Honda TRX 400EX Offroad Vehicle Owner's Manual

1999
TRX 400EX
HONDA FOURTRAX 400EX
OWNER'S MANUAL
The TRX400EX is designed as a high-performance sport model to be
used only by highly-experienced operators with advanced skills.
О
О
> =
CM FD
hs
DN
»
À
Zn
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USA only:
It conforms to US EPA Noise Emission regulations, but does not
conform to Federal Motor Vehicle Safety Standards or US EPA Exhaust
Emission regulations, and operation on public streets, roads, or
highways is illegal. The vehicle is equipped with a USDA qualified
spark arrester. Obey local laws and regulations.
It conforms to California exhaust emission regulations for ATVs.
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
15 miles (25 km). During this period, avoid full-throttie 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. 1998. No part of this publication may be
reproduced without written permission from Honda Motor Co., Ltd.
CONTENTS
Page
FOURTRAX SAFETY Lotito eee esate e reese eee seer even es eens 1
Special Safety Messages ...................00 ie e reee eones 1
Warning Information..................-..emee reee reee reee rene eeanees 6
PARTS LOCATION AND OPERATION ...............e.eremmerieeeraces eee ee 10
Parts Location .............. e... e. ...iiiee ene eee reese e ee eee sees aes seen 10
Parts Ope@ratION.…....………...………rssonersrrrransanneareararanaeeennr care nannan encre 13
eA] gL Oe] of fo LS nenere ner ereenereererneneneencereneme. 13
LIGNTS …...nvunascscecccerccassssamenecrenrerasamenensararnassasesenena nana seen ce cennanaa cena 18
Gearshift CONtrOIS......….........….....rcerreressersrrarersenanneacanrecer ananas 20
Brake Controls.....................eeerveeerii a nacen erre eererereaeeceneererees 21
Fuel Tank................ remera eee eee eee e eset e eases erate eens 22
e [0 eee eee eee eee eee eee eee aera 24
Front Suspension.........e.. ee... enana neon earn eeerarees 25
Rear Suspension............. eee erre narran ener ee eeeroaveroe 26
Additional Features .........................eimeriiir arar nene cerere marea 28
RIDING YOUR FOURTRAX................... reee anne erenereren eee enero. 32
Before 101 eee ner rene rananne nee craa sera nanas 32
Rider PreparatiON ee eee eee eee rena 4... 32
Vehicle Preparation co... ieee eee ener eee 34
Safe Riding Rules...............w.ennxe.rereee errar eee reneea tener eoreemes 42
RIQUNG ...…....……rovccccccrcercrereansenenranseneremerarrenraracansasaa seance ren en enr en nana anna 54
Starting the Engine esse eee eee area enero. 55
Shifting Gears ….…….….…...…...crssccrerrrseanenerarrrernenranmesrerennana eee esses 59
Making TUrNS ….…...…….....ercressercensarensararranencanen rene en rare crane nee 60
Riding Up HillS …..…………crerssrsenranerrrransererea rare sannen casser rare nana 63
Riding Down HIllS …....….…….……ererrrssentenerenneneraransaneara crane cecraanane ere ca scans 70
Crossing SIOPES ….…..….….…...….……sscrrreerenrensencrrereasranaaneenranne ren ca rave 72
Making Turns on Slopes..................... remera 73
Riding Over Obstacies........................imiie nie er ene ee ee 74
Riding Through Water .................eeeereere en ee reee ee eee. 75
Parking... N 76
(cont'd)
CONTENTS
Page
MAINTENANCE AND REPAIRS..............e.eenerernmcaceccraroreuenacariareroermenente 77
Emission Requirement.….....….........…….……ersescresenencenencas anrsas 77
Maintenance Schedul@ ….……............…vrsrerercansentenenenen anna nas enn ananas can ver 78
Maintenance PrecautionS ….…..…....…..…....…srsserersresnrannanenen entra na nana anne c cn 80
Tool Kit.….…............erccrerrenesrr care se enrena nana nen ane nan can nana ne see ane nana nt nee 81
I-II: 6:10:10 PT 82
Lubrication.............e—.....e=—eremeiioreren er ncrarare oe errercararraroreararonemereremareeme. 94
Drive Chain ........e.....eresererrcerererecnarorzerermenarieracionocaruecar nar e enacareeerEec 101
TE [= J POUR 105
CC are RAKEERARRRRRARRERKARKRKREBURBERDALKERKENRUEKURKARKERUKBURUUGKAHG 107
Electrical System ................—.eemenerneeicera ro een ai enero ne cerD ee eee 110
Brakes ...............e.resdeceasnerronacaomenereararoratoaoearraraauceaerenenarrEenmenenaciarreDes 115
Wheels and Tires................e.esernrrricarorccioooceartarearorracarcarereo rre nacacererTN 122
Seat Removal .............e.er-—ecrerrerercaverrcioooneciecenarororeoniainrrere en rare cane eme 127
Engine Guard and Skid Plates .....................eseeeeeemeereieere ene carre 128
Spark Arrester ..............-..-..e.eeeeeereenreenee enero encerrona. 130
TRANSPORTING YOUR FOURTRAX ............e.ee.er.eenecarvenvennearnereneo nece 132
CLEANING YOUR FOURTRAX ............ecessmcerenceccencaroenecnecanerserorennenacan. 135
STORING YOUR FOURTRAX ….….…....…rsrrsrenesnsenenars san ansaen aan ra canc ana sean ne 137
AO SEN 140
WIRING DIAGRAM. conocer ettarssen setae stsensssetnesrerasesanennsnsnessnsancns 142
CONSUMER INFORMATION ................-.cessrvernercieciorierenenccarenrenereen nena 143
WARRANTY SERVICE.................reseorerncicacarereorecucecaraeoereecerereerer aerea. 145
SERIAL NUMBERS AND COLOR LABEL ..............e...eseiiereccnccareareereneaces 146
IN DE CT O 147
AUTHORIZED MANUALS ..............e.cernenccoonciarerververvecerareeon e rarecrenenee 153
FOURTRAX SAFETY
SPECIAL SAFETY MESSAGES
AN ATV IS NOT ATOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handies 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.
* Never operate an ATV without proper instruction.
Take a training course. Beginners should receive training from a
certified instructor. Contact an authorized ATV dealer or call 1—800
—887— 2887 (USA only) to find out about the training courses
nearest you.
* 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 hills and for
braking 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.
+ Always 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 tires specified in this manual. Always
maintain proper tire 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. Allow greater distance
for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer
Product Safety Commission at 1—800—638—2772, or the ATV Dis-
tributors” Safety Hotline at 1—800— 852 — 5344 (USA only).
WARNING INFORMATION
Your FOURTRAX comes with a hang tag (USA only) and 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.
USA only
/ TN
A WARNING
improper use of ATVs can result in SEVERE INJURY
or DEATH
ALWAYS USE NEVER USE NEVER CARRY NEVER USE
AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS
HELMET AND RHOADS OR ALCOHOL
PROTECTIVE
GEAR
NEVER operate :
© without proper training or instruttion.
® at speeds too fast for your skills or the conditions.
son public roads - a collision can occur with
another vehicle.
e with a passenger - passengers affect balance
and steering and increase tisk of losing control.
