Honda FOURTRAX 250TM Offroad Vehicle Owner's Manual

TRX 250TM
Honda FOURTRAX 250TM
OWNER'S MANUAL
i
32HM8850
PREFACE
Thank you for buying a Honda FOURTRAX. Honda takes pride in a
worldwide reputation for quality —in research, design, production and
service. Quality is the hallmark of all Honda products and one reason
why Honda is the leading manufacturer of ATVs.
Help assure your FOURTRAX's future reliability and performance by
paying extra attention to how you ride during the first operating day or
25 km (15 miles). During this period, avoid full-throttle starts and rapid
acceleration.
For replacement parts and accessories, we recommend genuine
Honda products. They've been specially designed for your vehicle and
manufactured to meet Honda's demanding standards.
This manual contains a Maintenance Schedule and information on
basic maintenance procedures. If you have the required skills and tools,
your Honda dealer can supply you with an Official Honda Service
Manual to help you perform more advanced maintenance and repairs.
When you need service, remember that your Honda dealer knows your
vehicle best and is interested in your complete satisfaction.
We wish you many years of safe and enjoyable riding.
While reading this manual, remember:
AWARNING Indicates a strong possibility that serious injury
or death may result if instructions are not
followed.
All information in this publication is based on the latest product infor-
mation available at the time of approval for printing. Honda Motor Co.,
Ltd. reserves the right to make changes at any time without notice and
without incurring any obligation.
© Honda Motor Co., Ltd. 2001. No part of this publication may be
reproduced without written permission from Honda Motor Co., Ltd.
CONTENTS
Page
FOURTRAX SAFETY otitis ete eee e eee arene ee evan, 1
Special Safety Messages....................eeeeecerire DD RR DITA 1
Warning Information................. eee eee eases 6
PARTS LOCATION AND OPERATION cocci eee eee seers, 10
Parts LOCAtiON ……...……………...créasscresrarerarnsannenarare sean rrarranaens anaanan rare 10
Parts Operation... eee ree 14
Power CONtrOIS ….........….….crrererrrerenserecrererasaerenrensraa see nes n cars sr nana 14
1915 eens 21
Gearshift Controls.................... eee ene e eee era e RER 29
Brake Controls......................ee0irer reee rene enero eee eran 31
Fuel Tank Controls................eevemes ree rie re erre eee anereereres 32
Engine Olil,...............eemeresrconerarca rie eee Deo ner er erroneo ers 34
Additional Features ....................eeeeíeree O erre aceras 35
RIDING YOUR FOURTRAX .............eiennniceoreconen ene cerros rerre eee. 40
Before Riding......................... eee reee e reee Dee ere anio ercer 40
Rider Preparation...............- weee. ee RER EEE EEE 40
Vehicle Preparation ooo, 42
Safe Riding Rules......................ee EEE REEL EEE 50
RIdINg .............ee EEE EEE RER RER 62
Starting the ENGINE RER EEE an arr 63
ShiftiNG GRATIS oii eee eee eee eee, 67
Riding in Reverse.................meeee roer EEE EEE RER 68
Making Turns ....................emeeeeere ea RER EEE RER EEE RR ARE RR sean 70
Riding Up HilS ee EEE RER RER RER ER rereeos 73
Riding Down Hills... eee eee rene rene reee ree 80
Crossing Slopes...................eee EEE RER EEE nece erre 82
Making Turns on Siopes................ eee ee ee 83
Riding Over Obstacies......................ee e rene ear reee 84
Riding Through Water ...............e...e2ieee eee nee ee 85
Parking ....oociiii eee eee eee eee 86
(cont'd)
CONTENTS
Page
MAINTENANCE AND REPAIRS ..................eceeonercerrecianercereeotecereneneceoceneo 87
Maintenance Schedule ......................eserecierccererreconceoecerer cer eee. 87
Maintenance Precautions ..............e.._.eííverricerrer ee DIET TEETI TTD 89
Tool Kit... ccrcorssrersrrsrenransersc rar ana a arr aren te nane near enter aan e nana ee 90
Fuel SYSTEM ..…...….....……rurccrerrerrareneeereraraentenressranensesananan se nm des ce ne O 92
LUDFICAtION ..….........…..……crccrrrrenarenressererarrenren ae nensere ren nana nana sac Asa a nas nee» 104
Engine ................=e=iicieenereniroorene cor nee ren een or renre a recaen raarE ner renenenNe. 109
Clutch ..............e.e.emerecerernecercicere a eererecaouee o eareranrer ar recente eenDEa 111
Electrical System...................eescccicucrcccsrerroreneacerevecar renace veran eres 113
Brakes ...............ervceuciinorcaciosoveracics recover reracuorooeoaren ener rearrero eee 117
Wheels and Tyres... seer ene ee 127
Seat Removal .................eeeeerciccceocrcececarteascerrea rice eee ere eee 132
Engine Guard and Skid Plates .................e....enererieereenerenaie 133
Spark Arrester ...............e.eemcerererercecen ree DD RR RR RR DD e ee e 134
TRANSPORTING YOUR FOURTRAX .................e..e.erecerecarriererceneocen no. 136
CLEANING YOUR FOURTRAX ............eeneeeerececereeenirene sera acer eee 139
STORING YOUR FOURTRAX ..................veeesereiececreceneconeecenvecreareeece rene. 141
SPE CIF CATIONS Lier eee ce ee eee 144
\МИНИМС DIAGRAM ec eee, 146
SERIAL NUMBERS AND COLOR LABEL...............e.eeecercernenaccenerermeceee.. 147
INDEX ........... e. rornonerocreareacarconensenooeneroecanenenceroonrrrerarecarrereretavocerarerceeee 148
FOURTRAX SAFETY
SPECIAL SAFETY MESSAGES
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently from other vehicles including motorcycles
and cars. A collision or rollover can occur quickly, even during routine
maneuvers such as turning and driving on hills or over obstacles, if
you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these
instructions:
* Read this manual and all labels carefully and follow the operating
procedures described.
* Always follow this age recommendation: A child under 16 years old
should never operate an ATV with engine size greater than 90 cc.
* Never allow a child under age 16 to operate an ATV without adult
supervision, and never allow continued use of an ATV by a child if he
or she does not have the abilities to operate it safely.
* Never carry a passenger on an ATV.
+ Never operate an ATV on any paved surfaces, including sidewalks,
driveways, parking lots and streets.
* Never operate an ATV on any public street, road or highway, even a
dirt or gravel one.
* Never operate an ATV without wearing an approved motorcycle
helmet that fits properly. You should also wear eye protection
(goggles or face shield), gloves, boots, long-sleeved shirt or jacket,
and long pants.
* Never consume alcohol or drugs before or while operating this ATV.
* Never operate at excessive speeds. Always go at a speed that Is
proper for the terrain, visibility, operating conditions, and your
experience.
* Never attempt wheelies, jumps, or other stunts.
* Always inspect your ATV each time you use it to make sure it is in
safe operating condition. Always follow the inspection and mainte-
nance procedures and schedules described in this manual.
+ Always keep both hands on the handlebars and both feet on the
footpegs of the ATV during operation.
* Always go slowly and be extra careful when operating on unfamiliar
terrain. Always be alert to changing terrain conditions when operat-
ing the ATV.
* Never operate on excessively rough, slippery or loose terrain until
you have learned and practiced the skills necessary to control the
ATV on such terrain. Always be especially cautious on these kinds of
terrain,
* Always follow proper procedures for turning as described in this
manual. Practice turning at low speeds before attempting to turn at
faster speeds. Do not turn at excessive speed.
* Never operate the ATV on hills too steep for the ATV or for your
abilities. Practice on smaller hills before attempting larger hills.
* Always follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before you start up any hill.
Never climb hills with excessively slippery or loose surfaces. Shift
your weight forward. Never open the throttle suddenly or make
sudden gear changes. Never go over the top of any hill at high speed.
* Always follow proper procedures for going down hilis and for
oraking on hills as described in this manual. Check the terrain
carefully before you start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going down a hill at an
angle that would cause the vehicle to lean sharply to one side. Go
straight down the hill where possible.
*
*
*
Always follow proper procedures for crossing the side of a hill as
described in this manual. Avoid hills with excessively slippery or
loose surfaces. Shift your weight to the uphill side of the ATV. Never
attempt to turn the ATV around on any hill until you have mastered
the turning technique described in this manual on level ground.
Avoid crossing the side of a steep hill if possible.
Always use proper procedures if you stall or roll backwards when
climbing a hill. To avoid stalling, use the proper gear and maintain a
steady speed when climbing a hill. If you stall or roll backwards,
follow the special procedure for braking described in this manual.
Dismount and follow the procedures provided in this manual.
Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as large rocks or fallen
trees. Always follow proper procedures when operating over obsta-
cles as described in this manual.
Afways be careful when skidding or sliding. Learn to safely control
skidding or sliding by practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as ice, go slowly and
be very cautious in order to reduce the chance of skidding out of
control.
* Never operate an ATV in fast flowing water or in water deeper than
that specified in this manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after leaving water. If
necessary, apply them several times to let friction dry out the linings.
* Always be sure there are no obstacles or people behind you when
you operate in reverse. When it is safe to proceed in reverse, go
slowly.
* Always use the size and type tyres specified in this manual. Always
maintain proper tyre pressure as described in this manual.
* Never modify an ATV through improper installation or use of acces-
sories.
* Never exceed the stated load limits for an ATV. Cargo should be
properly distributed and securely attached. Reduce speed and follow
instructions in this manual for carrying cargo or pulling a trailer.
Allow greater distance for braking.
WARNING INFORMATION
Your FOURTRAX comes with several labels containing important
safety information. Anyone who rides the vehicle should read and
understand this information before riding.
The labels should be considered as permanent parts of the vehicle. If a
label comes off or becomes hard to read, contact your Honda dealer
for replacements.
While reading this manual, remember:
POTENTE Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
7
| Operating this ATV if you are under
.| ot severe injury or death
NEVER operate this ATV il you are
the age ot 16 increases your chancel
[under ages —
|
Overloading this ATV or carrying cargo
improperly can change handling, stability |
and braking performance and can lead to an h
accident.
Never exceed the maximum front cargo Hmil |
of: 33155 15kg
Refer to instructions in the Owner's
Manuat
TTT
improper tire pressure or overloading
can cause loss of control.
Loss of control can result in severe
injury or death.
e Cold tire pressure,
Front :20:3kPa 0.20 +0.00kgt/em 2.9+0.4psi
Rear :20:3kPa 0.2010.03kgi/cm 7.91:0.4psi
O Maximum weight capacity; 175kg ( 386lbs. )
С € TRX250TM 2001 ¡Nomina! power 11.6kw
HONDA OF SOUTH CAROLINA MEG.,INC. Dry weight 187kg
1111 HONDA WAY. TIMMONSVILLE, SOUTH CAROLINA 2916 U.S.A MADE IN USA
|
|
NEVER ride as a passenger.
Passengers can cause a
SEVERE INJURY or DEATH.
loss of control, resulting in].
{| The improper operation of ATVs may result in severe
injury or death
» Read the owner's Manual,
* Follow all warnings and instructions.
* Never use without proper training and instruction.
White riding -
* Never ride too fast for your skills or the conditions.
+ Always use proper riding techniques for hills.
slopes and rough terrain.
* Use care when changing riding surfaces. ATVs handie
ditterently on different suriaces, such as sand.dirt, or
pavement.
Never carry 3 passenger since it
would sttect balance and steering Le;
and may cause you to lose control,
Жуан operating an public roads, ‘
since à collision can occur with
another vehicle.
Never ride after drinking alcohol or
using drugs.
Always wear a helmet, eye
protection, and protective gear.
Overloading this ATV or carrying cargo
improperly can change handling, stability
and braking performance and can lead to an
accident
(Never exceed the maximum rear cargo limit
‘combined weight on the rear rack and in
the storage area'of: 66165 (30kg'.
ii Reter to instructions
[Manual
in the Owner's
Towing an improperiy toaded
trailer can cause loss of
| controt.
O Read owner's manual.
@ Tow weight limit : 2206N (225Kkgt)
500155
| O Tongue weight: 137N (tá4Kkgt)
30lbs
PARTS LOCATION AND OPERATION
PARTS LOCATION
(1) Rear brake lever
Parking brake
(2) Headlight switch
Engine stop switch
Headlight dimmer switch
Starter button
(3) Reverse selector knob
(4) Horn button
(5) Choke knob
(6) Ignition switch
(7) Throttle lever
(8) Front brake lever
(1) (2) (3) (4) (5) (6) (7) (8)
WE
> se 2s ALI. N
A o
ES Ч E
E W LEE
Fig. 2-1 Handlebars, from rider's point of view
10
(9) Reverse indicator
(10) Neutral indicator
(11) Oil high temperature indicator
(12) Multi-function display
e Speedometer
e Odometer/Tripmeter
e Digital clock/Hourmeter
(13) Minute select button
(14) Hour select button
(15) Hourmeter/Digital clock select button
(16) Odometer/Tripmeter select button
(9) (11)
(12)
1
|
—
(16) (15) (14) (13)
Fig. 2-2 Indicators and multi-function display, from rider's point
of view
11
(17) Flag pole bracket
(18) Rear cargo rack
(19) Fuel fill cap
(20) Front cargo rack
(21) Operator footpeg
(22) Rear brake pedal
(23) Headlights
(17) (18)
(19) (20)
(23)
Fig. 2-3
12
Right side of FOURTRAX
(24) Fuel valve
(25) Owner's Manual storage
(26) Storage compartment, containing:
Tool kit
Air pressure gauge
(27) Oil filler cap/dipstick
(28) Gearshift pedal
(29) Operator footpeg
(30) Trailer hitch
(26)
(27) (28) (29) (30)
Fig. 2-4 Left side of FOURTRAX
13
PARTS OPERATION
POWER CONTROLS
Ignition Switch
The ignition switch (Fig. 2-5) is in the center of the handlebars directly
in front of the seat.
(1)
6 ——
|!
Fig. 2-5 (1) Ignition switch
Key Position Function | Key
Removal
O The engine and headlight can- | The key can
(OFF) not be operated. be removed.
| The headlights can be turned on. The key can-
(ON) not be re-
With the engine stop switch at moved.
RUN (©) and the transmission
in neutral, the engine can be
started.
