Relay Switch, Diode |
| Lights/Meters/Switches | 535-554 | Headlight, Ignition Switch, Fuel Gauge/Fuel Level Sensor |
| Wiring Diagram | 555-556 | TRX680FA/Fga |
| Troubleshooting | 557-562 | Engine Does Not Start or Is Hard to Start, Engine Lacks Power, Poor Performance at Low and Idle Speed |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Spark plug | 22 N·m (2.2 kgf·m, 16 lbf·ft) | p. 79 |
| Lower engine hanger nut (left and right) torque | 54 N·m (5.5 kgf·m, 40 lbf·ft) | p. 190 |
| Upper engine hanger bolt torque | 54 N·m (5.5 kgf·m, 40 lbf·ft) | p. 190 |
| Engine oil capacity (after draining) | 2.7 liters (2.9 US qt, 2.4 Imp qt) | p. 9 |
| Engine oil capacity (after draining/filter change) | 2.9 liters (3.1 US qt, 2.6 Imp qt) | p. 9 |
| Engine oil capacity (after disassembly) | 4.1 liters | p. 9 |
| Tie-rod ball joint nut torque | 54 N·m (5.5 kgf·m, 40 lbf·ft) | p. 357 |
| Tie-rod lock nut | 54 N·m (5.5 kgf·m, 40 lbf·ft) | p. 79 |
| Reverse idle gear collar I.D. | 13.000 - 13.034 mm (0.5118 - 0.5131 in) | p. 11 |
| Reverse idle gear shaft O.D. | 12.966 - 12.984 mm (0.5105 - 0.5112 in) | p. 11 |
| Idle speed | 1,400 ± 50 rpm | p. 9 |
| Spark plug gap | 1.0 - 1.1 mm | p. 13 |
Honda TRX680FA, TRX680FGA Common Problems This Manual Covers
Honda TRX680FA PGM-FI fuel injection engine cranks but won't start, stalls, or MIL blinking
Check whether the MIL is blinking, then work the PGM-FI System Troubleshooting flow starting for crank-no-start, stalling and poor performance. Gap the spark plug to 1.0 to 1.1 mm and torque it to 22 N·m (16 lbf·ft) so ignition is ruled out before you start swapping fuel system parts.
Manual Section: PGM-FI System Troubleshooting p. 127Automatic transmission shift control failure or acceleration control failure with gear position indicator blinking
Check the gear position indicator blinking behavior and run the Drivetrain System Troubleshooting sequence in the Drive Train System section starting at page 281 before opening anything. Work through shift control and acceleration control failures step by step, and only pull the shift valve body or torque converter after the diagnosis narrows the fault.
Manual Section: Drivetrain System Troubleshooting p. 281Sub-transmission reverse idle gear collar and shaft worn beyond the service limit
Measure each end of the reverse idle gear collar I.D. against the 13.05 mm (0.514 in) service limit on page 261. Measure the shaft O.D. against 12.93 mm (0.509 in), then calculate collar-to-shaft clearance. Anything over 0.10 mm (0.004 in) is past the limit; replace the worn part before reassembly.
Manual Section: Sub-Transmission/Gearshift Linkage p. 261Lubrication system low oil pressure, no oil pressure, oil contamination or oil emulsification
Check the oil level first; refill after draining with a filter change takes 2.9 liters (3.1 US qt), per page 9. Warm the engine to 80°C (176°F) and measure oil pressure at 5,000 rpm against 785 kPa (114 psi) listed on page 104. Work the Lubrication System troubleshooting with any low reading.
Manual Section: Lubrication System p. 104Radiator and cooling system shows engine temperature running too high or coolant leaking
Check coolant level and look for leaks, then run the system testing procedures in the Cooling System section starting on page 172. Inspect the radiator, cooling fan and water pump. After repairs, refill the radiator and engine with 2.0 liters (2.1 US qt) of coolant, the capacity listed on page 9.
Manual Section: Cooling System p. 172Electric starter motor does not turn, turns the engine slowly, or spins without turning engine
Check the battery first in the Battery/Charging System section on page 504, since a weak battery can look like a bad starter. Test the starter relay switch, diode and starter motor following the Electric Starter section from page 521. If the motor spins but the engine doesn't, inspect the starter clutch and starter reduction gears covered on page 235.
Manual Section: Electric Starter p. 521Frequently Asked Questions
How do I reset the Honda TRX680FA error code?
To clear the DTC without the HDS pocket tester, remove the steering cover, turn the ignition switch OFF, and short the Brown/red and Green wire terminals of the DLC using the SCS connector (070PZ-ZY30100). Turn the ignition switch ON, remove the special tool, and then short the terminals again while the MIL lights for approximately 5 seconds. p. 129
What do Honda TRX680FA error codes mean?
The error codes (DTCs) are composed of a main code and a sub code. The main code indicates the component of function failure, while the sub code details the specific symptom. For example, DTC 08-1 indicates a TP sensor voltage lower than the specified value, while DTC 08-2 indicates a higher voltage. p. 127
How do I erase a Honda TRX680FGA problem code?
You can erase the problem code by connecting the HDS Pocket Tester to the DLC and clearing the DTC while the engine is stopped. Alternatively, you can use the SCS connector (070PZ-ZY30100) to short the DLC terminals as described in the manual's clearing procedure. p. 129
What is the torque spec for the Honda TRX680FA spark plug?
The torque specification for the spark plug is 22 N·m (2.2 kgf·m, 16 lbf·ft). p. 14
What are the Honda TRX680FA engine bolt torque specs?
Engine torque specifications include 17 N·m (1.7 kgf·m, 12 lbf·ft) for the valve adjusting screw lock nut, 25 N·m (2.5 kgf·m, 18 lbf·ft) for the engine oil drain bolt, and 18 N·m (1.8 kgf·m, 13 lbf·ft) for the engine oil filter center bolt. p. 14
Is this Honda TRX680FA manual a PDF I download?
This is a 565-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
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