ALWAYS :
e use proper riding techniques to avoid vehicis
overturns on hilis and rough terrain and in turns.
e avoid paved surfaces - pavement may seriously
affect handling and control,
READ THE OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
MM о >
=
SPORT MODEL
THIS ATV IS FOR
RECREATIONAL USE
BY EXPERIENCED OPERATORS ONLY
OPERATOR ONLY-NO PASSENGERS
NO OPERATOR UNDER AGE 16
THIS CATEGORY S (SPORT) ATV IS À HIGH PERFORMANCE
ATV FOR OFF ROAD USE ONLY. IT IS FOR SPORT TYPE
RECREATIONAL AND COMPETITIVE USE BY OPERATORS
WITH ADVANCED SKILLS AND SUBSTANTIAL EXPERIENCE.
TRAINING COURSES TO TEACH ATV RIDING SKILLS ARE
AVAILABLE.FOR INFORMATION CONTACT YOUR DEALER.
Des
>)
CE
CHECK WITH YOUR DEALER TO FIND OUT ABOUT
STATE OR LOCAL LAWS REGARDING ATV OPERATION.
THiS HANGTAG IS NOT TO BE REMOVED BIFCRE SALE
©
Improper tire pressure or overloading
can cause loss of control.
Loss of control can result in severe
injury or death.
® Cold tire pressure,
Front: 4.020.6psi 0.275%0.04kgf/cm’
Rear 4.0%0.6psi 0.275+0.04kgf/cm'
e Maximum weight capacity ; 243165. (110Ка)
— |
O)
АЕ 4A WARNING |
NEVER ride as a passenger.
Passengers can cause a
Operating this ATV if you are under
the age of 16 increases your chance
of severe injury or death.
loss of control, resulting in
SEVERE INJURY or DEATH.
NEVER operate this ATV if you are
under age 16. Г
—
a
— 0
de
A
E A WARNING
improper use of ATVs can result in SEVERE INJURY
or DEATH
ALWAYS USE NEVER USE NEVER CARRY NEVER USE
AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS
HELMET AND ROADS OR ALCOHOL
PROTECTIVE
GEAR
NEVER operate :
® without proper training or instruction, ©
(+) e at speeds too fast for your skills or the conditions,
e on public roads - a collision can occur with
another vehicle,
e with a passenger - passengers affect balance
and steering and increase risk of losing control.
ALWAYS |
e use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns.
e avoid paved surfaces - pavement may seriously
affect handling and control.
READ THE OWNER'S MANUAL,
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
PARTS LOCATION AND OPERATION
PARTS LOCATION
(1) Clutch lever/Parking brake lever
(2) Headlight switch
Engine stop switch
Headlight dimmer switch
Starter button
(3) Neutral indicator lamp
(4) Ignition switch
(5) Front brake lever
(6) Throttle lever
(7) Fuel tank cap
(1) (2) (3) (4) (5)
(7)
Fig. 2-1 Handlebars, from rider's point of view
10
(8) Headlights
(9) Helmet holder
(10) Fuel valve
(11) Flag pole bracket
(12) Seat lock lever
(13) Tire pressure gauge
Tool Kit
Owner's manual
(14) Operator footpeg
(15) Gearshift pedal
(16) Oil filler cap/dipstick
(8) (9) (10) (11)
(15) (14)
(16)
(12)
Fig. 2-2 Left side of FOURTRAX
11
(17) Rear brake fluid reservoir
(18) Front brake fluid reservoir
(19) Rear brake pedal
(20) Operator footpeg
Fig. 2-3
12
Right side of FOURTRAX
PARTS OPERATION
POWER CONTROLS
Ignition Switch
The ignition switch (Fig. 2-4) is located on the headlight case.
(1)
Fig. 2-4 (1) Ignition switch
Key Position Function Key
Removal
OFF The engine and headlight can- The key can
(O) not be operated. be removed.
ON The headlights can be turned on. The key can-
(1) not be re-
With the engine stop switch at moved.
RUN (CO) and the transmission
in neutral, the engine can be
started.
13
Engine Stop Switch
The engine stop switch (Fig. 2-5 ) is next to the left handgrip, and it has
three positions. When the switch is in the RUN (© ) position, the
engine will operate. When the switch is in either OFF (IX) 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 ( (DO ) position.
NOTE:
If you stop your FOURTRAX by turning the engine stop switch OFF
(& ), Бе sure to turn the ignition switch OFF (QO ) to prevent battery
discharge.
Fig. 2-5 (1) Engine stop switch
14
Choke Lever
The choke lever (Fig.2-6) is on the left side of the carburetor. The
choke has three positions: fully ON (C), halfway position (B), and fully
OFF (A).
To start a cold engine when air temperature is 10—35 °C (50—90 °F),
pull the choke lever up to fully ON before pressing the starter button.
At colder air temperatures, pull the choke lever up to the fully ON
position before pressing the starter button. As the engine warms, push
the lever down to the halfway position. After the engine is warm, push
the choke lever 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.
>
0 UNS —
Fig. 2-6 (1) Choke lever (A) Fully OFF
(B) Halfway position
(C) Fully ON
15
Starter Button
The starter button (Fig. 2-7) is below the engine stop switch. To start
the engine, press the starter button (1), with the transmission in
neutral, the ignition switch ON ( | ) and the engine stop switch (2) at
RUN (O).
—_/ — {сео
ie
ZZ 000
NS |
(1) pa | > O AN
oe
Г К
(2)
Fig. 2-7 (1) Starter button (2) Engine stop switch
16
Throttle Lever
The throttle lever (Fig. 2-8 ) 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.
ZB <a
| РО
GL Po) EE
Fig. 2-8 (1) Throttle lever
(A) To open the throttle
Rear Brake
The rear brake pedal (1) is near the right footpeg.
(1)
Fig. 2-9 (1) Rear brake pedal
17
LIGHTS
Headlight and Dimmer Switches
The headlight and dimmer switches (Fig. 2-10) are above the engine
stop switch, next to the left handgrip.
Turning the headlight switch (1) ON (7%) turns the headlight on. Use
the dimmer switch (2) to select either high beam HI (ED) or low beam
LO (2D).
Fig. 2-10 {1) Headlight switch (2) Dimmer switch
18
Neutral Indicator Lamp
The neutral indicator lamp (1) (Fig. 2-11) is located on the headlight
case.
The neutral indicator lamp will light when the transmission is in
neutral and the ignition switchis ON ( | ).
(1)
Fig. 2-11
(1) Neutral indicator lamp
19
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 iower gear in the shifting
sequence (Fig. 2-12). The pedal automatically returns to the horizontal
position when released.
Your FOURTRAX has five-forward gears (1, 2, 3, 4 and 5). To shift the
transmission, pull in the clutch lever, then operate the gearshift pedal
as follows.
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 59.)
23,4,
Fig. 2-12 Gearshifting sequence
20
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 by depressing the brake pedal.
Parking Brake
The clutch lever also functions as the parking brake lever (Fig. 2-13). To
apply the parking brake, push down the parking brake pin (3), squeeze
the clutch lever (1) and lock it with the lock (A). Always apply the
parking brake when parking the FOURTRAX or starting the engine. To
release the parking brake, squeeze the clutch lever (1) so the lock (2)
automatically retracts.
NOTE:
Use of the parking brake in freezing weather may cause the rear brake
parking linkage to freeze in the locked position.