14
Engine Stop Switch
The engine stop switch (Fig. 2-6 } is next to the left handgrip, and it has
three positions. When the switch is in the O) (RUN) position, the
engine will operate. When the switch is in either XI (OFF) position, the
engine will not operate.
This switch is intended primarily as a safety or emergency control, and
it should normally remain in the © (RUN) position.
NOTE:
If you stop your FOURTRAX by turning the engine stop switch 33 (OFF),
be sure to turn the ignition switch O (OFF) to prevent battery
discharge.
Fig. 2-6 (1) Engine stop switch
15
Choke Knob
The choke knob (Fig.2-7) is located above the indicator lamp. The
choke has three positions: fully ON (A), halfway position (B), and fully
OFF (C).
To start a cold engine when air temperature is 10—35 °C (50—90 °F),
pull the choke knob up to fully ON before pressing the starter button.
At colder air temperatures, pull the choke knob up to the fully ON
position before pressing the starter button. As the engine warms, push
the knob down to the halfway position. After the engine is warm, push
the choke knob down to fully OFF. To restart a warm engine, it is not
necessary to use the choke.
CAUTION:
+ Extended use of the choke may impair piston and cylinder wall
lubrication and shorten the life of the engine.
* Pushing the choke knob too hard to the OFF position may dislodge
the choke cable boot. If this happens, water and dirt may enter the
choke cable and cause corrosion. If the choke is hard to actuate, or
feels like it is sticking, check the cable boot.
Fig. 2-7 (1) Choke knob (A) Fully ON
(B) Halfway position
(C) Fully OFF
16
Starter Button
The starter button (Fig. 2-8) is below the engine stop switch. To start
the engine, press the starter button (1), with the transmission in
neutral, the ignition switch 1 (ON) and the engine stop switch (2) at
O (RUN).
Fig. 2-8 (1) Starter button (2) Engine stop switch
Horn button
Horn button (Fig. 2-9 ) is next to the headlight switch.
Press the button to sound the born.
Fig. 2-9 (1) Horn button
17
Recoil Starter
The recoil starter (Fig. 2-10) is on the left side of the FOURTRAX. lt is
used to start the engine when the battery is low.
To operate the recoil starter:
Fig. 2-10 (1) Recoil starter grip
18
Grasp the starter grip ( 1) firmly, then pull it out slowly approxi-
mately 100 mm (4 in).
Pull the grip up briskly and fully.
After the engine starts, allow the starter grip to return slowly.
A Ш Sms
7 7 Ny a
. и #
Fig. 2-11 (1) Recoil starter grip
Pull the recoil starter grip straight out so that the cord does not touch
the side cover. Repeated contact with the side cover can damage the
starter cord.
19
Throttle Lever
The throttle lever (Fig. 2-12) is next to the right handgrip, and it is
operated by the thumb. Pressing the lever opens the throttle. When
pressure is released, spring tension automatically closes the throttle.
Fig. 2-12 {1) Throttle lever (A) To open the throttle
20
LIGHTS
Headlight and Dimmer Switches
The headlight and dimmer switches (Fig. 2-13) are above the engine
stop switch, next to the left handgrip.
Turning the headlight switch (1) E (ON) turns the headlight on. Use
the dimmer switch (2) to select either high beam ED (HI) or low beam
20 (LO).
Fig. 2-13 (1) Headlight switch (2) Dimmer switch
21
Reverse and Neutral Indicators
The reverse indicator (1) and the neutral indicator (2) (Fig. 2-14) are
located above the multi-function display.
The reverse indicator will light when the transmission is in reverse and
the ignition switch is | (ON). The neutral indicator will light when the
transmission is in neutral and the ignition switch is | (ON).
Oil High Temperature Indicator
If the engine oil gets too hot, the oil high temperature indicator (3) (Fig.
2-14) will light.
NOTE:
The oil high temperature indicator should come on when the ignition
switch is turned | (ON). This is not a problem. The light should go off
a few seconds after the engine is started.
CAUTION:
If the light does not come on with ignition switch | (ON), contact
your authorized Honda dealer for assistance if you cannot correct the
problem.
If the oil high temperature indicator comes on while you are riding,
immediately bring the vehicle to a stop, turn the engine off and let it
cool.
CAUTION:
* Failure to stop the engine immediately after the oil high
temperature indicator comes on will adversely affect the service life
of the engine.
* Do not carry or store articles on the front bumper. This may restrict
air flow through the engine oil cooler, causing it to overheat.
If the oil high temperature indicator comes on often, have your
FOURTRAX inspected by your Honda dealer.
22
(= ) [a / © |
Fig. 2-14 (1) Reverse indicator (3) Oil high temperature
(2) Neutral indicator indicator
Multi-function Display
(Ref. No.) Description
Function
(1) Multi-function display
The display includes the following
functions.
(A) Speedometer Shows riding speed.
(B)| Odometer Shows accumulated mileage.
(page 26 )
Tripmeter Shows mileage per trip.
(page 26 )
(С) Digital clock Shows the time (hours and
minutes). (page 28 )
Hourmeter Shows hours and tenths of hours
of engine operation. (page 27 )
(2) Odometer/tripmeter Selects display of the odometer or
select button tripmeter. Resets the tripmeter to
zero (0). (page 26 )
(3) Digital clock/hourmeter Selects display of the hourmeter
select button or digital clock. (page 27, 28)
(4) Hour select button Advances the hour displayed by
the digital clock. (page 28 )
(5) Minute select button Advances the minute displayed by
the digital clock. (page 28 )
(=== AA)
e
— 0)
SF nm
/ | |
/
(2) (3) (4) 5
Fig. 2-15
24
Initial Display
When the ignition switch is turned | (ON), the display (1) (Fig. 2-16)
will temporarily show all the modes and digital segments so you can
make sure the liquid crystal display is functioning properly.
The digital clock will reset if the battery is disconnected.
(1)
O
E cua
Em (578) DE
Fig. 2-16 (1) Multi-function display
25
Odometer/Tripmeter
Odometer
When selected, the odometer (1) (Fig. 2-17) registers total distance
traveled in kilometers while the ignition is | (ON). To change the
display (2) from tripmeter to odometer, press and release the
Odometer/Tripmeter select button (3).
pm
(3)
Fig. 2-17 (1) Odometer (3) Odometer/Tripmeter select button
(2) “ODO” display
Tripmeter
When selected, the tripmeter (1) (Fig. 2-18) shows mileage per trip
while the ignition is | (ON). To change the display (2) from odometer
to tripmeter, press and release the Odometer/Tripmeter select button
(3). To reset the tripmeter to zero, press the Odometer/Tripmeter
select button and hold it in for at least two seconds.
PES (909
(3)
Fig. 2-18 (1) Tripmeter (3) Odometer/Tripmeter select button
(2) “TRIP” display
26
Hourmeter
When selected, the hourmeter (1) (Fig. 2-19) shows accumulated hours
while the ignition is | (ON). The hourmeter provides accurate service
period information for initial and regular maintenance. To change the
display from the digital clock to the hourmeter mark (2), press and
release the hourmeter/digital clock select button (3).
Fig. 2-19 (1) Hourmeter (3) Hourmeter/digital clock
(2) Hourmeter mark select button
27
Digital Clock
When selected, the digital clock (1) (Fig. 2-20) shows the time while the
ignition is | (ON). To change the display from hourmeter to digital
clock, press and release the hourmeter/digital clock select button (2).
Fig. 2-20 (1) Digital clock (2) Hourmeter/digital clock select button
Digital Clock Adjustment:
Turn the ignition switch | (ON).
To advance the hour display one unit at a time, press and release the
hour select button (1).
To advance the hour display automatically, press and hold the hour
select button. After two seconds, the hour display will begin advancing.
Release the button when the display reaches the desired hour (2).
To advance the minute display one unit at a time, press and release the
minute select button (3).
To advance the minute display automatically, press and hold the
minute select button. After two seconds, the minute display will begin
advancing. Release the button when the display reaches the desired
minute (4).
To zero the minute display, press and hold both the hour and minute
buttons simultaneously for two seconds.
(2) (4)
® ®
в
=
| NY me
Ta
48
E E QE
Fig. 2-21 (1) Hour select button (3) Minute select button
(2) Hour (4) Minute
28
GEARSHIFT CONTROLS
Gearshift Pedal
The gearshift pedal is near the left footpeg. One full stroke of the pedal
shifts the transmission to the next higher or lower gear in the shifting
sequence (Fig. 2-22). The pedal automatically returns to the horizontal
position when released.
Your FOURTRAX has five forward gears (1, 2, 3, 4 and 5).
To upshift to a higher gear, put the toe of your boot under the gearshift
pedal and raise the pedal one full stroke. To downshift, step on the
gearshift pedal and depress the pedal one full stroke. (For further
operational instructions, see page 67 .)
UP SHIFTING SEQUENCE
( To reverse:
use reverse selector knob
DOWN SHIFTING SEQUENCE
Fig. 2-22 Gearshifting sequence
29
Reverse Selector Knob
The reverse selector knob (Fig. 2-23} (1) is on the rear brake lever.
To shift into reverse, first bring the FOURTRAX to a complete stop and
make sure the transmission is in neutral. While pushing the reverse
selector knob (1) in, squeeze the rear brake lever (2), then depress the
gearshift pedal.
CAUTION:
Bring the FOURTRAX to a complete stop before shifting the
transmission into reverse. If the transmission is shifted into reverse
while the vehicle is moving, the transmission will be damaged.
(2) (1)
Fig. 2-23 (1) Reverse selector knob (2) Rear brake lever
30
BRAKE CONTROLS
Front Brakes |
The front brakes are operated by squeezing the front brake lever, near
the right handgrip.
Rear Brake
The rear brake is operated either by depressing the brake pedal or by
squeezing the rear brake lever (Fig. 2-24).
Parking Brake
The rear brake lever has a lock which allows it to be used as a parking
brake.
To set the parking brake, squeeze the rear brake fever ( 1) and lock it
with the lock lever { 2). Always set the parking brake when parking and
before starting the engine.
To unlock the parking brake, squeeze the rear brake lever until the lock
lever releases.
Using the parking brake in freezing weather may cause the brakes to
freeze in the locked position.
Fig. 2-24 (1) Rear brake lever/ (2) Lock lever
Parking brake lever (A) To lock
31
FUEL TANK CONTROLS
Fuel Fill Cap
After refueling, be sure to tighten the fuel fill cap (Fig.2-25) until it
clicks.
Insert the breather tube ( 2 ) into the handlebar cover hole (3).
To refuel refer to page 92.
(3)
(2)
NS 5
V
Fig. 2-25 (1) Fuel fill cap (2) Breather tube
(3) Handlebar cover hole
32
Fuel Valve
The fuel valve (Fig. 2-26) is on the left side of the fuel tank, and it has
three positions:
OFF
When the fuel valve is in the OFF position, fuel cannot flow to the
carburetor. Turn the valve OFF whenever the FOURTRAX is not in use.
ON
When the fuel valve is in the ON position, fuel will flow from the main
fuel supply to the carburetor.
RES
When the fuel valve is in the RES position, fuel will flow from the
reserve fuel supply to the carburetor. Use the reserve fuel only when
the main supply is gone.
Refill the tank as soon as possible after switching to RES. The reserve
fuel supply is:
2.4 8 (0.63 US gal , 0.53 Imp gal)
NOTE:
After refueling, do not operate the FOURTRAX with the fuel valve in
the RES position. If you run out of fuel, there will be no reserve supply.
For gasoline recommendations and refueling instructions, see pages
92—95.
OFF ON RES
RES (1) RES RES
OFF < O) FUEL OFF
Fig. 2-26 (1) Fuel valve
FUEL
33
ENGINE OIL
Oil Filler Cap/Dipstick
The oil filler cap/dipstick (Fig. 2-27), on the front crankcase cover, is
used to measure the oil level. The oil should be checked each day
before operating the FOURTRAX and maintained between the upper
level mark (2) and the lower level mark (3).
For oil recommendations and instructions on checking, adding and
changing oil, see pages 104— 107.
(1)
Fig. 2-27 (1) Oil filler cap/dipstick (2) Upper level mark
(3) Lower level mark
While reading this manual, remember:
NENE Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
34
ADDITIONAL FEATURES
Flag Pole Bracket
The flag pole bracket (Fig. 2-28) is on the rear cargo rack. Flag poles are
optional equipment available from your Honda dealer. To mount a
pole in the bracket, follow the instructions that come with the flag pole
kit.
NOTE:
Flag poles are required in some riding areas. Check local regulations
before riding.
Fig. 2-28 (1) Flag pole bracket
35
Trailer Hitch
The trailer hitch is located on the rear axle housing. As illustrated in Fig.
2-29 , to use the hitch, you'll need a proper size ball as specified by the
trailer manufacturer.
To attach the ball and properly hook up a trailer, follow the trailer
manufacturer's instructions. For load limits and operational guidelines,
see pages 45—47.
К
—
К
К
N—
FA 4
— 1
(=)
(
a
Fig. 2-29 (1) Trailer hitch (2) An example boll
36
Storage Compartment
The storage compartment (Fig. 2-30) is below the rear cargo rack. To
open the compartment, unhook the rubber strap (2). The tool kit (3)
should be stored in the storage compartment.
Be careful not to flood this area when washing your FOURTRAX or rid-
ing through water.
(1)
Fig. 2-30 (1) Storage compartment (3) Tool kit
(2) Rubber strap
37
Owner's Manual Storage
The owner's manual storage area (Fig. 2-31 ) is located under the seat
(1).
The owner's manual (2) and spare fuse (3) should be stored ín the
plastic document bag (4).
To remove the seat, see page132 .
Be careful not to flood this area when washing your FOURTRAX or rid-
ing through water.
Fig. 2-31 (1) Seat (3) Spare fuse
(2) Owner's manual (4) Plastic document bag
38
While reading this manual, remember:
Ne Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
39
RIDING YOUR FOURTRAX
This part of the Owner's Manual discusses how to ride your
FOURTRAX safely. Please review the special safety messages on
pages 1—5 . While reading this manual, remember:
NC NIDIEE Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
BEFORE RIDING
You need to be prepared before riding. This includes getting proper
instruction, making sure your FOURTRAX is in good operating
condition, and learning some basic safe-riding rules.
RIDER PREPARATION
Age Recommendation
The minimum recommended age for this FOURTRAX model is 16. For
safety, never let children under 16 years old operate this vehicle.
40
POTENTIAL HAZARD
Failure to follow the age recommendation for this ATV.
WHAT CAN HAPPEN
If children use ATVs that are not recommended for their age,
severe injury or death can result.
Even though a child may be within the age group for which an
ATV is recommended, he or she may not have the skills, abilities,
or judgment needed to operate the ATV safely and may be
involved in a serious accident.
HOW TO AVOID THE HAZARD
A child under 16 should never operate an ATV with engine size
greater than 90 cc.
41
VEHICLE PREPARATION
Pre-Ride Inspection
Inspect your FOURTRAX every day before you ride it. Checking the
items below will take only a few minutes, and in the long run, they can
save time, expense, and possibly your life.
1.
2.
с в
10.
11.
12.
42
Engine oil level. Check the oil level and add oil if required (pages
104 107). Check for leaks.
Fuel level. Fill the fuel tank when necessary (pages 92—95 J.
Check for leaks.
Brakes. Check operation. Make sure there is no brake fluid leakage.
If necessary, adjust free play (pages 117—126).
Tyres. Check condition and pressure (pages 128—130).
Throttle. Check for smooth opening and closing in all steering
positions.
Headlight and headlight dimmer switches. Check for proper func-
tion (page 21 ).
Engine stop switch. Check for proper function (page 15 ).
Nuts, bolts, fasteners. Check the wheels to see that the axle nuts
are tightened. Check the security of all other nuts, bolts and fasten-
ers.
Steering. Check that the wheels turn properly as you steer the
handlebars.
Cargo. Check that all cargo is properly secured.
Underbody and exhaust system. Check for, and remove, any dirt,
vegetation or other debris that could be a fire hazard or interfere
with the proper operation of the vehicle.
Air cleaner housing drain tube. Check for deposits in the drain
tube. If necessary, clean the tube (page100) and check the air
cleaner case.
A WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you use it to make sure the
ATV is in safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in this Owner's Manual.
43
Correct any problem before you ride. If you can’t correct a problem,
contact your Honda dealer for assistance.
if your FOURTRAX has overturned or been involved in a collision, do
not ride the vehicle until it has been inspected by an authorized Honda
dealer. There may be damage or other problems you cannot see.
Tyres
Before riding, make sure your FOURTRAX has the proper tyres and
that they are in good condition. Also be sure the tyres are inflated to
the proper tyre pressure (see page 129).
POTENTIAL HAZARD
Operating this ATV with improper tyres, or with improper or
uneven tyre pressure.
WHAT CAN HAPPEN
Use of improper tyres on this ATV, or operation of this ATV with
improper or uneven tyre pressure, may cause loss of control,
increasing your risk of an accident.
HOW TO AVOID THE HAZARD
Always use the size and type tyres specified in the Owner's
Manual for this vehicle.
Always maintain proper tyre pressure as described in this Owner's
Manual.
Loading
Load Limits
There are limits to how much weight can be carried on your
FOURTRAX and be pulled in a trailer.
NOTE:
The following weight limits apply to standard equipment only. Modi-
fying your FOURTRAX, using non-standard equipment or riding on
terrain that is not flat and smooth could further reduce these limits.
Maximum weight capacity 175 kg (386 Ibs) maximum
(Combined weight of the rider, all accessories and ali cargo)
Front cargo rack weight limit 15 kg (33 Ibs} maximum
Rear cargo rack weight limit 30 kg (66 Ibs) maximum
Tow weight limit = 2206 № {225 kgf
(Combined weight of the (500 ibs) maximum
trailer and all cargo in the
trailer)
Tongue weight = 137 N 114 kgf!
(Weight on the trailer (30 Ibs) recommended
tongue)
Tongue and rear cargo weight = 30 kg (66 Ibs) maximum
(Combined weight on the
trailer tongue and on the
rear cargo rack)
45
Loading and Operational Guidelines
Carrying cargo or pulling a trailer will affect how your FOURTRAX
handles and greatly reduce its ability in accelerating, braking and
making turns and other maneuvers.
Be sure to observe the weight limits and follow these guidelines:
1.
Do not place cargo anywhere on the FOURTRAX other than on the
front and rear racks. Otherwise, operating stability may be ad-
versely affected.
Never ride with a passenger on the front or rear cargo racks. The
FOURTRAX is not designed to carry a passenger.
Do not tow another vehicie or a trailer with a rope or cable
attached to the rear rack. Use the trailer hitch.
Load cargo on the rear rack as far forward as possible. Make sure
cargo on the front rack does not interfere with handlebar move-
ment.
Do not allow cargo to extend beyond the edges of either the front
or rear racks.
Make sure all cargo is secured before riding.
When towing a trailer, take care to maintain balance and stability.
Distribute cargo between the front and rear of the trailer to obtain
the recommended tongue weight.
NOTE:
Tongue weight can be measured with an ordinary bathroom scale.
Place the scale under the tongue, using either a tongue jack or other
support to keep the trailer level.
8.
9.
10.
46
Allow extra room for starting, stopping and turning whenever you
carry cargo or pull a trailer.
Avoid riding on steep slopes when carrying cargo or pulling a
trailer.
Never cross a slope when towing a trailer.
AWARNING |
POTENTIAL HAZARD
Overloading this ATV or carrying or towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling, stability and braking
which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load limits for this ATV.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow
greater distance for braking.
Use extra care when operating on hills and riding over obstacles.
Never cross a slope when pulling a trailer.
Always follow the instructions in this Owner's Manual for
carrying cargo or pulling a trailer.
47
Accessories
Genuine Honda accessories have been specifically designed for and
tested on this vehicle. Because Honda cannot test all other accessories,
you are personally responsible for properly selecting, installing, and
using non-Honda accessories. Always follow the loading instructions
above, plus the following:
1. Carefully inspect the accessory to make sure it does not block any
lights, reduce ground clearance, or limit suspension travel, steer-
ing travel, or other controls.
2. Make sure the accessory does not interfere with your ability to
shift body position on the seat or operate hand and foot controls.
3. Do not add electrical equipment that will exceed the vehicle's
electrical system capacity. A blown fuse could cause a loss of
lights or engine power.
48
POTENTIAL HAZARD
Operating this ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this vehicle
may cause changes in handling which could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improper installation or use of
accessories. All parts and accessories added to this vehicle should
be genuine Honda or equivalent components designed for use on
this ATV and should be installed and used according to
instructions. If you have questions, consult an authorized Honda
dealer.
While reading this manual, remember:
Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
49
No Modifications
Modifying this FOURTRAX or removing original equipment may
render the vehicle unsafe or illegal. Spark arresters and mufflers are
required in most areas. Don't modify your exhaust system. Remember,
excessive noise bothers everyone and creates a bad image for off-road
vehicles.
SAFE RIDING RULES
Protective Apparel
Always wear an approved motorcycle heimet when riding your
FOURTRAX. You should also always wear goggles or a face shield,
gloves, boots, a long-sleeved shirt or jacket, and long pants.
Fig. 3-1 An example of a properly dressed rider.
50
A WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an approved motorcycle
helmet, eye protection and protective clothing.
WHAT CAN HAPPEN
Operating without an approved motorcycle helmet increases your
chances of a severe head injury or death in the event of an
accident.
Operating without eye protection can result in an accident and
increases your chances of a severe injury in the event of an
accident.
Operating without protective clothing increases your chances of
severe injury in the event of an accident.
HOW TO AVOID THE HAZARD
Always wear an approved motorcycle helmet that fits properly.
You should also wear: eye protection (goggles or face shield),
gloves, boots, long-sleeved shirt or jacket and long pants.
51
No Passengers
This FOURTRAX is designed as an operator-oniy vehicle. The long seat
is designed to allow the rider to change body position, not for carrying
a passenger. Never let a passenger ride on the seat or on the front or
rear cargo racks.
Fig. 3-2 Never carry a passenger on your FOURTRAX.
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this ATV.
Could cause an accident, resulting in harm to you and/or your
passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The long seat is to allow the operator to
shift position as needed during operation. It is not for carrying
passengers.
52
No Alcohol or Drugs
Alcohol, drugs and FOURTRAX's don't mix. Even a small amount of
alcohol can impair your ability to operate a FOURTRAX safely.
Likewise, drugs — even if prescribed by a physician — can be dangerous
while operating a FOURTRAX. Consult your doctor to be sure it is safe
to operate a vehicle after taking medication.
A WARNING
POTENTIAL HAZARD
Operating this ATV after consuming alcohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while driving this ATV.
53
Off-Road Only
Your FOURTRAX is designed and manufactured for off-road use only,
not for pavement. Riding on pavement can affect handling and control.
You should not ride your FOURTRAX on pavement.
Fig. 3-3 Never ride on paved surfaces.
POTENTIAL HAZARD
Operating this ATV on paved surfaces.
WHAT CAN HAPPEN
The ATV and its tyres are designed for off-road use only, not for
use on pavement. Paved surfaces may seriously affect handling
and control of the ATV, and may cause the vehicle to go out of
control.
HOW TO AVOID THE HAZARD
Never operate the ATV on any paved surfaces, including
sidewalks, driveways, parking lots and streets.
54
You should never ride your FOURTRAX on public streets, roads or
highways, even if they are not paved. Drivers of street vehicles may
have difficulty seeing and avoiding you, which could lead to a collision.
Fig. 3-4 Never ride on public roads or highways.
POTENTIAL HAZARD
Operating this ATV on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this ATV on any public street, road or highway,
even a dirt or gravel one.
In many states it is illegal to operate ATVs on public streets,
roads and highways.
55
When riding off-road, also remember to always obey local off-road
riding laws and regulations. Obtain permission to ride on private
property. Avoid posted areas and obey “no trespassing” signs.
56
Keep Hands and Feet on Controls
Always keep both hands on the handlebars and both feet on the
footpegs when riding your FOURTRAX. This is important to maintain
your balance and to control the vehicle. If you put your feet on the
ground while the FOURTRAX is moving, they could come in contact
with the rear wheels, causing injury.
POTENTIAL HAZARD
Removing hands from handlebars or feet from footpegs during
operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce your ability to
control the ATV or could cause you to lose your balance and fall
off of the ATV. If you remove a foot from the footpeg, your foot or
leg may come into contact with the rear wheels, which could
injure you or cause an accident.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet on the
footpegs of your ATV during operation.
57
Control Speed
Riding at excessive speed increases the chance of an accident. In
choosing a proper speed, you need to consider the capability of your
vehicle, the terrain, visibility and other operating conditions, plus your
own skills and experience.
НН вме
POTENTIAL HAZARD
Operating this ATV at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the ATV, which can
result in an accident.
HOW TO AVOID THE HAZARD
Always go at a speed that is proper for your vehicle, the terrain,
visibility and other operating conditions, and your experience.
58
No Stunts
When riding, you should keep all four wheels of your FOURTRAX on
the ground. Avoid “wheelies,” jumps and other stunts, as they could
cause loss of control.
POTENTIAL HAZARD
Attempting wheelies, jumps, and other stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, including an overturn.
HOW TO AVOID THE HAZARD
Never attempt stunts, such as wheelies or jumps.
Don’t try to show off.
Fig. 3-5 Never attempt wheelies or other stunts.
59
Use Care on Unfamiliar Terrain
Before riding in a new area, always check the terrain thoroughly. Don’t
ride fast on unfamiliar terrain or when visibility is limited. (It's some-
times difficult to see obstructions.)
Fig. 3-6 Be alert for changes in the terrain.
POTENTIAL HAZARD
Failure to use extra care when operating this ATV on unfamiliar
terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or holes without
enough time to react.
Could result in the ATV overturning or going out of control.
HOW TO AVOID THE HAZARD
Go stowly and be extra careful when operating on unfamiliar
terrain.
Always be alert to changing terrain conditions when operating
the ATV.
60
Never ride past your limit of visibility. Maintain a safe distance be-
tween your FOURTRAX and other off-road vehicles.
Always exercise caution, and use extra care on rough, slippery and
loose terrain.
Fig. 3-7 Use extra care on rough terrain.
A WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on excessively rough,
slippery or loose terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle control, which could result
in an accident, including an overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose terrain
until you have learned and practiced the skills necessary to
control the ATV on such terrain.
Always be especially cautious on these kinds of terrain.
61
RIDING
For your initial riding practice, select a safe area free of obstacles with
a level surface of dirt or sand. Practice at low speed until you are
confident in shifting gears, braking, and making turns.
POTENTIAL HAZARD
Running the engine in an enclosed area.
WHAT CAN HAPPEN
Engine exhaust contains carbon monoxide gas that can cause
loss of consciousness and may lead to death.
HOW TO AVOID THE HAZARD
Never operate the ATV engine in an enclosed area, such as a
garage.
62
STARTING THE ENGINE
Preparation
1.
PON
Select a level surface and lock the parking brake (page 31 ) before
starting the engine.
Turn the fuel valve (1) and ignition switch (2) to ON.
Make sure the engine stop switch (3 ) is at OO (RUN).
Make sure that the transmission is in neutral by checking that the
neutral indicator (4) lights.
Fig. 3-8 (1) Fuel valve (3) Engine stop switch
(2) Ignition switch (4) Neutral indicator
63
Starting Procedure (After Preparation)
To restart a warm engine, follow the procedure for High Air Tempera-
ture.
The starter motor will operate only when the transmission is in neutral.
Normal Air Temperature
10°—35 °C {50° —95 °F)
1. Pull the choke knob (1) up all the way to fully ON (A) position, if
the engine is cold.
2. With the throttle slightly open, press the starter button.
CAUTION:
Pressing the electric starter button for more than 5 seconds at a time
may cause the starter to overheat and damage the starter. Release
the starter button for approximately 10 seconds before pressing it
again.
Fig. 3-9 (1) Choke knob (A) Fully ON
(B) Halfway position
(C) Fully OFF
immediately after the engine starts, push the choke knob down to
the haifway position (B).
Warm up the engine by opening and closing the throttle slightly.
After the engine has warmed up, push the choke knob down all the
way to fully OFF. (C)
If idling is unstable, open the throttle slightly.