Fig. 2-13 (1) Clutch lever/ (3) Parking brake pin
Parking brake lever (A) To lock
(2) Lock lever
21
FUEL TANK
Fuel Fill Cap
After refueling, be sure to tighten the fuel cap (1) firmly by turning it
clockwise.
Insert the breather tube (2) into the handlebar cover hole (3).
To refuel refer to page 82 .
Py || (2)
NS
Fig. 2-14 (1) Fuel fill cap
(2) Breather tube
(3) Handlebar cover hole
22
Fuel Valve
The fuel valve (Fig. 2-15) 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:
0.42 US gal (1.6 2, 0.35 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
82—85
Fig. 2-15 (1) Fuel valve
23
ENGINE OIL
Oil Filler Cap/Dipstick
The oil filler cap/dipstick (Fig.2-16 ), on the oil tank (2), 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 (3) and the lower level mark (4).
For oil recommendations and instructions on checking, adding and
changing oil, see pages 94—100 .
3)
Fig. 2-16 (1) Oil filier cap/dipstick (3) Upper level mark
(2) Oil tank (4) Lower level mark
While reading this manual, remember:
INGUIN Tel Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
24
FRONT SUSPENSION
The front shock absorbers (1) have five adjustment positions for
different rider weights and riding conditions.
Position | and Il are for light weight and smooth ground conditions.
Positions Il to V progressively increase spring tension for a stiffer
suspension. Be certain to adjust each shock absorber to the same
position.
STANDARD POSITION: IV
Fig. 2-17 (1) Shock absorber
(2) Adjuster
25
REAR SUSPENSION
The rear suspension can be adjusted for the rider's weight and riding
conditions by changing the rebound and compression damping.
The rear shock absorber assembly includes a damper unit that
contains high pressure nitrogen gas. Do not attempt to disassemble,
service, or dispose of the damper; see your Honda dealer. The
instructions found in this owner's manual are limited to adjustments of
the shock assembly only.
Rebound damping:
To reduce (SOFT):
Turn the adjuster counterclockwise toward SOFT for a light load and
smooth road conditions.
To increase (HARD):
Turn the adjuster clockwise toward HARD for a firmer ride and rough
road conditions.
To adjust the adjuster to the standard position, proceed as follows:
1. Turn the damping adjuster (1) clockwise until it will no longer turn.
This is the full hard setting.
2. The adjuster is set in the standard position when the adjuster is
turned counterclockwise approximately 1.5turns so that its punch
mark (2) aligns with the reference punch mark (3).
Fig. 2-18 {1) Damping adjuster
(2) Punch mark
(3) Reference punch mark
26
Compression damping:
To reduce (SOFT):
Turn the adjuster counterclockwise toward SOFT for a light load and
smooth road conditions.
To increase (HARD):
Turn the adjuster clockwise toward HARD for a firmer ride and rough
road conditions.
To adjust the adjuster to the standard position, proceed as follows:
1. Turn the damping adjuster (1) clockwise until it will no longer turn.
This is the full hard setting.
2. The adjuster is set in the standard position when the adjuster is
turned counterclockwise approximately 2 turns so that its punch
mark (2) aligns with the reference punch mark (3).
(3)
(2)
SAL UN
>
7
<
f (
+
Г
e
7
O
is
[i
OI
Fig. 2-19 (1) Damping adjuster
(2) Punch mark
(3) Reference punch mark
27
ADDITIONAL FEATURES
Helmet Holder
The helmet holder (1), (Fig.2-20) is a hook below left side of the
handlebar cover (2). To use the holder, hang the D-ring on your
helmet strap over the hook. Use the helmet holder only when the
FOURTRAX is parked.
TE
A
La
7
ZA
1
и
1
a
LV
< Л > SI itey
Fig. 2-20 (1) Helmet holder
(2) Handlebar cover
EY: TS
POTENTIAL HAZARD
Operating this ATV with a helmet attached to the helmet holder.
WHAT CAN HAPPEN
Can impair your ability to steer the vehicle.
HOW TO AVOID THE HAZARD
Never ride this ATV with a helmet attached to the helmet holder.
Use the helmet holder only while the ATV is parked.
28
Flag Pole Bracket
The flag pole bracket (Fig. 2-21) is on the carry pipe. 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.
(1)
Fig. 2-21 (1) Flag pole bracket
29
Storage Compartment
The storage compartment (Fig. 2-22) is below the rear fender. Remove
the compartment cover (1) to gain access to the compartment. The
Owner's Manual (2), tire pressure gauge (3) and tool kit (4) should be
stored in the storage compartment (5).
Be careful not to flood this area when washing your FOURTRAX or rid-
ing through water.
(5)
Fig. 2-22 {1) Compartment cover (4) Tool kit
{2) Owner's manual (b) Storage compartment
(3) Tire pressure gauge
30
While reading this manual, remember:
"LGN el Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
31
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:
NA NV 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.
32
A WARNING
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.
33
Rider Training
Beginning and inexperienced riders should get proper instruction on
how to operate this FOURTRAX safely. A hands-on rider training
course is available in your area. For information, contact your Honda
dealer.
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does
not know how to operate the ATV properly in different situations
and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the
certified training course offered by Honda. They should then
regularly practice the skills learned in the course and the
operating techniques described in this Owner's Manual.
For more information about the training course, contact an
authorized Honda dealer or call 1— 800 — 887 — 2887 (USA only).
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. Engine oil level. Check the oil level and add oil if required {pages
94—96 ). Check for leaks.
34
2. Fuel level. Fill the fuel tank when necessary (pages 82—85 ).
Check for leaks.
3. Brakes. Check operation. Make sure there is no brake fluid leakage.
If necessary, adjust free play (pages 115— 121).
4, Tires. Check condition and pressure (pages 123— 125).
5. Throttle. Check for smooth opening and closing in all steering
positions.
6. Headlight and headlight dimmer switches. Check for proper func-
tion (page 18).
7. Engine stop switch. Check for proper function (page 14 ).
8. 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.
9. Steering. Check that the wheels turn properly as you steer the
handlebars.
10. 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.
11. Drive chain. Check condition and slack. If necessary adjust and
lubricate (pages 101— 104).
12. Air cleaner housing drain tube. Check for deposits in the drain
tube. If necessary, clean the tube (page 90 ) 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.
35
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.
Tires
Before riding, make sure your FOURTRAX has the proper tires and that
they are in good condition. Also be sure the tires are inflated to the
proper tire pressure (see page 124).
GN
POTENTIAL HAZARD
Operating this ATV with improper tires, or with improper or
uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or operation of this ATV with
improper or uneven tire pressure, may cause loss of control,
increasing your risk of an accident.
HOW TO AVOID THE HAZARD
Always use the size and type tires specified in the Owner's
Manual for this vehicle.
Always maintain proper tire pressure as described in this Owner's
Manual.
36
Loading
Load Limits
There are limits to how much weight can be carried on your
FOURTRAX.
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 243 Ibs (110 kg) maximum
(Combined weight of the rider, all accessories and all cargo)
37
Loading and Operational Guidelines
This FOURTRAX is not designed to carry cargo or tow a trailer.
If you decide to add accessories to allow you to carry cargo or tow a
trailer, use common sense.
Carrying cargo 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. Never ride with a passenger.
2. Do not tow another vehicle.
3. Make sure all cargo is secured before riding.
4. Allow extra room for starting, stopping and turning whenever you
carry cargo or pull a trailer.
5. Avoid riding on steep slopes when carrying cargo or pulling a
trailer.
6. Never cross a slope when towing a trailer.
38
A WARNING
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.
39
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.
40
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:
NACER Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
41
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 or emission
control system components. Remember, excessive noise bothers
everyone and creates a bad image for off-road vehicles.
SAFE RIDING RULES
Protective Apparel
Always wear an approved motorcycle helmet 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.
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.
43
No Passengers
This FOURTRAX is designed as an operator-only vehicle. The seat is
designed to allow the rider to change body position, not for carrying a
passenger. Never let a passenger ride on your FOURTRAX.
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.
44
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.
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.
45
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 tires are designed for off-road use only, not for
use on pavement. Paved surfaces may seriously affect handling
and contro! 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.
46
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.
47
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USA only:
It conforms to US EPA Noise Emission regulations, but does not
conform to Federal Motor Vehicle Safety Standards or US EPA Exhaust
Emission regulations, and operation on public streets, roads, or
highways is illegal. The vehicle is equipped with a USDA qualified
spark arrester. Obey local laws and regulations.
It conforms to California exhaust emission regulations for ATVs.
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.
48
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 contro! 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.
49
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.
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.
50
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.
51
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 slowly and be extra careful when operating on unfamiliar
terrain.
Always be alert to changing terrain conditions when operating
the ATV.
52
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.
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.
53
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.
AWARNING
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.
54
STARTING THE ENGINE
Your FOURTRAX is equipped with a gear position starter cut-off sys-
tem. The engine cannot be started if the transmission is in a forward
gear —unless the clutch lever is pulled in.
Preparation
1.
Select a level surface and lock the parking brake (page 21 ) before
starting the engine.
2. Turnthe fuel valve (1) and ignition switch (2) to ON ( 1).
3. Make sure the engine stop switch (3) is at RUN (O).
4. Make sure that the transmission is in neutral by checking that the
neutral indicator lamp (4) lights.
(4)
Fig. 3-8 (1) Fuel valve (3) Engine stop switch
(2) Ignition switch (4) Neutral indicator lamp
55
Starting Procedure (After Preparation)
The carburetor is equipped with an accelerator pump. Do not open the
throttle when starting the engine. This will flood the engine with
excess fuel, resulting in hard starting.
To restart a warm engine, follow the procedure for High Air Tempera-
ture.
Normal Air Temperature
10° — 35 °C (50° — 95 °F)
1. Pull the choke lever up all the way to fully ON (C) 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 lever (A) Fully OFF
(B) Halfway position
(C) Fully ON
3. Immediately after the engine starts, push the choke lever down to
the halfway position. (B)
4. Warm up the engine by opening and closing the throttle slightly.
5. After the engine has warmed up, push the choke lever down all the
way to fully OFF. (A)
6. Ifidling is unstable, open the throttle slightly.
56
High Air Temperature
35 °C (95 °F) or above
1. Do not use the choke.
2. With the throttle slightly open, push the starter button.
Fig. 3-10 (1) Starter button
Low Air Temperature
10 °C (50 °F) or below
1. Follow step 1 — 2 under “Normal Air Temperature”.
NOTE:
If the engine dose not start after several attempts, operate the starter
button after opening and closing the throttle lever several times.
2. Warm up the engine by opening and closing the throttle slightly.
3. When the engine begins to run slightly rough, push the choke
fever (Fig. 3-9) 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 lever (Fig.3-9 ) down
all the way to fully OFF (A).
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.
57
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 OFF ( 2% ).
2. Move the choke lever 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 RUN ( O) ) and repeat the normal starting procedure,
but don't use the choke.
High Altitude Adjustment
For operation above 3,000 feet (1,000 m), it may be necessary to
switch to high altitude carburetor jetting (see page 92).
58
SHIFTING GEARS
After starting the engine and letting it warm up, follow these proce-
dures:
1. Depress and hold down the brake pedal. Release the parking brake
(see page 21 ).
2. While the engine is idling, pull in the clutch lever and depress the
gearshift pedal to shift into 1st (low) gear.
3. Release the brake pedal, gradually release the clutch lever, and
increase engine speed by gradually opening the throttle.
4. When the speed increases, close the throttle, pull in the clutch
lever, and shift to 2nd gear by raising the gearshift pedal.
5. Repeat this sequence to progressively upshift to 3rd, 4th and 5th
(top) gear.
6. To downshift, reverse this sequence. Remember to close the
POTENTIAL HAZARD
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.
59
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.
60
Fig. 3-11 Lean your body to the inside of a turn and forward.
A WARNING
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.
61
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 low 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.
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.
62
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.
63
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.
AZ
&
(SEA =)
Fig. 3-12 Shift weight forward when climbing hiils.
64
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 about to lose all forward speed:
Using the front and rear brakes together, bring the FOURTRAX to
a stop with the vehicle pointed straight uphill.
65
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.
66
Co ——— WARNING
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.
67
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 front brake lever with your left hand (See Figure 3-14.)
2. Be sure your legs are clear of the wheels.
3. Check your footing.
4. Then slowly and carefully back the FOURTRAX down the hill using
the front brake lever to control speed.
5. If you lose control of the FOURTRAX, for your safety, get away
from the vehicle.
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.
68
While reading this manual, remember:
ANIMEN Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
69
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 slowly with the throttle 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.
Fig. 3-15 On downhills, shift your weight back.
70
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.
71
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.
Fig. 3-16 Shift weight uphill when crossing slopes.
72
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.
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.
73
RIDING OVER OBSTACLES
Watch out for bumps, rain ruts, potholes and other obstacles 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.
74
RIDING THROUGH WATER
Your FOURTRAX is designed to travel through water up to approxi-
mately 10 inches 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.
After riding through water, the brakes may be less effective than nor-
mal. Test the brakes after traveling through any water, and if necessary,
apply the brakes repeatedly until the heat of friction has dried them,
and the brakes regain their normal effectiveness.
A WARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast flowing water.
WHAT CAN HAPPEN
Tires 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 pads.
75
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 OFF { O ). If you're through
riding for the day, also turn the fuel valve OFF.
While reading this manual, remember:
NANI Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
76
MAINTENANCE AND REPAIRS
EMISSION REQUIREMENTS
The California Air Resources Board (CARB) requires that your
FOURTRAX comply with applicable exhaust emissions standards
during its useful life, when operated and maintained according to the
instructions provided.
The Vehicle Emission Control Information Label (1) is attached on the
right side of the frame.
(1)
Fig. 3-17 (1) Vehicle Emission Control Information Label
77
MAINTENANCE SCHEDULE
FREQUENCY Whichever INITIAL] REGULAR
comes first MAINTENANCE] MAINTENANCE INTERVAL
> mi | 100 | 600 | 1200 | Refer to
ITEMS km | 150 | 1000 | 2000 | page
NOTE ¡HOURS| 20 | 100 | 200
FUEL LINE —
о THROTTLE OPERATION | 86
и AIR CLEANER (NOTE 1) С C | 87-89
= AIR CLEANER HOUSING | (NOTE 2) | 90
u DRAIN TUBE
< SPARK PLUG | | 105
or VALVE CLEARANCE | | | 106
= ENGINE OIL R R R |2494—96
D ENGINE OIL FILTER R R R | 97-100
= ENGINE OIL STRAINER С —
Lu SCREEN IN OIL TANK
ENGINE IDLE SPEED | | | 91
78
C: Clean
A: Adjust
Inspect and Clean, Adjust,
Lubricate or Replace if necessary.