© ID 9
$
High Air Temperature
35 °C (95 °F) or above
1. Do not use the choke.
2. Start the engine (follow step 2under Normal Air Temperature).
Fig. 3-10 (1) Starter button
Low Air Temperature
10 °C (50 °F) or below
1. Follow steps 1 — 2 under “Normal Air Temperature.”
2. Warm up the engine by opening and closing the throttle slightly.
3. When the engine begins to run slightly rough, push the choke
knob down to the halfway position (B).
4. Continue warming up the engine until it runs smoothly and
responds to the throttle, then push the choke knob down all the
way to fully OFF (C).
5. Ifidling is unstable, open the throttle slightly.
CAUTION:
+ Extended use of the choke may impair piston and cylinder wall
lubrication and shorten the life of the engine.
* Do not race the engine during the warm-up period.
Racing a cold engine wastes fuel and increases engine wear.
If the engine doesn't start after pushing the starter button several times,
use the recoil starter.
65
Flooded Engine
If the engine does not start after pushing the starter button several
times, it may have become flooded with excess fuel. To clear the
engine:
1. Turn the engine stop switch 5% (OFF).
2. Move the choke knob to the OFF position.
3. Hold the throttle fully open and briefly press the starter button
several times.
4. When the engine is cleared, wait 10 seconds. Then turn the engine
stop switch to (7 (RUN) and repeat the normal starting procedure,
but don't use the choke.
Low Battery
If the battery is low or dead, use the recoil starter (page 18) to start the
engine.
High Altitude Adjustment
For operation above 1,000 m (3,000 feet), it may be necessary to
switch to high altitude carburetor jetting (see page 103).
66
SHIFTING GEARS
After starting the engine and letting it warm up, follow these proce-
dures:
1.
2.
3.
POTENTIAL HAZARD
With the transmission in neutral, release the parking brake, but
continue squeezing the rear brake lever.
With the throttle closed, raise the gearshift pedal one full stroke to
shift into 1st (first) gear.
Release the rear brake lever and increase engine speed by
gradually opening the throttle.
When speed increases, release the throttle and shift to 2nd gear by
raising the gearshift pedal one full stroke.
Repeat this sequence to progressively upshift to 3rd, 4th and 5th
(top) gear.
To downshift, reverse this sequence. Remember to close the
throttle each time you shift to the next lower gear.
Shifting gears without releasing the throttle.
WHAT CAN HAPPEN
Could cause loss of control or cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Always release the throttle when shifting gears.
67
RIDING IN REVERSE
To shift into reverse, first bring the vehicle to a complete stop and
make sure the transmission is in neutral. Then follow these proce-
dures:
1.
2.
Be sure there are no obstacles or people in the way.
While pushing the reverse selector knob in, squeeze the rear brake
lever, then depress the gearshift pedal (page 29).
Release the rear brake lever.
Open the throttle gradually and ride slowly. Do not open the
throttie suddenly or make abrupt turns.
To stop, close the throttle and gradually apply both the front and
rear brakes. Do not abruptly apply the rear brake by itself.
To shift out of reverse and into neutral, raise the gearshift pedal
one stroke.
While reading this manual, remember:
NANI Indicates a strong possibility that serious injury or
68
death may result if instructions are not followed.
A WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind you, resulting in
serious injury.
HOW TO AVOID THE HAZARD
When you select reverse gear, make sure there are no obstacles
or people behind you. When it is safe to proceed, go slowly.
POTENTIAL HAZARD
Applying only the rear brake abruptly when operating in reverse
gear.
WHAT CAN HAPPEN
The front wheels could lift off the ground and the ATV could
overturn backwards.
HOW TO AVOID THE HAZARD
Carefully apply both the front and rear brakes when stopping in
reverse gear.
69
MAKING TURNS
To make a turn on level ground, steer the handlebars and lean your
body toward the inside of the turn. (Fig 3-11) Leaning helps balance the
vehicle, and it feels more comfortable. Leaning into a turn is an impor-
tant technique to master in riding a FOURTRAX.
To make a sharp turn at low speed, it helps to shift your body slightly
forward on the seat (Fig3-11), and lean inside, as you steer the
handlebars. Shifting weight forward allows the rear wheels to turn
easier, and it also improves front-wheel steering. Remember to shift
your body forward to make sharp low-speed turns and whenever you
turn while accelerating from a full stop.
Apply the throttle slowly and gradually when you turn and start up at
the same time. During other turns, use the throttle to maintain the
desired speed throughout the turn. Practice these techniques on level
ground until you are confident in making turns.
70
Fig. 3-11 Lean your body to the inside of a turn and forward.
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
The ATV can go out of control, causing a collision or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning as described in this
Owner's Manual.
Practice turning at low speeds before attempting to turn at faster
speeds.
Do not turn at excessive speeds.
71
The terrain surface can be a major factor affecting turns. Skidding
during a turn is more likely to occur on slippery surfaces, such as snow,
ice, mud and loose gravel. If you skid on ice, you may lose all
directional control. To avoid skidding on slippery terrain, keep your
speed fow and ride with caution.
If your FOURTRAX skids sideways during a turn, steer in the direction
of the skid. Avoid hard braking or accelerating until you have regained
directional control.
TAC
POTENTIAL HAZARD
Skidding or sliding improperly.
WHAT CAN HAPPEN
You may lose control of this ATV.
You may also regain traction unexpectedly, which may cause the
ATV to overturn.
HOW TO AVOID THE HAZARD
Learn to safely control skidding by practicing at low speeds and
on level, smooth terrain.
On extremely slippery surfaces, such as ice, go slowly and be very
cautious in order to reduce the chance of skidding or sliding out of
control.
72
RIDING UP HILLS
The FOURTRAX's ability to safely climb hills largely depends on the
rider's skill and judgment. Begin by practicing on smooth, gentle
slopes. As you gain experience, you'll learn the hazards and your own
limitations. You may then proceed to ride on more difficult terrain.
However, you must be able to decide which hills or hazards might
cause the FOURTRAX to overturn. Avoid excessively steep hills.
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on extremely steep hills
than on level surfaces or small hills.
HOW TO AVOID THE HAZARD
Never operate the ATV on hills too steep for the ATV or for your
abilities.
Practice on smaller hills before attempting larger hills.
73
When climbing hills, you must shift weight toward the front wheels to
help keep them on the ground. To do this, shift your body slightly
forward on the seat and lean forward. For greater weight shift, move
your body farther forward and lean forward.
To climb a hill, take a running start in an appropriate gear and speed
for the conditions. Maintain a steady speed as you ascend the hill.
—
TaN
>
`
DE
Fig. 3-12 Shift weight forward when climbing hills.
74
A WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for climbing hills as described in
this Owner's Manual.
Always check the terrain carefully before you start up any hill.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly or make sudden gear changes.
The ATV could flip over backward.
Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.
If you incorrectly estimate climbing capability or terrain conditions, the
FOURTRAX may not have enough power or traction to continue uphill.
If you are aboutto lose all forward speed:
1. Using the front and rear brakes together, bring the FOURTRAX to
a stop with the vehicle pointed straight uphill.
75
2. Get off the FOURTRAX while you continue holding the brakes.
3. Shift into neutral, set the parking brake and turn the engine off.
4. Then assess the situation.
If the FOURTRAX starts rolling backwards before you begin braking,
keep your weight uphill, apply the front brakes first, then carefully
apply the rear brake as well. Do not apply the rear brake only or
abruptly if you are rolling backwards, or the vehicle may overturn.
if the FOURTRAX continues sliding backwards after you've applied the
brakes, get off and away from the vehicle.
Fig. 3-13 If you roll backwards down a hill, don’t apply the rear
brake abruptly.
76
POTENTIAL HAZARD
Stalling, rolling backwards or improperly dismounting while
climbing a hill.
WHAT CAN HAPPEN
Could result in ATV overturning.
HOW TO AVOID THE HAZARD
Use proper gear and maintain steady speed when climbing a hill.
If you lose all forward speed:
Keep weight uphill.
Apply the brakes.
Lock parking brake, after you are stopped.
If you begin rolling backwards:
Keep weight uphill.
Never apply the rear brake abruptly while rolling backwards.
Apply the front brake.
When fully stopped, apply rear brake as well, and then lock
parking brake.
Dismount on the uphill side if the vehicle is not pointed straight
uphill.
Back the vehicle down the hill, following the instructions in this
Owner's Manual.
77
If the hill is not too steep and you have good footing, you may be able
to walk the FOURTRAX back down the hill. Make sure your intended
path is clear in case you lose control of the FOURTRAX.
If you decide you can walk the FOURTRAX safely:
1. Stand with your body facing downhill, beside the vehicle so you
can reach the rear brake lever with your right hand (see Figure
3-14).
Be sure your legs are clear of the wheels.
Check your footing.
Then slowly and carefully back the FOURTRAX down the hill using
the rear brake lever to control speed.
5. If you lose control of the FOURTRAX, for your safety, get away
from the vehicle.
PON
If the hill is too steep or too slippery, or if you have any doubt whether
you can safely walk the FOURTRAX back down the hill, leave the
vehicle where it is and get help. If possible, block the wheels so the
vehicle won't roll backwards.
Fig. 3-14 Be sure your legs are Body position for backing
clear of the wheels. down a hill.
78
While reading this manual, remember:
УМА Тем Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
79
RIDING DOWN HILLS
it's usually advisable to descend hills with the FOURTRAX pointed
straight downhill. Avoid angles that would cause the vehicle to lean
sharply to one side.
As you approach a downhill, stop and survey the terrain below. Never
ride past the limit of your visibility.
When you've selected a safe downhill path, shift into a lower gear,
shift your weight back with your arms extended and braced against the
handlebars, then go down siowly with the throttie closed.
Use mainly the rear brake to control speed. Avoid using the front brake
hard or abruptly when riding down hills.
Remember, braking effectiveness is reduced on any hill with a loose
surface.
/
‘(а idx
SS >
77 ="x
us AN
RSS
Fig. 3-15 On downhills, shift your weight back.
80
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause ATV to overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for going down hills as
described in this Owner's Manual.
Note: a special technique is required when braking as you go
down a hill.
Always check the terrain carefully before you start down any hill.
Shift your weight backward.
Never go down a hill at high speed.
Avoid going down a hill at an angle that would cause the vehicle
to lean sharply to one side. Go straight down the hill where
possible.
81
CROSSING SLOPES
To maintain balance and stability when riding across a slope, you need
to shift weight toward the uphill side of the vehicle. To do this, move
your body off the center of the seat and lean toward the uphill side. On
a slippery or loose surface, you may also need to steer slightly uphill to
maintain a straight course across the slope. Avoid crossing hills that
are excessively steep, slippery or rough.
a > u 7 À aD
ik „а A | vr a, NU 77 AN —
Ji _ 0
Fig. 3-16 Shift weight uphill when crossing slopes.
82
MAKING TURNS ON SLOPES
Compared to riding on level ground, you may need to shift more
weight and lean more when making turns on slopes. Do not make
turns on any slopes until you have first mastered the techniques for
making turns on level terrain.
Begin by practicing turning on gentle, smooth slopes before
attempting turns on steeper or more difficult terrain. Avoid making
turns on very steep, rough or slippery hills.
A WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
Could cause loss of control or cause ATV to overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around on any hill until you have
mastered the turning technique as described in this Owner's
Manual on level ground.
Be very careful when turning on any hill.
Avoid crossing the side of a steep hill if possible.
When crossing the side of a hill:
Always follow proper procedures as described in this Owner's
Manual.
Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.
83
RIDING OVER OBSTACLES
Watch out for bumps, rain ruts, potholes and other obstacies in the
terrain. When you approach any obstacle, reduce your speed and be
prepared to stop.
Never try to ride over large obstacles, such as large rocks or fallen logs.
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a collision. Could cause the ATV to
overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for obstacles.
Never attempt to ride over large obstacles, such as large rocks or
fallen trees.
When you go over obstacles, always follow proper procedures as
described in this Owner's Manual.
84
RIDING THROUGH WATER
Your FOURTRAX is designed to travel through water up to approxi-
mately 250 mm (10 in) deep. Before crossing a stream, make sure the
water is not too deep or flowing too fast.
Choose a path where both banks have gradual slopes, then proceed
through the water at a slow, steady speed. Watch out for submerged
obstacles and slippery rocks. Avoid getting the spark plug or air
cleaner wet, as this would cause the engine to stop.
Riding through water can make the brakes less effective than normal.
After leaving water, always test both the front and rear brakes. If
necessary, apply the brakes repeatedly until they dry out and operate
normally. If the brakes don’t regain effectiveness, stop your
FOURTRAX and follow the procedures on page 126.
————ARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast flowing water.
WHAT CAN HAPPEN
Tyres may float, causing loss of traction and loss of control, which
could lead to an accident.
HOW TO AVOID THE HAZARD
Never operate this ATV in fast flowing water or in water deeper
than that specified in this Owner's Manual.
Remember that wet brakes may have reduced stopping ability.
Test your brakes after leaving water. If necessary, apply them
several times to let friction dry out the linings.
85
PARKING
Always choose a level place to park. After bringing your FOURTRAX to
a stop, hold the brakes while you shift into neutral. Then set the
parking brake and turn the ignition switch O (OFF). If you're through
riding for the day, also turn the fuel valve OFF.
While reading this manual, remember:
NINE Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
86
MAINTENANCE SCHEDULE
MAINTENANCE AND REPAIRS
FREQUENCY
ITEMS
Whichever
comes first
=>
INITIAL
MAINTENANCE
REGULAR
MAINTENANCE INTERVAL
mi
100
600 1200
km
150
1000 | 2000
NOTE
HOURS
20
100
Refer to
page
FUEL LINE
THROTTLE OPERATION
CARBURETOR CHOKE
101
AIR CLEANER
(NOTE 1)
97 — 99
AIR CLEANER HOUSING
DRAIN TUBE
(NOTE 2)
100
SPARK PLUG
109
VALVE CLEARANCE
110
ENGINE OIL
104— 107
ЖЖ
ENGINE OIL STRAINER
SCREEN
ЖЖ
ENGINE OIL CENTRIFUGAL
FILTER
ENGINE IDLE SPEED
101
I. Inspect and Clean, Adjust,
Lubricate or Replace if necessary.