R: Replace
L: Lubricate
FREQUENCY Whichever INITIAL| REGULAR
comes first MAINTENANCE| MAINTENANCE INTERVAL
> mi 100 600 1200 | Refer to
ITEMS km 150 1000 | 2000 page
NOTE |HOURS! 20 100 | 200
DRIVE CHAIN (NOTE1,2) IL ILL EVERY 300mi (S00km) | 101 — 103
or 50 operating hours!
on DRIVE CHAIN SLIDER | | 104
=|*| BRAKE FLUID (NOTE3) | || 115—117
= BRAKE PAD WEAR (NOTE1,2) | 118, 119
TT BRAKE SYSTEM | | || 115—121
<| | SKID PLATES,ENGINE | | 128
= GUARD
> *| CLUTCH SYSTEM | | | 107
>| *| SUSPENSION | | 25—27
Dix! SPARK ARRESTER С С 130
2|*| NUTS, BOLTS, FASTENERS | | —
Sfe* WHEELS/TIRES | 122—125
© | STEERING SHAFT HOLDER —
BEARINGS
«k| 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
NOTES:
1. Service more frequently when riding in dusty areas, sand or snow.
BY YOUR AUTHORIZED HONDA DEALER.
2. Service more frequently after riding in very wet or muddy conditions.
3. Replace every 2 years. Replacement requires mechanical skill.
79
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.
80
TOOLKIT
A tool kit (Fig. 4-1) is provided with your FOURTRAX and stored in the
storage compartment below the rear fender. |
The tools in the kit are sufficient to perform routine maintenance and
simple repairs. Any extensive work requiring additional tools should
be performed by your authorized Honda dealer.
The tool kit includes the following items:
* Standard/Phillips screwdriver * Spark plug wrench
* Screwdriver handle * Tire pressure gauge
* 6 mm hex wrench * Tool bag
Fig. 4-1 (1) Tool kit (2) Tire pressure gauge
While reading this manual, remember:
NE NNNEN Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
81
FUEL SYSTEM
FUEL
Refueling
The fuel tank capacity, including reserve, is:
2.64 US gal (10.0 8, 2.20 Imp gal)
The reserve fuel supply is:
0.42 US gal (1.6 2, 0.35 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 cap firmly by turning it
clockwise until it is secure.
Insert the breather tube into the handle cover hole.
(3) (2) (4)
Fig. 4-2 (1) Fuel fill cap (4) Filler neck
(2) Breather tube
(3) Handle cover hole
82
HA 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 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.
83
Fuel Recommendations
Your engine is designed to use any gasoline that has a pump octane
number of 92 or higher. (Gasoline pumps at service stations normally
display the pump octane number.)
We recommend unleaded fuel because it produces fewer engine and
spark plug deposits and extends the life of the exhaust system. Never
use stale or contaminated gasoline or an oil/gasoline 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 gasoline. 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.
84
Oxygenated Fuels
Some conventional gasolines are being blended with alcohol or an
ether compound. These gasolines are collectively referred to as
oxygenated fuels. To meet clean air standards, some areas of the
United States and Canada use oxygenated fuels to help reduce emis-
sions.
If you use an oxygenated fuel, be sure it is unleaded and meets the
minimum octane rating requirement.
Before using an oxygenated fuel, try to confirm the fuel's contents.
Some states/provinces require this information to be posted on the
pump.
The following are the EPA approved percentages of oxygenates:
ETHANOL (ethyl or grain alcohol} 10 % by Volume
You may use gasoline containing up to 10 % ethanol by volume.
Gasoline containing ethanol may be marketed under the name
“Gasohol”.
MTBE (Methyl Tertiary Butyl Ether) 15 % by Volume
You may use gasoline containing up to 15 % MTBE by volume.
METHANOL (methyl or wood alcohol) 5 % by Volume
You may use gasoline containing up to 5 % methanol by volume as
long as it also contains cosolvents and corrosion inhibitors to protect
the fuel system. Gasoline containing more than 5 % methanol by
volume may cause starting and/or performance problems. It may also
damage metal, rubber, and plastic parts of your fuel system.
If you notice any undesirable operating symptoms, try another service
station or switch to another brand of gasoline.
Fuel system damage or performance problems resulting from the use
of an oxygenated fuel containing more than the percentages of oxygen-
ates mentioned above are not covered under warranty.
85
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. 4-4),
should be:
1/8—5/16 in (3—8 mm)
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.
(2)
(3)
1/8—5/16 in
(3—8 mm)
{ ubrication point
Fig. 4-4 (1) Rubber sleeve (4) Throttle lever
(2) Cable adjuster (A) To decrease free play
(3) Lock nut (B) To increase 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.
86
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 cieaner housing
before starting the engine.
Tocleanthe air cleaner:
1. Remove the seat by pulling up the seat lock lever (1) (Fig. 4-5).
2. Unlatch the six retainer clips (2) and remove the air cleaner hous-
ing cover (3).
Fig. 4-5 (1) Seat lock lever (2) Retainer clips
(3) Air cleaner housing cover
87
3. Loosen the screw on the clamp (2) (Fig. 4-6) and remove the air
cleaner assembly (1) from the case.
4. Unscrew the clamp (2).
5. Remove the air cleaner (3) from the air cleaner body (4).
(3)
Fig. 4-6 (1) Air cleaner assembly (3) Air cleaner
(2) Clamp (4) Air cleaner body
88
6. Wash the air cleaner in nonflammable or high flash point solvent
and allow it to dry thoroughly.
POTENTIAL HAZARD
Using gasoline 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 clean ATV
parts.
7. Soak the air cleaner in Pro Honda Foam Filter Oil or an equivalent
[Canadian Vehicles: gear oil (SAE 80—90)] 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.
89
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.
(1)
Fig. 4-7 (1) Drain tube (3) Air cleaner case
(2) Clip
90
Carburetor
Adjusting Idle Speed
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 attaching a tachometer and using a screw-
driver to turn the screwdriver by turning the throttle stop screw
(Fig. 4-8).
Idle Speed:
1,400 £ 100 rpm
(1)
Fig. 4-8 (1) Throttle stop screw (A) Increase
(B) Decrease
91
High Altitude Adjustment
When operating this FOURTRAX at altitudes ranging above 3,000 feet
(1,000 m), 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 5,000
feet (1,500 m) may cause engine overheating and damage.
92
While reading this manual, remember:
IGN el Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
93
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 5
minutes. If the air temperature is below 10°C (50°F), let the engine
idle for an additional 5 minutes (a total of 10 minutes).
An engine that is not warmed sufficiently may give an inaccurate
(low) oil level reading.
3. Stop the engine.
4. After a few minutes, remove the oil filler cap/dipstick (1) (Fig. 4-9 )
from the oil tank (2) 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 (3) and the lower level mark (4) 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 filler cap/dipstick.
CAUTION:
Running the engine with improper oil level can cause serious engine
damage.