C: Clean
A: Adjust
R: Replace
L: Lubricate
87
FREQUENCY Whichever INITIAL; REGULAR
comes first MAINTENANCE] MAINTENANCE INTERVAL
> mi 100 600 1200 | Referto
ITEMS km 150 1000 | 2000 page
NOTE ¡HOURS| 20 100 200
REAR FINAL GEAR CASE (R: EVERY | 108
OIL 2 YEARS)
BRAKE FLUID (NOTE 3) | | 120
BRAKE SHOE WEAR (NOTE 1} | 125
BRAKE SYSTEM | | | 117—126
*| REVERSE LOCK SYSTEM | | | 112
SKID PLATES. ENGINE | | 133
GUARD
* CLUTCH SYSTEM | 1 | 111
*| SUSPENSION | | —
*| SPARK ARRESTER С С 134
*| NUTS, BOLTS, FASTENERS ] | —
** WHEELS/TIRES i | | 127—131
.. STEERING SHAFT HOLDER | —
BEARINGS
kx STEERING SYSTEM | —
* Should be serviced by your authorized Honda dealer, unless the owner has proper
tools and service data and is mechanically qualified. Refer to the official Honda service
manual.
** In the interest of safety, we recommend these items be serviced only by your
authorizes Honda dealer.
NOTES: 1. Service more frequently when riding in dusty areas, sand or snow.
88
2. Service more frequently after riding in very wet or muddy conditions.
3. Replace every 2 years. Replacement requires mechanical skill.
MAINTENANCE PRECAUTIONS
Before beginning any maintenance or repairs, read the appropriate
instructions and warnings and make sure you have all the tools and
materials you will need.
Choose a clean area that is level and has good ventilation and good
light. Make sure the engine is off unless otherwise instructed. If you
need to replace any parts, remember to use only new genuine Honda
parts or their equivalents.
POTENTIAL HAZARD
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident or equipment damage.
HOW TO AVOID THE HAZARD
Always follow the inspection and maintenance procedures and
schedules described in this Owner's Manual.
Use only genuine Honda replacement parts or parts of equivalent
quality.
POTENTIAL HAZARD
Performing maintenance operations with the engine running.
WHAT CAN HAPPEN
Increases the chances of injury from moving parts or hot surfaces.
HOW TO AVOID THE HAZARD
Unless otherwise stated, always turn the engine off before
performing any maintenance operations.
89
TOOLKIT
A tool kit (Fig. 4-1) is provided with your FOURTRAX and stored in the
storage compartment below the rear cargo rack.
The tools in the kit are sufficient to perform routine maintenance and
simple repairs. Any extensive work requiring additionat tools should
be performed by your authorized Honda dealer.
The tool kit includes the following items:
+ Standard/Phillips screwdriver + Spark plug wrench
+ Screwdriver handle * Tool case
* Air pressure gauge
Fig. 4-1 (1) Tool kit
30
While reading this manual, remember:
INTL [IM fell Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
91
FUEL SYSTEM
FUEL
Refueling
The fuel tank capacity, including reserve, is:
9.1 £ (2.40 US gal , 2.00 Imp gal)
The reserve fuel supply is:
2.4 2 (0.63 US gal , 0.53 Imp gal)
To open the fuel fill cap (1), pull out the breather tube (2) from the
handle cover hole (3). Then turn the fuel fill cap counterclockwise.
Do not overfill {make sure there is no fuel in the filler neck (4)).
After refueling, be sure to tighten the fuel fill cap firmly by turning it
clockwise until it clicks.
Insert the breather tube into the handle cover hole.
(4)
ES
и T_T
_
Fig. 4-2 (1) Fuel fill cap (4) Filler neck
(2) Breather tube
(3) Handlebar cover hole
92
A WARNING
POTENTIAL HAZARD
Refueling this ATV or handling fuel improperly.
WHAT CAN HAPPEN
The fuel could explode or ignite.
HOW TO AVOID THE HAZARD
Always refuel this ATV and handle fuel in a well-ventilated area
with the engine off. Do not smoke or allow flames or sparks in the
area where fuel is handied.
Do not overtill the tank. Be careful not to spill fuel when refueling.
After refueling, make sure the fuel fill cap is closed properly and
securely.
If any fuel is spilled, make sure the area is dry before starting the
engine.
POTENTIAL HAZARD
Prolonged contact of fuel with the skin.
Breathing fuel vapor.
WHAT CAN HAPPEN
The fuel can cause skin irritation.
Fuel vapor could cause lung damage.
HOW TO AVOID THE HAZARD
Avoid repeated or prolonged contact of fuel with the skin or
breathing of fuel vapor.
KEEP QUT OF REACH OF CHILDREN.
93
Fuel Recommendations
Your engine is designed to use any petrol that has a pump octane
number (R+M)/2 of 86 or higher, or a research octane number of 81 or
higher. (Petrol pumps at service stations normally display the pump
octane number.)
Use unleaded fuel only because it produces fewer engine and spark
plug deposits and extends the life of the exhaust system. Never use
stale or contaminated petrol or an oil/petrol mixture. Avoid getting dirt,
dust or water in the fuel tank.
Using a lower octane than recommended can cause persistent
“pinging” or heavy “spark knock” (a metallic rapping noise). If severe,
these can lead to engine damage.
CAUTION:
If “spark knock’ or “pinging’’ occurs at a steady engine speed under
normal load, change brands of petrol. If spark knock or pinging
persists, consult your authorized Honda dealer. Failure to do so is
considered misuse, and damage caused by misuse is not covered by
Honda's Limited Warranty.
94
Petrol Containing Alcohol
If you decide to use a petrol containing alcohol {gasohol), be sure its
octane rating is at least as high as that recommended above.
There are two types of gasohol: One contains ethanol, and the other
contains methanol. Do not use gasohol that contains more than 10%
ethanol. Do not use gasohol that contains methanol (methy! or wood
alcohol) unless it also contains cosolvents and corrosion inhibitors for
methanol. Never use petrol containing more than 5% methanol, even if
it has cosolvents and corrosion inhibitors.
NOTE:
* Engine performance problems resulting from the use of fuels that
contain alcohol are not covered under the warranty. Honda cannot
endorse the use of fuels containing methanol since evidence of their
suitability is not yet complete.
* Before buying fuel from an unfamiliar station, try to find out if the
fuel contains alcohol. If it does, confirm the type and percentage of
alcohol used. If you notice any undesirable operating symptoms
while using a petrol that contains alcohol, or one that you think
contains alcohol, switch to a petrol that you know does not contain
alcohol.
95
THROTTLE
Throttle Cable and Lever
Check the condition of the throttle cable and the operation of the
throttle lever. Make sure the cable does not bind or interfere with
smooth operation of the throttle in any steering position. If the cable is
worn or kinked, have it replaced by your Honda dealer.
Throttle Free Play
Throttle free play, measured at the tip of the throttle lever (Fig. 4-3),
should be:
3—8 mm (0.1—0.3 in)
To adjust throttle free play:
1. Slide the rubber sieeve (1) back to expose the throttle cable
adjuster (2).
2. Loosen the lock nut { 3), then turn the adjuster to obtain the correct
free play.
3. Tighten the lock nut and reinstall the sleeve.
(0.1—0.3 in)
Fig. 4-3 (1) Rubber sleeve (4) Throttle lever
(2) Cable adjuster (A) To decrease free play
(3) Lock nut (B) To in crease free play
Other Checks
Check the throttle cable for kinks and signs of wear that could cause
stretching or failure. Lubricate the throttle cable with a commercially
available lubricant to prevent premature wear and corrosion.
96
AIR CLEANER
Air Cleaner Filter
The air cleaner accumulates dust and must be cleaned periodically. If
the FOURTRAX is ridden in dusty areas, the air cleaner must be
cleaned at more frequent intervals than specified in the Maintenance
Schedule.
If the FOURTRAX is submerged in water, the air cleaner should be
checked and water should be drained from the air cleaner housing
before starting the engine.
To clean the air cleaner:
1. Remove the seat by pulling up the seat lock lever ( 1) (Fig. 4-4).
2. Unlatch the four retainer clips (2) and remove the air cleaner hous-
ing cover (3).
(2)
y
(1)
(3)
Fig. 4-4 (1) Seat lock lever (3) Air cleaner housing
(2) Retainer clips cover
97
Remove the screws (2) (Fig.4-5) and remove the air cleaner
assembly ( 1) from the air cleaner housing.
Unscrew the clamp (3).
Rumove the air cleaner (4) from the air cleaner body (5).
(2)
Fig. 4-5 (1) Air cleaner assembly (4) Air cleaner
(2) Screws (5) Air cleaner body
(3) Clamp
Gently wash the air cleaner in clean, non-flammable (high flash
point) solvent such as kerosene — not gasoline.
Allow the air cleaner to dry throughly before applying oil. A wet air
cleaner will not fully absorb the oil.
POTENTIAL HAZARD
Using petrol or low flash point solvents for cleaning ATV parts.
WHAT CAN HAPPEN
A fire or explosion could result.
HOW TO AVOID THE HAZARD
Use only a nonflammable or high flash point solvent to ciean ATV
parts.
98
7, Soak the air cleaner in clean gear oil (SAE 80— SAE 90) or an
equivalent until saturated, then squeeze out the excess oil.
CAUTION:
Twisting the air cleaner when squeezing out excess oil could damage
the air cleaner.
8. Reassemble by reversing the disassembly sequence.
Dust Cover
Do not push the dust cover (1) (Fig. 4-6) into the air cleaner housing (2).
If the dust cover is dirty, clean it.
(1)
Fig. 4-6 (1) Dust cover
(2) Air cleaner housing
99
Air Cleaner Housing Drain Tube
The air cleaner housing drain tube (Fig. 4-7) should be serviced in
accordance with the Maintenance Schedule. (Riding through water
may require more frequent inspection.) If deposits can be seen in the
drain tube, the tube must be cleaned before starting the vehicle.
To clean the drain tube:
1. Remove the drain tube (1) by removing the clip (2 ).
2. Drain the deposits.
3. Reinstall the drain tube, securing it with the clip.
(3)
Fig. 4-7 (1) Drain tube (3) Air cleaner housing
(2) Clip
100
CARBURETOR
Choke Cable and Knob
Check the condition of the choke cable (Fig. 4-8) and the operation of
the choke knob (2). If the cable is damaged or kinked, have it replaced
by your Honda dealer.
(2)
E) |
7 Y
я
(1)
Fig. 4-8 (1) Choke cable (2) Choke knob
101
Adjusting Idle Speed and Air-Fuel Mixture
NOTE:
Do not try to compensate for faults in other systems by adjusting the
carburetor.
To adjust the idle speed:
1. Warm up the engine. The engine must be warm for accurate idle
adjustment. Ten minutes of stop-and-go riding is sufficient.
2. Adjust idle speed by turning the throttle stop screw (Fig. 4-9).
Idle Speed:
1,400 + 100 min” (rpm)
To adjust the air-fuel mixture:
1. Turn the pilot screw (2) clockwise until you hear the engine miss
or decrease In speed.
2. Then turn the screw counterclockwise until the engine misses or
decreases in speed again.
3. Center the pilot screw exactly between the two extreme positions.
Usually, the correct setting (between extremes of rich and lean)
will be found at 2.0 turns open from a fully closed position.
4. if idle speed changes after adjusting the fuel mixture, readjust the
throttie stop screw.
Fig. 4-9 (1) Throttle stop screw (2) Pilot screw
102
High Altitude Adjustment
When operating this FOURTRAX at altitudes ranging above 1,000 m
(3,000 feet), the air-fuel mixture becomes overly rich. This may result
in poor engine performance and increased fuel consumption.
A high altitude jet is available to compensate for high altitude richness.
For those who are mechanically proficient and have the necessary
tools, installation and adjustment procedures are given in the official
Honda Service Manual available from your Honda dealer. All others
should have this carburetor modification performed by an authorized
Honda dealer.
CAUTION:
Sustained operation with the high altitude jet at altitudes below 1,500
m (5,000 feet) may cause engine overheating and damage.
Altitude range Main jet | Pilot screw
0— 1,500 т Мо. 95 Factory preset
(0— 5,000 feet)
1,000— 2,500 m Screw in 1/8 turn
or higher No. 92 clockwise from
(3,000 — 8,000 feet) factory preset
103
LUBRICATION
ENGINE OIL
Checking Engine Oil Level and Adding Oil
Check the engine oil level each day before operating your FOURTRAX
and add oil if needed.
To check the oil level:
1.
Make sure the vehicle is on level ground.
2. Start the engine in a well-ventilated area and let it idle for a few
minutes.
3. Stop the engine.
4. After a few minutes, remove the oil filler cap/dipstick (Fig. 4-10)
from the front crankcase cover and wipe it clean.
5. Insert the dipstick without screwing it in, then remove the dipstick
and check the oil level. The oil level should be between the upper
level mark (2) and the lower level mark (3) on the dipstick.
6. If required, add the specified oil into the filler cap hole, up to the
upper level mark on the dipstick. Do not overfill.
7. Reinstall the oil filier cap/dipstick.
CAUTION:
Running the engine with improper oil level can cause serious engine
damage.
so
(2)
(3)
Fig. 4-10 (1) Oil filler cap/dipstick (2) Upper level mark
104
(3) Lower level mark
Engine Oil Recommendations
Recommended Oi! Viscosity: SAE 10W-40. Other viscosities shown in
Fig.4-11 may be used when the average temperature in your riding
area is within the indicated range.
Use Honda 4-stroke oil or an equivalent.
Do not use oils with graphite or molybdenum additives. They may
adversely affect clutch operation,
Use only high detergent, premium quality motor oil certified to meet
API Service Classification SE, SF or SG. Motor oils intended for Service
SE, SF or SG will show this designation on the container. The use of
special oil additives is unnecessary and will only increase operating
expenses.
NOTE:
Engine oil is a major factor affecting the performance and service life
of the engine. Nondetergent, vegetable, or castor based racing oils are
not recommended.
SAE 20W-50
NE E
SAE 20W-40
Co a aa
SAE 10W-40
CL |
SAE 10W-30
Fig. 4-11 Recommended oil viscosities
105
Changing the Engine Oil
Engine oil should be changed in accordance with the Maintenance
Schedule. Use motor oils of the grade and viscosity recommended.
When changing oil, drain the oil from the crankcase while the engine is
still warm. This will ensure complete and rapid draining.
To change the oil:
1. With the FOURTRAX on level ground, remove the oil filler cap/
dipstick from the front crankcase cover (Fig. 4-10).
2. Place an oil drain pan under the crankcase and remove the oil
drain plug (Fig. 4-12).
Fig. 4-12 (1) Oil drain plug
106
3. Check that the drain plug sealing washer is in good condition, then
reinstall the oil drain plug securely. If necessary, replace the
sealing washer.
Oil drain plug torque:
25 N-m (2.5 kgf-m , 18 Ibf-ft)
4. Fill the crankcase with the recommended oil approximately:
1.5 8 (1.6 US qt, 1.3 Imp qt)
Reinstall the oil filler cap/dipstick.
Start the engine and let it idle for a few minutes.
Stop the engine and check the oil level. Make sure the oil is be-
tween the upper and lower level marks on the dipstick.
if necessary, add more oil but do not overfill.
Noo
CAUTION:
Running the engine with improper oil level can cause serious engine
damage.
NOTE:
* To protect the environment, please dispose of used engine oil
properly. We suggest you place used oil in a sealed container and
take it to your local service station for reclamation. Do not put it in
the trash or pour it on the ground.
* If a torque wrench was not used for installation, see your authorized
Honda dealer before operating the vehicle to verify proper assembly.
While reading this manual, remember:
INVA IN Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
107
REAR FINAL GEAR CASE OIL
Change the oil in the rear final gear case when specified by the Main-
tenance Schedule. Change the oil with the final gear case warm, and
the FOURTRAX on level ground to assure complete and rapid draining.
To change the rear final gear case oil:
1. To drain the oil, first place an oil drain pan under the oil drain plug
(Fig. 4-13). |
2. Remove the oil filler cap (1) and the drain plug (2).
3. After the oil has completely drained, reinstall the drain plug.
Drain Plug Torque:
12 N-m (1.2 kgf-m , 9 Ibf-ft)
4. Fill the gear case with the recommended oil.
Rear final gear case oil:
80 cm? (2.7 US oz, 2.8 Imp oz)
Recommended oil:
HYPOID GEAR OIL SAE 80
Remove the oil level check bolt (3).
Make sure the oil level reaches the oil level check hole (4).
5. Install the oil filler cap and oil level check bolt.
Fig. 4-13 (1) Oil filler cap (3) Oil level check boit
(2) Drain plug (4) Lower edge of oil level
check hoie
108
ENGINE
SPARK PLUG
The standard spark plug is: DPR8EA-9 (NGK)
or X24EPR-U9 (DENSO)
For cold climate (Below 5 *C, 41 *F): DPR7EA-9 (NGK)
or X22EPR-U9 (DENSO)
For extended high speed riding: DPR9EA-9 (NGK)
or X27EPR-U9 (DENSO)
CAUTION:
Using a spark plug of incorrect size or heat range can cause serious
engine damage.
To check and change the spark plug:
1.
2.
3.
4
Disconnect the spark plug cap.
Clean any dirt from around the spark plug base.
Remove the plug with the wrench provided in the tool kit.
Visually inspect the spark plug electrodes for wear. The center
electrode (Fig. 4-14) should have a flat tip and sharp edges, and
the side electrode (2) should not be eroded. If the electrodes and
Insulator tip appear unusually fouled or burned, we suggest that
you contact your authorized Honda dealer.
Discard the spark plug if there is apparent wear or if the insulator
is cracked or chipped.
Using a wire-type feeler gauge, make sure that the spark plug gap
is correct. If adjustment is necessary, bend the side electrode
carefully.
The gap should be:
0.8—0.9 mm (0.03—0.04 in)
With the plug washer attached, thread the spark plug in by hand to
prevent cross-threading.
After threading by hand, tighten a new spark plug 1/2 turn with the
spark plug wrench to compress the washer. If you are reusing a
plug, it should only take 1/8— 1/4 turn after the plug seats.
109
CAUTION:
The spark plug must be securely tightened. An improperly tightened
plug can become very hot and possibly damage the engine.
2
| I~ 0.8— 0.9 mm
GS 1 (003 — 0,04 in)
—
—
——
—
(1)
Fig. 4-14 (1) Center electrode (2) Side electrode
VALVES
Valve clearance should be:
0.13 mm (0.005 in)
Excessive clearance will cause noise. Insufficient clearance will cause
loss of power and possibly damage the valves.
For those who are mechanically proficient and have the proper tools,
instructions on adjusting valve clearances are given in the official
Honda Service Manual. All others should have valves adjusted by an
authorized Honda dealer.
110
CLUTCH
Clutch Adjustment
To adjust the clutch:
1.
Make sure the ignition switch is O (OFF).
2. Loosen the lock nut (Fig.4-15), and turn the clutch adjuster (2)
counterclockwise until you feel slight resistance.
3. Then turn the adjuster 1/4 turn clockwise, and tighten the lock nut
to hold the adjuster in this position.
4. After adjustment, start the engine and test ride the FOURTRAX to
be sure the clutch is operating properly.
07
(1)
=
(2)
Fig. 4-15 (1) Lock nut (2) Clutch adjuster
111
Reverse Lock System
Measure the reverse assist lever (2) free play. Free play, measured at
the lever (2) end near the cable (Fig. 4-16), should be approximately:
2-4 mm (0.1—0.2 in)
To adjust, loosen the lock nut (3) and turn the adjusting nut (4).
Tighten the lock nut securely.
Other Checks:
Check the reverse assist lever and cable for loose connections or other
damage. If the cable is worn or kinked, have it replaced by your Honda
dealer.
(0.1—0.2 in) (4)
Fig. 4-16 (1) Rear brake lever (3) Lock nut
(2) Reverse assist lever (4) Adjusting nut
While reading this manual, remember:
IT: Te Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
112
ELECTRICAL SYSTEM
BATTERY
Your FOURTRAX battery is located in a compartment under the seat.
The battery is sealed, so it is not necessary to check the electrolyte
level or add distilled water. If the battery seems weak, see your
authorized Honda dealer for information on recharging or replacement.
If you replace the battery, choose one that is sealed and equivalent to
the original. Be sure to read and follow all safety precautions indicated
on the battery.
CAUTION:
Do not attempt to remove the caps from the battery cells as this may
damage the battery.
Although the battery is sealed, it vents explosive gases and should be
handled with appropriate care.
A WARNING
POTENTIAL HAZARD
Allowing open flames or sparks near the battery.
WHAT CAN HAPPEN
Gases may explode and possibly cause injury.
HOW TO AVOID THE HAZARD
Do not allow open flames or sparks near the battery.
When the FOURTRAX is to be stored for an extended period, remove
the battery from the vehicle and charge it fully. Then store it in a cool,
dry place. If the battery is to be left on the vehicle, disconnect the
negative cable from the battery terminal.
113
Battery Removal
1.
Make sure the ignition switch is O (OFF).
2. Remove the seat (page 132).
3. Release the rings and remove the rubber band (2).
4. Disconnect the negative (—) terminal lead (3) from the battery (1)
first, then disconnect the positive (+) terminal lead (4).
5. Remove the battery.
* Install in the reverse order of removal.
* Check all bolts and other fasteners are secure.
* After installing the battery, check to see if the battery cables are
routed correctly.
(4)
(1) (3)
Fig. 4-17 (1) Battery (3) Negative (—) terminal lead
114
(2) Rubber band (4) Positive (+) terminal lead
FUSE
As illustrated in Fig. 4-18, the fuse (2) is located in the battery
compartment.
A spare fuse is located in the owner's manual storage area under the
seat (page 38).
The specified fuse is:
15A
If a fuse fails frequently, it usually indicates a short circuit or an over-
load in the electrical system. See your authorized Honda dealer for
repair.
5 9
(2)
Fig. 4-18 (1) Fuse holder assembly
(2) Fuse
115
To replace a fuse:
1. Make sure the ignition switch is O (OFF).
CAUTION:
Turn the ignition switch O (OFF) before checking or replacing the
fuse to prevent accidental short-circuiting which could damage the
electrical system.
Remove the seat (page 132).
Remove the fuse holder assembly (Fig. 4-18).
Pull the old fuse out of the fuse holder.
Push the new fuse in to the fuse holder.
Install the fuse holder assembly and seat.
DOH WN
(2)
Fig. 4-19 (1) Fuse (2) Fuse holder
HUN
POTENTIAL HAZARD
Improperly replacing a fuse.
WHAT CAN HAPPEN
Serious damage to the electrical system, which could cause a fire
or a loss of lights or engine power, which could lead to an
accident.
HOW TO AVOID THE HAZARD
Never use a fuse with a different rating from that specified in this
Owner's Manual.
Do not pry the clips open to get a fuse out, as a loose fuse could
cause damage to the electrical system or start a fire.
116
BRAKES
FRONT BRAKES
This FOURTRAX has hydraulic front drum brakes on both front wheels.
Each day before riding you should check the brake lever free play and
inspect the system for fluid leaks. The brake fluid level should be
checked frequently, and the brake shoe linings should be inspected
periodically.
To check lever free play and shoe lining clearance:
1. Measure the distance the brake lever (Fig. 4-20) moves before the
brakes start to take hold. Free play, measured at the tip of the front
brake lever (1) should be:
25—30 тт (1—1.2 тп)
(1) 25—30 тт (1—1.2 тп)
y
Fig. 4-20 (1) Front brake lever
117
2. Remove the inspection hole plug (Fig.4-21) and measure the
lining thickness (2) on both front wheels.
Lining Thickness:
Standard: 4.0 mm (0.16 in)
Service Limit: 2.0 mm (0.08 in)
If either lining is worn beyond the limit, both brake shoes must be
replaced by an authorized Honda dealer.
3. If the brake lever free play and the brake shoe lining thicknesses
are within the recommended limits, reinstall the inspection hole
plugs, seating them into the inspection holes as shown in Fig. 4-21.
4. If the brake lever free play is excessive but the linings are not worn
beyond the service limit, adjust the brake lining clearance.
(3)
(2)
E SN
OS | | ) |
A
Fig. 4-21 (1) Inspection hole plug (3) Front brake drum
(2) Lining thickness (4) Front wheel rim
118
To adjust the brake lining clearance:
1. Squeeze the brake lever firmly two or three times then release it.
2. Raise the front wheels off the ground by placing a support block
under the vehicle.
3. Beginning with either the left or right front wheel, remove the
inspection hole plug (Fig. 4-21) and line up the hole with one of the
brake adjusters (Fig. 4-22).
4. Using a screwdriver, turn the brake shoe adjuster (1) in the
direction of the arrow until the front brake locks.
и \
Fig. 4-22 (1) Brake adjuster
5. Back the adjuster off three clicks, then squeeze the brake lever
several times. Spin the wheel manually to make sure the brake
does not drag.
6. Line up the inspection hole with the second adjuster and repeat
steps 3 through 5.
7. Reinstall the inspection hole plug, seating it into the inspection
hole as shown in Fig. 4-21.
8. Follow steps 3 through 7 to adjust the other front brake.
9. Recheck the brake lever free play. If free play is still excessive after
adjusting the brake lining clearance, there is probably air in the
brake system and it must be bled out. See your authorized Honda
dealer for this service.
119
To check the brake fluid level:
Brake fluid must be added to the reservoir (Fig. 4-23) whenever the
fluid level approaches the lower level mark (1). Use only DOT 3 or 4
brake fluid and have it added by an authorized Honda dealer.
NOTE:
If the fluid level approaches the lower level mark (1), the brake system
should be inspected by your authorized Honda dealer. A low fluid level
may indicate fluid leakage. Brake failure may occur if this condition
exists and is not corrected.
CAUTION:
+ To prevent damage to the brake system, use only fluid from a
sealed container. Never allow contaminants (dirt, water, etc.) to
enter the brake fluid reservoir.
+ Brake fluid can damage paint and plastic, so handle the fluid with
care. When adding brake fluid, be sure the reservoir is horizontal
before removing the cover to prevent accidental spilling.
120
Fig.
POTENTIAL HAZARD
Brake fluid contacting the skin or eyes.
WHAT CAN HAPPEN
May cause irritation.
HOW TO AVOID THE HAZARD
Avoid contacting brake fluid with the skin or eyes. In case of
contact, flush thoroughly with water and call a doctor if your eyes
were exposed.
4-23 (1) Lower level mark
A WARNING
Oth
1.
2.
er Checks:
Make sure there are no fluid leaks.
Check for deterioration or cracks in the hose and fittings.
Make sure there are no fluid leaks.
Check the condition of brake hoses and fittings. If the hoses are
worn or cracked, have them replaced by an authorized Honda
dealer.
121
REAR BRAKE
This FOURTRAX has a single mechanical drum brake on the rear axle
housing. Each day before riding you should check the operation of
both the rear brake pedal and the rear brake lever. You should also
periodically check the brake shoes for wear.
To check and adjust brake pedal free play:
Measure the distance the rear brake pedal moves before the brake
starts to take hold. Free play, measured at the end of the pedal (Fig.
4-24), should be:
15— 20 mm (0.6—0.8 in)
en
15 — 20 mm
(0.6 — 0.8 in)
(1)
Fig. 4-24 (1) Rear brake pedal
122
To adjust the free play, turn the brake pedal adjusting nut (1), (Fig.
4-25 ), located on the brake operating rod at the rear of the frame.
Make sure the cut-out on the adjusting nut is properly seated on the
brake arm pin (3).
„ (3)
Fig. 4-25 (1) Brake pedal adjusting nut
(3) Brake arm pin
(2) Brake lever adjusting nut
123
To check and adjust brake lever free play:
Measure the distance the rear brake lever moves before the brake
starts to take hold. Free play, measured at the tip of the brake lever (Fig.
4-26 ), should be:
15—20 mm (0.6—0.8 in)
To adjust the free play, turn the brake lever adjusting nut (2), (Fig.
4-25 ), located on the brake operating rod at the rear of the frame.
Make sure the cut-out on the adjusting nut is properly seated on the
brake arm pin (3).
15—20 mm (1)
(0.6— 0.8 in)
ST
Fig. 4-26 (1) Brake lever
124
To check rear brake shoe wear:
When the brake is applied, an arrow (3) attached to the brake arm (2)
moves toward a reference mark (4) on the brake panel (see Fig. 4-27).
If the arrow aligns with the reference mark on full application of the
brake, the brake shoes must be replaced. See your authorized Honda
dealer for this service.