> (1)
Fig. 4-9 (1) Oil filler cap/dipstick (3) Upper level mark
94
(2) Oil tank (4) Lower level mark
NOTE:
The engine contains a crankcase oil level check bolt (5). Remove the
bolt and check that the level is flush with the lower edge of the hole. If
it is, install and tighten the bolt, start the engine and check the engine
oil level. If the crankcase oil level is low, add the recommended engine
oil before starting the engine to check the engine oil level.
< 06% %€
© , OO
Fig. 4-10 (5) Check bolt
95
Engine Oil Recommendations
Recommended Oil 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 PRO HONDA GN4 OR HP4 4-STROKE OIL OR AN EQUIVALENT.
For Canada:
USE HONDA 4-STROKE OIL OR AN EQUIVALENT
Use only high detergent, premium quality motor oil certified to meet
API Service Classification SF or SG. Motor oils intended for Service 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
I ОНЛ
SAE 20W-40
1
SAE |0W-40
Cl
SAE 10W-30
Fig. 4-11 Recommended oil viscosities
96
Changing the Engine Oil and Oil Filter
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 oil tank and crankcase while
the engine is still warm. This will ensure complete and rapid draining.
To change the oil and oil filter:
1. With the FOURTRAX on level ground, start the engine and let it
idle for a few minutes.
2. Stop the engine, place an oil drain pan under the oil tank and
crankcase. Remove the oil filler cap/dipstick, the drain bolt (1) on
the oil tank and drain bolt (2) on the left crankcase (Fig. 4-12).
3. After the oil has drained, make sure the sealing washers on the
drain plugs are in good condition.
4. Install the drain bolts.
Fig. 4-12 (1) Drain bolt (oil tank)
(2) Drain bolt (left crankcase)
97
5. Remove the oil filter cover (3) (Fig. 4-13) by removing the bolts (4).
Let the remaining oil drain out.
Discard the oil filter (6).
Fig. 4-13 (3) Oil filter cover
(4) Bolts
98
6. Check that the oil filter cover O-ring (5) is in good condition and
then install a new oil filter (6). Use only the Honda genuine oil
filter or a filter of equivalent quality specified for your model.
Using the wrong Honda filter or a non-Honda filter which is not of
equivalent quality may cause engine damage.
7. Install the filter with the rubber seal (7) facing out, away from the
engine. You will see the “OUTSIDE” (8) mark on the filter body,
near the seal.
CAUTION:
Improper installation of the oil filter can cause serious engine damage.
8. Reinstall the oil filter cover (3), making sure the bolts are tightened
securely.
A об % o, ©
Fig. 4-14 (5) O-ring (7) Rubber seal
(6) Oil filter (8) OUT-SIDE mark
(cont'd)
99
9. Fill the oil tank with the recommended grade oil; approximately:
2.3 US gt (2.2 2, 1.9 Imp gt)
10. Reinstall the oil filler cap/dipstick.
11. Start the engine and let it idle for 5 minutes.
12. Stop the engine and after a few minutes, remove the oil filler cap/
dipstick.
13. Add the recommended oil up to the upper level mark. (Do not
overfill.)
14. Reinstall the oil filler cap/dipstick.
15. Check for oil leaks.
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.
While reading this manual, remember:
Ne Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
100
DRIVE CHAIN
The drive chain (1) will wear with use and requires periodic adjust-
ment in accordance with the maintenance schedule.
NOTE:
Check, adjust or lubricate the chain with the engine off.
Chain slack should be checked by measuring the amount of chain slack
midway between the sprockets. The amount of slack should be:
1 3/16—1 9/16 in (30 — 40 mm)
To adjust slack, use an Allen wrench (4) to loosen the rear axle holder
lock bolts (2), (Fig. 4-15). Turn the adjuster (3) to decrease or increase
chain slack. Retighten the rear axie holder fixing bolts.
13/16—19/16 in
(30 — 40 mm)
(1)
Fig. 4-15 (1) Drive chain (3) Adjuster
(2) Lock bolts (4) Allen wrench
101
Lubrication and Cleaning
Lubricate every 30 days of riding or sooner if chain appears dry. The O-
rings in this chain can be damaged by steam cleaning, high pressure
washers, and certain solvents.
Clean the side surfaces of the chain with a dry cloth. Do not brush the
rubber O-rings. Brushing will damage them. Wipe dry and lubricate
only with Honda Chain Lube or an equivalent drive chain lubricant
which specifies use for O-ring chains. Other commercial chain
lubricants may contain solvents which could damage the rubber O-
rings.
Replacement chain:
DID520V6 or RK520 SMOZ10S
102
Replacement
With the upper or lower section of drive chain tight between the
sprockets measure the distance between a span of 21pins from pin
center to pin center. If the distance exceeds the service limit, the chain
is worn out and should be replaced.
Service limit: 12.56 in (319.1 mm)
Measure a span of 21 pins
103
Drive Chain Slider
Check the drive chain slider (1) at the intervals specified in the Mainte-
nance Schedule.
The chain slider must be replaced if it is worn to the wear limit line (2).
For replacement, see your authorized Honda dealer.
Fig. 4-17 (1) Drive chain slider (2) Wear limit line
104
ENGINE
SPARK PLUG
The standard spark plug is: DPR8Z (NGK)
or X24GPR-U (DENSO)
For extended high speed riding: DPR9Z (NGK)
or X27GPR-U (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. 4-18) 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:
0.024— 0.028 in (0.60— 0.70 mm)
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.
105
CAUTION:
The spark plug must be securely tightened. An improperly tightened
plug can become very hot and possibly damage the engine.
(2)
— | 0.024 — 0.028 in
(1)
Fig. 4-18 (1) Center electrode (2) Side electrode
VALVES
Valve clearance should be:
Intake: 0.004 in (0.10 mm)
Exhaust: 0.005 in (0.12 mm)
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.
106
CLUTCH
Clutch Adjustment
Clutch adjustment may be required if the FOURTRAX stalls when
shifting into gear, if it tends to creep, or if the clutch slips, causing
acceleration to lag behind engine speed.
Normal clutch lever freeplay at the lever (1), (Fig. 4-19) is:
3/8—13/16 in (10—20 mm)
1. Pull back the dust cover (2), (Fig. 4-20). Loosen the lock nut (4) and
turn the clutch cable adjuster (3). Tighten the lock nut (4) and
check the adjustment.
(1)
3/8— 13/16 in
(10—20 mm)
Fig. 4-19 (1) Clutch lever
107
2. Ifthe cable adjuster is threaded out near its limit or the correct free
play cannot be obtained using the cable adjuster (3), a major
adjustment must be made. Loosen the lock nut (4) and turn in the
cable adjuster (3) completely. Tighten the lock nut (4) and pull on
the dust cover (2).
NOTE:
If proper adjustment cannot be obtained or the clutch does not work
correctly, the cable or clutch friction discs may be worn. See your
authorized Honda dealer.
Other Checks:
Check the clutch cable for kinks or signs of wear that could cause
sticking or failure. Lubricate the clutch cable with a commercially
available cable lubricant to prevent premature wear and corrosion.
(4)
(2)
Fig. 4-20 (2) Dust cover (A) Decrease free play
(3) Clutch cable adjuster (B) Increase free play
(4) Lock nut
108
While reading this manual, remember:
ANNIE Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
109
ELECTRICAL SYSTEM
BATTERY
Your FOURTRAX battery is located in a compartment under the rear
fender. 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 replace-
ment. if you replace the battery, choose one that is sealed and
equivalent to the original. Be sure to read and follow all safety precau-
tions 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.