(
<>
—
(
= (
SOS
Fig. 4-27 (1) Brake lever adjusting nut (3) Arrow
(2) Brake arm (4) Reference mark
Other Checks:
Check the condition of the brake cables. If there are kinks or signs of
wear that could cause sticking or failure, have the cables replaced by
an authorized Honda dealer. Make sure the brake arm, spring, and
fasteners are in good condition.
125
DRAINING WATER FROM BRAKES
Make sure the engine is off and the parking brake is set. Then remove
the inspection hole plug (Fig. 4-28) from the front brakes, and the drain
bolt (Fig. 4-29) from the bottom of the rear brake cover. If any water
drains, the brake seals must be replaced by your Honda deaier as soon
as possible.
Fig. 4-28 (1) Front brake inspection
hole plug
Fig. 4-29 {1) Rear brake drain bolt
126
WHEELS AND TYRES
WHEEL REMOVAL
If you need to remove a wheel from your FOURTRAX, follow these
procedures:
1. Raise the front (or rear) wheels off the ground and place a support
securely under the vehicle.
2. Loosen the wheel nuts (Fig. 4-30) with a 17 mm socket wrench.
3. Remove the wheel.
When reinstalling a wheel, tighten the wheel nuts in a crisscross
(rather than a circular) pattern.
Wheel nuts torque:
64 N-m (6.5 kgf-m , 47 |bf-ft)
Be sure the tapered side of the wheel nuts face the wheel rim (2).
POTENTIAL HAZARD
Installing wheels improperly.
WHAT CAN HAPPEN
A wheel may come loose, possibly leading to an accident.
HOW TO AVOID THE HAZARD
Carefully follow the instructions in this Owner's Manual when
installing wheels.
127
NOTE:
if a torque wrench was not used for installation, see your authorized
Honda dealer before operating the vehicle to verify proper assembly.
Fig. 4-30 (1) Wheel nuts (2) Wheel rim
TYRES
This FOURTRAX is equipped with low pressure tubeless tyres.
Although the tyres are designed specifically for off-road use, they are
not inmune to punctures. Always select your riding area with care.
Tyre Pressure
Check the tyre pressure frequently with the tyre pressure gauge
supplied with the vehicle. For normal use, the tyres should be inflated
to the pressure recommended in Fig. 4-31. -
NOTE:
* Tyre pressure should be checked before you ride, when the tyres are
“cold.” Be sure to check tyre pressure at the riding site, since
changes in altitude can affect air pressure.
+ A manually operated tyre pump should be used rather than the high
pressure systems found in service stations. This will minimize the
possibility of tyre damage from overinflation. If you use a high
pressure system at a service station, add air in small amounts and
check the pressure increase frequently to prevent possible tire
damage from overinflation.
128
FRONT REAR
TYRE SIZE AT22 x 7-11 XK AT22 x 10-9 Xx
TYRE BRAND TRACKER HP TRACKER HP
GOOD YEAR GOOD YEAR
RECOMMENDED | 20 kPa (0.20 kgf/em? , | 20 kPa (0.20 kgf/em? ,
PRESSURE 2.9 psi) 2.9 psi)
о
E | MAXIMUM 23 kPa (0.23 kgf/cm? , | 23 kPa (0.23 kgf/cm? ,
& | PRESSURE 3.3 psi) 3.3 psi)
O
< | MINIMUM 17 kPa (0.17 kgf/em? , | 17 kPa (0.17 kgf/em? ,
PRESSURE 2.5 psi) 2.5 psi)
E 9 | RECOMMENDED | 20 kPa(0.20 kgf/em?, | 20 kPa (0.20 kgf/em2,
= & | PRESSURE 2.9 psi) 2.9 psi)
Fig. 4-31 Tyre specifications
POTENTIAL HAZARD
Operating this ATV with improper tyres, or with uneven tyre
pressure.
WHAT CAN HAPPEN
Use of improper tyres on this ATV, or operation of this ATV with
improper or uneven tyre pressure, may cause loss of control,
increasing your risk of an accident.
HOW TO AVOID THE HAZARD
Always use the size and type tyres specified in this Owner's
Manual for this vehicle.
Always maintain proper tyre pressure as described in this Owner's
Manual.
129
Tyre Tread Condition
To check the condition of a tyre tread, measure the groove depth (1)
(Fig. 4-32) in the center of the tyre, or check the wear indicator (2).
The minimum tread depth is 4 mm (0.16 in). When the tread depth is
less than recommended, the tyre should be replaced.
New
Replace
Fig. 4-32 (1) Groove depth (3) Wear indicator location
(2) Wear indicator mark
130
Repairing a Flat Tyre
If you have a flat tyre, use the plug method to make a temporary repair.
(The plug method is applied from the outside of the tyre and is the
same as that for conventional tubeless tyres.)
A plug-type repair kit, available at most auto parts stores or service
stations, provides a plug, an installation tool, tyre cement, and an
instruction sheet. Follow the instructions provided with the repair kit to
make a temporary repair.
As soon as possible, have the tyre permanently repaired by an
authorized Honda dealer. Any tyre that cannot be repaired should be
replaced.
Whenever the FOURTRAX is to be operated far from service facilities
or available transportation, we recommend that you carry a tyre pump
and a repair kit with the vehicle.
131
SEAT REMOVAL
To remove the seat (Fig. 4-33), pull up the seat lock lever (1) at the left
side of the seat and lift it up.
To install the seat, align the tabs on the seat with the grommets on the
frame and press the seat down until it locks.
(2)
Fig. 4-33 (1) Seat lock lever (2) Seat
132
ENGINE GUARD AND SKID PLATES
The engine guard (Fig. 4-34) protects the engine crankcase.
The skid plates (2) protect the frame and rear final gear case. Check
the guard and plates for cracks, damage or looseness at intervals
shown in the Maintenance Schedule (page 87 —88).
Replace the guard and plates with new ones if they are cracked or
damaged. If the guard and plate bolts are loose, tighten them securely.
(2)
Fig. 4-34 (1) Engine guard (2) Skid plates
133
SPARK ARRESTER
The exhaust system must be periodically purged of accumulated
carbon.
To purge the system:
1.
Select a well-ventilated area free of combustible materials and
make sure the exhaust pipe is cool.
2. Remove the bolt. (Fig. 4-35)
3. Start the engine and rev it up approximately twenty times while
momentarily creating exhaust system back pressure by blocking
the end of the muffler with a shop towel.
4. Stop the engine and allow the exhaust pipe to cool.
5. Reinstall the bolt securely.
Fig. 4-35 (1) Bolt
134
A WARNING
POTENTIAL HAZARD
Improperly purging the exhaust system.
WHAT CAN HAPPEN
Could injure the eyes.
Could cause burns.
Could cause carbon monoxide poisoning, possibly leading to
death.
Could start a fire.
HOW TO AVOID THE HAZARD
When purging the exhaust system:
Always wear eye protection, and make sure no one stands behind
the vehicle.
Always let the exhaust system cool before performing this
operation.
Never run the engine in an enclosed area.
Make sure there are no combustible materials in the area.
135
TRANSPORTING YOUR FOURTRAX
When you transport your FOURTRAX, we recommend that you carry
the vehicle in its normal operating position (on all four wheels) and
follow these procedures:
1. Setthe parking brake and place the transmission in gear.
2. Turnthe fuel valve OFF.
3. Secure the vehicle with “tie downs” in the areas shown (Fig. 4-36).
Suitable “tie downs” are available from your Honda dealer.
Ordinary rope is not recommended because it can stretch under
load.
CAUTION:
Using tie downs in any other areas can damage your FOURTRAX.
Fig. 4-36 Points to secure (1) Front cargo rack
FOURTRAX with (2) Right footpeg
tie downs
136
(4)
(3) (4)
Fig. 4-37 Points to secure (3) Left footpeg
FOURTRAX with (4) Rear cargo rack or
tie downs Trailer hitch
If it is necessary to incline your FOURTRAX upright on the rear end:
Follow steps 1 and 2 on the previous page.
Place a suitable container under the carburetor drain tube.
Turn the drain screw counterclockwise and drain the fuel from the
carburetor.
After draining the carburetor, turn the drain screw clockwise until
itis tight.
5. Pour the drained fuel into the fuel tank.
6. Tilt the vehicle and secure properly.
К ою
Do not tow your FOURTRAX behind a car or other vehicle.
137
POTENTIAL HAZARD
Inclining this ATV without first draining fuel from the carburetor.
WHAT CAN HAPPEN
The fuel could explode or ignite.
HOW TO AVOID THE HAZARD
Always drain fuel from the carburetor before inclining this ATV.
Always handle fuel in a well-ventilated area with the engine off.
Do not smoke or allow flames or sparks in the area where fuel is
handled.
if any fuel is spilled, make sure the area is dry before starting the
engine.
POTENTIAL HAZARD
Prolonged contact of fuel with the skin.
Breathing fuel vapor.
WHAT CAN HAPPEN
The fuel can cause skin irritation.
Fuel vapor could cause lung damage.
HOW TO AVOID THE HAZARD
Avoid repeated or prolonged contact of fuel with the skin or
breathing of fuel vapor.
KEEP OUT OF REACH OF CHILDREN.
138
CLEANING YOUR FOURTRAX
CLEANING
Clean your FOURTRAX regularly to protect the surface finishes and
inspect for damage, wear, and oil or brake fluid leakage.
Avoid cleaning products that are not specifically designed for ATV or
automobile surfaces.
They may contain harsh detergents or chemical solvents that could
damage the metal, paint, and plastic on your FOURTRAX.
If your FOURTRAX is still warm from recent operation, give the engine
and exhaust system time to cool off.
Park in a shady area. Washing your FOURTRAX in bright sunlight may
cause the finish to fade because water droplets intensify the sun's
brightness. Spotting is also more likely because surface water can dry
before you have time to wipe it off.
We recommend avoiding the use of high pressure water spray (typical
in coin-operated car washes.)
CAUTION:
High pressure water (or air) can damage certain parts of the
FOURTRAX.
139
1. Rinse the FOURTRAX thoroughly with cool water to remove loose
dirt.
2. Clean the FOURTRAX with a sponge or soft cloth using cool water.
Avoid directing water to muffler outlets and electrical parts.
3. After cleaning, rinse the FOURTRAX thoroughly with plenty of
clean water.Detergent residue can corrode alloy parts.
Dry the FOURTRAX.
Start the engine and let it run for several minutes.
Test the brakes before riding the FOURTRAX. Several applications
may be necessary to restore normal braking performance.
pop
Braking efficiency may be temporarily impaired immediately after
washing the FOURTRAX.
Anticipate longer stopping distances to avoid a possible accident.
140
STORING YOUR FOURTRAX
STORAGE
Before storing your FOURTRAX for an extended time, be sure you
thoroughly check the vehicle for needed repairs and have them
corrected. Otherwise, the repairs may be forgotten by the time you
remove the vehicle from storage.
In addition, extended storage requires that you take the following steps
to reduce the effects of deterioration from non-use of the vehicle:
1. Change the engine oil.
2. Drain the fuel tank and carburetor. Be sure to drain the fuel ina
well-ventilated area, not in a garage.
141
INV: TH —_—
POTENTIAL HAZARD
Refueling this ATV or handling fuel improperly.
WHAT CAN HAPPEN
The fuel could explode or ignite.
HOW TO AVOID THE HAZARD
Always refuel this ATV and handle fuel in a well-ventilated area
with the engine off. Do not smoke or allow flames or sparks in the
area where fuel is handled.
Do not overfill the tank. Be careful not to spill fuel when refueling.
After refueling, make sure the fuel fill cap is closed properly and
securely.
If any fuel is spilled, make sure the area is dry before starting the
engine.
POTENTIAL HAZARD
Prolonged contact of fuel with the skin.
Breathing fuel vapor.
WHAT CAN HAPPEN
The fuel can cause skin irritation.
Fuel vapor could cause lung damage.
HOW TO AVOID THE HAZARD
Avoid repeated or prolonged contact of fuel with the skin or
breathing of fuel vapor.
KEEP OUT OF REACH OF CHILDREN.
142
Y.-S
Remove the spark plug and pour one tablespoon (15— 20 cm”) of
clean engine oil into the cylinder.
Operate the starter for a few seconds to distribute the oil, then
reinstall the spark plug. (Make sure the engine stop switch is
Xi (OFF) before pressing the starter button.)
Remove the battery (page114) and store it in an area protected
from freezing temperatures and direct sunlight and out of the
reach of children, slow charge the battery once a month.
POTENTIAL HAZARD
Allowing open flames or sparks near the battery.
WHAT CAN HAPPEN
Gases may explode and possibly cause injury.
HOW TO AVOID THE HAZARD
Do not allow open flames or sparks near the battery.
мо
Wash and dry the FOURTRAX, and wax all painted surfaces.
Inflate the tyres to their recommended pressures.
Place the FOURTRAX on blocks to raise all four tyres off the
ground.
143
SPECIFICATIONS
DIMENSIONS
Overall length 1,794 mm (70.6 in)
Overall width 1,034 mm {40.7 in)
Overall height 1,054 mm (41.5 in)
Wheelbase 1,131 mm (44.5 in)
WEIGHT
Dry Weight 187 kg (412 Ibs)
CAPACITIES
Engine oi! .9 2 (2.0 US gt , 1.7 Imp gt)
1
Fuel tank 9.1 2 (2.40 US gal , 2.00 Imp gal)
Fuel reserve 2.4 2 (0.63 US gal , 0.53 Imp gal)
ENGINE
Bore and stroke 68.5 X 62.2 mm (2.70 Xx 2.45 in)
Compression ratio 9.2:1
Displacement 229 em? (14.0 cu-in)
Engine idle speed 1,400 + 100 min” (rpm)
Spark plug, standard DPR8EA-9 (NGK)
X24EPR-U9 (DENSO)
Spark plug gap 0.8—0.9 mm (0.03—0.04 in)
Valve clearance 0.13 mm (0.005 in)
CHASSIS AND SUSPENSION
Caster angle 8°
Trail length 42 mm (1.7 in)
Tire size, Front АТ22 X 7-11 %
Rear AT22 X 10-9 %
144
POWER TRANSMISSION
Primary reduction 3.087
Final reduction 3.692
Gear ratio 1st 3.231
2nd 2.167
3rd 1.667
4th 1.280
5th 1.042
Reverse gear ratio 5.550
Noise level (ISO 5131) 77.0 dB (A)
Vibration on seat Not exceed 0.5 m/s?