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.
110
Battery Removal
1. Make sure the ignition switch is OFF (O ).
2. Remove the seat (page 127).
3. Remove the battery holder (1), (Fig. 4-21) by removing the mount
bolts (2).
4. Disconnect the negative (—) terminal lead (3) from the battery (4)
first, then disconnect the positive (+) terminal lead (5).
5. Remove the battery.
* Install in the reverse order of removal.
* Check all bolts and other fasteners are secure.
111
(3)
(2)
(2)
Fig. 4-21
112
(1) Battery holder
(2) Mount bolts
(3) Negative (—)
terminal lead
(4) Battery
(5) Positive (+)
terminal lead
FUSE
As illustrated in Fig.4-22 , the fuse (1) is located on left of the battery
behind the seat.
To 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.
Fig. 4-22 (1) Fuse (3) Fuse box cover
(2) Spare fuse
113
To replace a fuse:
1. Make sure the ignition switch is OFF ( O ).
CAUTION:
Turn the ignition switch OFF ( O ) before checking or replacing the
fuse to prevent accidental short-circuiting which could damage the
electrical system.
Remove the seat (page 127 ).
Remove the fuse box cover (3) (Fig. 4-22).
Pull the old fuse out of the clips.
Push a new fuse into the clips and install the fuse box cover.
Install the seat.
4 WARNING
POTENTIAL HAZARD
BT SON
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.
114
BRAKES
This FOURTRAX has both front and rear hydraulic disc brakes.
As the brake pads wear, brake fluid level drops, automatically com-
pensating for wear.
There are no adjustments to perform, but fluid level and pad wear
must be inspected periodically. The system must be inspected fre-
quently to ensure there are no fluid leaks.
NOTE:
If the brake lever or pedal travel become excessive and the brake pads
are not worn beyond the recommended limit (pages 118 —119), there
is probably air in the brake system and it must be bled. See your
authorized Honda dealer for this service.
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.
+ Use only DOT 4 brake fluid from a sealed container.
115
Front Brake Fluid Level:
Check if the fluid level is below the lower level mark (1) through the
inspection window (2).
Fig. 4-23 (1) Lower level mark (2) Inspection window
A WARNING
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.
116
Rear Brake Fluid Level:
Check if the fluid level is below the lower level mark (1).
UU
(2) — = per" -
©
LOWER
Fig. 4-24 (1) Lower level mark (2) Upper level mark
117
Brake Pads:
Brake pad wear will depend upon the severity of usage and riding
conditions. The pads will wear faster in wet or muddy conditions.
Inspect the pads visually during ail regular service intervals to
determine the pad wear.
1. Front brake pads/Rear brake pads — If the wear indicator (1) aligns
with the edge of the reference mark (2), both pads must be
replaced, see your authorized Honda dealer for this replacement.
FRONT
Fig. 4-25 (1) Wear indicator (2) Edge of reference mark
118
REAR
Fig. 4-26 (1) Wear indicator (2) Edge of reference mark
Other Checks:
1. Make sure there are no fluid leaks.
2. Check for deterioration or cracks in the hose and fittings.
3. The rear brake pedal pivot must be inspected according to the
Maintenance Schedule.
See your authorized Honda dealer for this service.
119
Parking Brake
Parking brake adjustment may be required if the parking brake does
not hold properly.
Parking Brake Adjustment:
1. Temporarily adjust the clutch lever free play to more than 1 3/16 in
(30 mm) (page 107).
2. Loosen the lock nut (1) on the parking brake cable, and screw in
the adjuster (2) completely.
3. Loosen the lock nut (3) on the parking brake arm (4) and turn the
adjusting bolt (5) clockwise until you feel resistance.
4. Then turn the adjusting bolt (5) 1/8 counterclockwise, and tighten
the lock nut (3).
(2)
Fig. 4-27 (1) Lock nut (3) Lock nut
(2) Adjuster (4) Parking brake arm
(A) Screw in (5) Adjusting bolt
120
5. Push down the parking brake pin (6) and then squeeze the clutch
lever (7) until firm resistance is felt. Measure the distance the
clutch lever has moved; the distance should be:
1—1 3/16 in (25—30 mm)
If necessary, turn the adjuster (2) and tighten the lock nut (1).
6. Adjust the clutch lever free play (page 107) is:
3/8—13/16 in (10—20 mm)
(7) (6)
1—13/16 in
(25—30 тт)
—]
Fig. 4-28 (6) Parking brake pin (7) Clutch/Parking
brake lever
While reading this manual, remember:
INARI [ell Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
121
WHEELS AND TIRES
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 vehicie.
2. Loosen the wheel nuts (Fig. 4-29) 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:
47 Ibf-ft (64 N-m , 6.5 kgf-m)
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.
122
NOTE:
If a torque wrench was not used for installation, see your authorized
Honda dealer before operating the vehicle to verify proper assembly.
Fig. 4-29 (1) Wheel nuts (2) Wheel rim
TIRES
This FOURTRAX is equipped with low pressure tubeless tires.
Although the tires are designed specifically for off-road use, they are
not immune to punctures. Always select your riding area with care.
Tire Pressure
Check the tire pressure frequently with the tire pressure gauge
supplied with the vehicle. For normal use, the tires should be inflated
to the pressure recommended in Fig. 4-30.
NOTE:
* Tire pressure should be checked before you ride, when the tires are
“cold.” Be sure to check tire pressure at the riding site, since
changes in altitude can affect air pressure.
123
* À manually operated tire pump should be used rather than the high
pressure systems found in service stations. This will minimize the
possibility of tire 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.
FRONT REAR
TIRE SIZE АТ 22 Хх 7-10 Ж Ж АТ 20 Хх 10-9 ЖЖ
TIRE BRAND M/R 101 Ohtsu M/R 501 Ohtsu
RECOMMENDED 4.0 psi (27 kPa, 0.275 | 4.0 psi (27 kPa, 0.275
PRESSURE kgf/cm?) kgf/cm?)
MAXIMUM 4.6 psi (31 kPa, 0.315 | 4.6 psi (31 kPa, 0.315
PRESSURE kgf/cm?) kgf/cm?)
MINIMUM 3.4 psi (23 kPa, 0.235 | 3.4 psi (23 kPa, 0.235
PRESSURE kgf/cm?) kgf/cm?)
Fig. 4-30 Tire specifications
AWARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or with uneven tire
pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or operation of this ATV with
improper or uneven tire pressure, may cause loss of control,
increasing your risk of an accident.
HOW TO AVOID THE HAZARD
Always use the size and type tires specified in this Owner's
Manual for this vehicle.
Always maintain proper tire pressure as described in this Owner's
Manual.
124
Tire Tread Condition
To check the condition of a tire tread, measure the groove depth (1)
(Fig. 4-31) in the center of the tire, or check the wear indicator (2).
The minimum tread depth is 3/16 in (4 mm). When the tread depth is
less than recommended, the tire should be replaced.
eplace
(3)
Fig. 4-31 (1) Groove depth (3) Wear indicator
(2) Wear indicator location mark
125
Repairing a Flat Tire
If you have a flat tire, use the plug method to make a temporary repair.
(The plug method is applied from the outside of the tire and is the
same as that for conventional tubeless tires.)