(EN 1032, ISO 5008)
Vibration on handlegrip 6.4 m/s’
(EN 1033, EN 709)
ELECTRICAL
Battery 12 V— 10 Ah
Generator 0.123 kW/5,000 min” (rpm)
LIGHTS
Head light (Low/High) 12 V 25/25 W X 2
Taillight 12V—5 W
Neutrai indicator LED
Reverse indicator LED
Oil high temperature indicator LED
FUSE
Fuse 15 À
145
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146
SERIAL NUMBERS AND COLOR LABEL
The frame, engine and key numbers (Fig. 5-1) will be needed when you
order replacement parts. The color is also helpful. Record the numbers
and color here for your reference.
The frame serial number (2) is stamped on the front of the frame. The
engine serial number (3) is stamped on the right crankcase.
The color label (4) is attached to the frame below the seat (page 132 ).
KEY NO.
FRAME NO.
ENGINE NO.
COLOR
Fig. 5-1 (1) Key number (3) Engine number
(2) Frame number (4) Color label
147
INDEX
A
Accessories ............e.e.e..evccericcecarercarvereneceaonuccarenceneoraccarereanenementranenenvem mana. 48
Age recommendation ...............—...<.r.eeeeenenere Lennon rene neare 40
Air cieaner
Air cleaner..................e.erscccarererereneooocereocaneenanenenertn Dore ren neneneraronennavena 97
Housing drain tube..................ee..eseeeeeriere ne een eee ereDe 100
Air pressure gauge..................e.emmineenoniere ene ne ee enn eee 90
Apparel, recommended.........ccoeiriniin EEK eenassensrensrencensnnes 50
B
= 11(-1a AT 113
Brakes
Brake cables...................eesrcicccececroceneeoonecrer cera nene nen tane e rcanercoceona 125
Brake fluid.................ecerreornicacororeeneconerrenar een atener re ecorernenenorrennerencene. 120
Front brakes
Adjustment....................ereeeceenennen recen ocana ene een nene neeaneenereeeenna 119
Brake lever ..................e.eccemiiecrececanenortenanecanarier cero eencanoororercanaaceronere. 31
Brake lever free play... ss 117
Parking brake .................e=ererermeecenien re nene een ner enormes 31
Rear brake
Brake lever ................_.escenccarernrnenecacanevercancarcare oe enarenreenenoreeaveanvevee 31
Brake lever free play .................ee.e..dsc0riviiecenoerneneneroonenece arre aceros 124
Brake pedal ...............——.eeeonerrccanerererracone cancer sean 31
Brake pedal free play ..................e.e.=e00erneeneie nene ene 122
Brake shoes..................esererererenerereoccerenenencentecarnevoorenenerveenenenenenene 125
ВгеаК-!т ргосейигеб..........ененеееннненннеенненнннснненнееннненнннннненнееенонненннее ii
С
Carburetor
Air — fuel mixture adjustment...............e.e—..+=-.emeececaneenrne rare ace cen sens 102
High altitude adjustment.….….….…...….…...….…crroncerereeneententeneenensrenssencennennes 103
Idle speed adjustment.……..…..…..……eseceresieneenennen enaD eee 102
Cargo carrying
Loading and operational guidelines...…........….….…..….….….ecenersenenennenens 46
Weight limit ..................e=eexeeoreeerene encerrar cercare reoanrencereconencanneneneees 45
Cargo racks.............e..ceeeereerecererccnneec ene enn nereeneene ene receeeceanaceeen.es 45
Choke
Cable ...............eescraczerreresuconeconeneroonenreavonecerventnanenoreerecaveronaneerno Danes 101
Knob...............e-.esecacccrriecernerenareacaneerereanenmeceneneenenaaonnatanernrencancannonanene 101
0] 12Y: 111127 = PEO OP OP PPP RTI TROT ICIIOCT 139
148
Climbing hills creer eres mr eneurre cerro. 73
Clutch adjustment..................... e... er nee eee teneccreeeees 111
Crossing slopes.................e..ee=e=renreeveriiere recen ree enen arars sas resessssssanssnnnnnnes 82
D
Digital clock .......................... erez rimar eonenenen nano rrennereanerero e eenenenoneacer men. 28
U nene encereeeree ee erearereereneneneneos 21
D[.- [+] TT 34,104
Display (see Multi-function display) ...........................xrecreseevererreneene_ 24
E
Engine
ldle speed adjustment….…........…..….erreressersensannrerrenvenseneeraasanareuremanace 101
Break-in procedures .....................e.eemmemmiereeee e ID DIR OIR RR ER DOI! il
Flooded =Tq To 11 U-TURN 66
Starting the engine....................eervm0ere e ere Deere rencencaneorencene earn. 63
Engine oil
Changing Oil..................ee.eereesceneeerc ec ercer e eee rene nereocareerencenen Tee 104
Checking oil level and adding Oil.…..….…….…..…….….…srescerecrarsennsannences RI 104
Oil filler cap/dipstick......................e.eeeeereee ne DN II TRI ZA 34, 104
Oil high temperature indicator lamp.................c=..e..erervereerrmie ee 22
Recommendations ...............e....esreericaner rear enerne near erre. 105
Engine stop switCh....................e..mer seee eee ee DR Rea DD 15
Exhaust system
Cleaning ..............e.eeecnerrrennecerre e enrerecerereeeere nera rerrarerenenee rene rereeDee 42
PUrging..............e.e_rercereresocancencerracenteoareane rea oeren recae racerereeneaonareaneneneneee 134
F
Final gear case Oil ....................e.icencaceceracencon one reenareen e nceneneneoococeeoenceceme 108
Flag pole bracket......................e.esenccorrenconree encerrona recen reee. 35
Flooded engine ....................eerceccererner cer rene Reena rereereene nen enneca. 66
Fuel
Fuel recommendations... rere es caressa anes 94
Fuel fill CAP .........……..…....vsverrensensererensanansesenerennenensnasance carre encens name 32, 92
Fuel tank capacity ................e...e.ee.er.ercescerencaorentacene eee ereneece reee. 92
Fuel Valve.................eeeceeroceenenercenerron reee rroe near eCerereeeraroaneceacareorcantencenes 33
High altitude fuel mixture adjustment ....................e..eserssrenece 103
Refueling.............e. e —.... e. .eeeereiaranerer encarnan ercer encarernenea annonces 92
Reserve fuel supply ...................eeresiermiernen enero eee rene eee enero. 33
Fuse
LOCATION ...........….…recerrrecrrssrenrrnsrrenranrenrenvennaconarenencassenesa case escanreuses 114
Replacement....................eenerecoccnraccocenc errar nene Darren reee. 116
G
Gasoline (see Fuel)
Gearshift pedal.........................e.cemieerrcaar ee e enero enero ener recen. 29
Gearshifting........…….....….….....….crerssancencercenseoneanentensercereneean entree essence 29, 67
Gear case oil
Rear final gear case Oil.….….....….…...rresssasensererrmnertarnaneneentenencensennecceumes 108
H
Headlight SwitchEs..…..…........….….…rrmierenseneneneannen anrrrarerena see en ere nenane 21
High altitude fuel mixture adjustment....................——....=.e=eessennece 103
Hills
Riding across slopes ......................ee-erreceverenecenceveroeneneneae enana. 82
Riding down hills.................e.....ecmreemenerere ee Deere 80
Riding up hills...............e.eeeeeeererecees rece ercer ener re rene e reo ce ren erncanenne. 73
Stopping on hills ......................=.remieere ener ene 75
Turning on slopes................=...ee.emercersecrcnnene tere Dr enea ineracoo ene. 83
Horn button ......................ee.eererieeeizereerecerence ren nenanarorneneereorerro venere 17
Hour meter ...................eecercerirecocarrenenen ener anreneenovencennenorercenereacearareceen 27
|
Idle speed adjustment .....................eereermeeererecaee ener Den cs ce canes 102
Ignition switch ..............——e.ee..vesmmrecerene ree Renan rca neon nenene enenneneiieeo.. 14
Indicator
Neutral indicator................e — eee. resercereererieoc erre neo arce enereano erereceneeaee 22
Oil high temperature indicator ....................e=...miereeeeeie ee 22
Reverse indicator.................e--...e-eeerrernenieetenennrocea nene ere ne ere eue 22
Inspection, pre-ride................. e... 00.0 een ene De neceneces 42
L
Loading
Loading guidelines and procedures..................e-e.e-..eeverecccranceneneecere. 46
Weight limitS..…...........…ccrerssercernenereesrenreneane rennes en renrenen terres ect crane 45
Lubrication
(see Engine oil, Gear case oil)
M
Maintenance
PreCAaUtIiONS ….….…....…......ecssrasaverrenrrenrrsranraenerenneraanan ta ven send na sa ns AVE ne sen 00000 89
Schedule ................e.eseeesererorcccorenereicecrocanoarencanreeaonoconneneatanere neo eeacemoo. 87
Modifications ...................e.e.e.-eccercirrcercceiceen eee rente reranea earn ene. 50
150
N
Neutral indicator ..................e.e.er. eesnreeenrenseeaeeasenaeenreasentatansnsasensensonses 22
O
Obstacles, MAING OVI... evecare seers essen anes 84
Oil (see Engine oil, Gear case oil)
Oil filler cap/dipsticK …..…........rirrreonsenrenssanvencransssasr een eneaa nan nra eme 34,104
Oil high temperature indicator......................eee.....0i2er erre RR RDA 22
Owner's manual StOrAGE ….…....…......…rsrrssssrenserssassanenaanarenanrane nous enacenuees 38
P
Parking................e.orcercroceecoreienecce neon eee. Peeecaononeoro ens anarrer ameno nen raaneneneDe. 86
Parts location.............e.—....—....eerereiiiee reese sere steve serra enonacenoranreceaeeces 10
Parking brake..................-e-esescariieacereeeonacere cane reee arenero rRere Tes 31
Passenger carrying ................... ==... eeieveciccenreorenereroeo er reee nene re. 52
Pavement, no riding ON ................e.eevesceieicai rare eo rene arce Der rene e 54
PINGING cece reese sree arn esse esr a res ee re raanns 94
ad (5 A To [oT TT 0 T=To3 (To o [SNR 42
R
Rear final gear Case Oil ss ae ere re enaa as 108
a T=ToTe 11 IE 7: To = cS 18
Reverse
Assist CADE... rere errr reese errr eas eaes 112
Assist lever ..................eeesceonercerececeuaona cone eea caro nocereeoe reee entere nene 112
Gear, shifting into ................er..eí=.scencvecorsonceecenricrnocen rece reaoneer ee. 29, 67
Indicator ...............—e.e=rercerrrareoronrinerereeaane ere ra ser sa ease ra saab renee as 22
Riding IN FEVEISE ..…..….........cccsrerrenriennanerecrnnaccne menace ren rereersavesanrenec ananas 68
Selector KnOD.........….…...........rocrrerrrerrasaresererenanearenaaneanrenee rran canne n ac 0000 30
Rider training Course .................er=ecereciiocerec er ee ee e Re DDD 1,42
S
Safety messages, special .........................eeerrezeri ee e DD DR RI II RRA RI ED IA 1
Seat removal! and installation ...............e......ee.eseriiieoe ee RT TIE 132
Serial numbers and color label... eee, 147
3) 412 (a To Je [=F JOU 29, 67
Skid plates ...................e.ervvereerrcarceccerire rene ner ere re rencenencareneanenneenees 133
Skidding...............e. e... .esmecrensarecerenenenereoacencanane sere ee sere er esse reser a nna e nen ne snes 72
Spark arrester..................esresvereoorrccricerenee once nor erre rara reee nene ner. 134
Spark knock ......................eeeeeenreerecere rencor enn n eee ene nenercereeaceneeeneoracnes 94
Spark plug «eerie eres srs 109
Specifications...................=..=.eerereene Ne e reee 144
Stalling ona hilt .....................eeemreereereen reee recrean one en nene recen 75
Starter button ....................=.e==rrererercecrnencene cen areere ena nenereerenorcerenecanecere 17
Storage compartment.…..…...…....….….…..….…rereneeseniencensen ee 37
Storing procedures ..................e.iremececern nene De Renee. 141
T
Throttle
Cable ..............e.eericccccrooreaorieorcecercarrereo nene rnencaneocrarerrceccereane recreo. 96
Lever................ecceccceccccrencenarereorevareooroarerermeareavencoaeeccacenvooeracan ene 0 20, 96
Tires
Inflation and air pressure...............——.... e... eee Dn 128
Repairing...................=.ee.eeriecerien erre e ener cen ire ene neenecerceneneeneneaecanes 131
Specifications ................=..eereeere ee Dres 129
Tread condition ..............e...esressererererernacenrecne econ irene arses ane sssnsasnees 130
Tool Kit ...............e.e.eccooroncaranioreaceoverererrecueaa ne neccar enero neroccanerarntaaceneneneeetocarne 90
Trailer hitch ..................e---rermnecorceneneneranaanoacentrancanca oeeniacr roo rear rare enero 36
Trailer towing
Operational guidelines.…..…...…....…..….….….……sseresesensenentennençenenen essences 46
Weight limits................—...=eeeeeeeirenen erre neneronenee ricerca no rereacenercanerennenee.s 45
Transporting procedures...............ee.ee0enieenrennne ene ener 136
Turning
On level ground.....................=rereenoececa ran nn enran DD rcs assess anaes 70
On SIOPES …......………recrroceranercentensanearenecsacen essere asst esse aaa nese 83
Vv
Valve clearance .................essmcosccareesrerenerozanercooecocenene nn eoracanreacanenemerceren 110
W
Warning labels o.com ececanaeenererenereeneracennenenenos 8
Water
Draining from БгаКеб .........ееееееененненннененнененннненнненененнеененннеененннненене) 126
Riding through... iirc enano. 85
Weight limits ..............e...seresereeerer eee reee De renae eee neReererranenrereneneencen- 45
Wheel removal ..................escirercearrren cesen nene eceerece reee reee necerererecen 127
Wiring diagram .….….….….….…ercensencresceonnenenrenencenarnnen ete ee 146
152