A plug-type repair kit, available at most auto parts stores or service
stations, provides a plug, an installation tool, tire cement, and an
instruction sheet. Follow the instructions provided with the repair kit to
make a temporary repair.
As soon as possible, have the tire permanently repaired by an
authorized Honda dealer. Any tire 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 tire pump
and a repair kit with the vehicle.
126
SEAT REMOVAL
To remove the seat (Fig. 4-32), pull up the seat lock lever ( 1) behind the
seat and lift it up.
If the muffler is hot, take care to lift the seat so that the rear fender
does not touch the silencer.
CAUTION:
Allowing the rear fender to touch a hot muffler while removing the
seat may damage the plastic.
To install the seat, align the tabs on the seat with the grommets on the
frame and press the seat down until it locks.
Fig. 4-32 (1) Seat lock lever (2) Seat
127
ENGINE GUARD AND SKID PLATES
The engine guard (Fig. 4-33) protects the engine crankcase.
The skid plates (2) protect the frame/lower arm, the drive components
and the rear brake. Check the guard and plates for cracks, damage or
looseness at intervals shown in the Maintenance Schedule (page
78—79).
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.
Fig. 4-33 (1) Engine guard (2) Skid plates
128
While reading this manual, remember:
NUNES Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
129
SPARK ARRESTER
The spark arrester must be serviced every 100 operating hours to
maintain its efficiency.
Regular servicing prevents carbon buildup (which can diminish engine
performance) and also complies with USDA regulations for regular
maintenance to assure proper function. The spark arrester prevents
random sparks from the combustion process in your engine from
reaching the environment.
To purge the system:
1. Allow the engine and muffler to cool.
2. Remove the three bolts (2), the spark arrester (1), and the gasket
(3) from the muffler (4).
Fig. 4-34 (1) Spark arrester (3) Gasket
(2) Bolts (4) Muffler
130
Use a brush to remove carbon deposits from the spark arrester
screen. Be careful to avoid damaging the spark arrester screen.
The spark arrester must be free of breaks and holes. Replace, if
necessary. Check the gasket. Replace, if necessary.
Fig.4—35
4. install the spark arrester and the gasket in the muffler and tighten
the three bolts securely.
131
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. Set the parking brake and place the transmission in gear.
2. Turn the 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.
(2) __ (1)
h
7
Fig. 4-36 Points to secure (1) Front carry pipe
FOURTRAX with (2) Right footpeg
tie downs
132
Fig. 4-37 Points to secure (3) Left footpeg
FOURTRAX with (4) Rear carry pipe or
tie downs Rear axle shaft
If it is necessary to incline your FOURTRAX upright on the rear end:
1.
2.
3
4.
5.
6.
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
it is tight.
Pour the drained fuel into the fuel tank.
Tilt the vehicle and secure properly.
Do not tow your FOURTRAX behind a car or other vehicle.
133
A WARNING
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.
134
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.
135
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.
NOTE:
The inside of the headlight lens may be clouded immediately after
washing the ATV. Moisture condensation inside the headlight lens will
disappear gradually by lighting the headlight in high beam. Run the
engine while keeping the headlight on.
4. Dry the FOURTRAX and lubricate the drive chain.
5. Startthe engine and let it run for several minutes.
6. Test the brakes before riding the FOURTRAX. Several applications
may be necessary to restore normal braking performance.
Braking efficiency may be temporarily impaired immediately after
washing the FOURTRAX.
Anticipate longer stopping distances to avoid a possible accident.
136
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 and oil filter.
2. Lubricate the drive chain.
3. Drain the fuel tank and carburetor. Be sure to drain the fuel in a
well-ventilated area, not in a garage.
137
CNT TON rm
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.
138
© oN
Spray the inside of the fuel tank with an aerosol rust-inhibiting oil.
Reinstall the fuel cap.
Remove the spark plug and pour one tablespoon {15-20 cc) 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 OFF
{ I} ) before pressing the starter button.)
Remove the battery (page 111) 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.
Wash and dry the FOURTRAX, and wax all painted surfaces.
Inflate the tires to their recommended pressures.
Place the FOURTRAX on blocks to raise all four tires off the ground.
139
SPECIFICATIONS
DIMENSIONS
Overall length 72.2 in (1,835 mm)
Overall width 45.3 in (1,150 mm)
Overall height 43.7 in (1,110 mM)
Wheelbase 48.4 in (1,230 mm)
WEIGHT
Dry Weight 375 Ibs (170 kg)
CAPACITIES
Engine oil 2.3 US at (2.2 2, 1.9 Imp gt)
Fuel tank 2.64 US gal (10.0 £ , 2.20 Imp gal)
Fuel reserve 0.42 US gal (1.6 2, 0.35 Imp gal)
ENGINE
Bore and stroke 3.35 x 2.76 in (85.0 x 70.0 mm)
Compression ratio 9.1:1
Displacement 24.23 cu-in (397.2 cm?)
Engine idle speed 1,400 — 100 rpm
Spark plug, standard DPR8Z (NGK)
X24GPR-U (DENSO)
Spark plug gap 0.024 — 0.028 in (0.60 — 0.70 mm)
Valve clearance Intake 0.004 in (0.10 mm)
Exhaust 0.005 in (0.12 mm)
CHASSIS AND SUSPENSION
Caster angle 6.5°
Trail length 1.1 in (28 mm)
Tire size, Front AT 22 x 7-10 xXx
Rear АТ 20 X 10-9 %%
140
POWER TRANSMISSION
Primary reduction 2.826
Gear ratio 1st 2.917
2nd 1.938
3rd 1.474
4th 1.182
5th 1.000
ELECTRICAL
Battery 12V — 8Ah
Generator 0.147 kW/5,000 rpm
LIGHTS
Head light {Low/High) 12V 30/30W X 2
Taillight 12V 5W
Neutral indicator light 12V 3.4W
FUSE
15A
141
WIRING DIAGRAM
0000- LNH -ZDEDD
AM | D [u0169
Avas UHM —- BÍA | 8 |н0702 O+O | 440
WI d Qu ——# THO [end od
NATED LHOM += n NATED oe 9
NIG (HOA oe 07 NE ng 3d] | OTO | «0
JONYHD —— 0 MOTIJA ——— A 15 |Zivs M |ZLYE
NMOYE oo JB WW ee 8
[ HOLAS MIlMYLS
BOLYNHZL Tr
HOJAS dEl Ion
MOLIMS TELA
HILIMS AYIIS WILWVIS =
HYBAZL
O sue y
W
NOLOM 431MYLS
LHD YL
ROI LINDL
97 | H| H
HOLIAS MANO
ALINNLNOS HILIMS
CH |1Y81 3 | 9
HOLIAS NUIT MOLIMS WOLLINSI
ENId HNOS
т
HILIAS HSLATO MILIMS Энцо d0LS 2NIDA9-U31aViS
EX MOC/DEAZI
5. HOY 3H
HILIAS NOH LIND!
HDLYIION THIN
142
CONSUMER INFORMATION
EMISSION CONTROL SYSTEMS
Source of Emissions
The combustion process produces carbon monoxide and
hydrocarbons. Control of hydrocarbons is very important because
under certain conditions, they react to form photochemical smog when
subjected to sunlight. Carbon monoxide does not react in the same
way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings and other
systems to reduce carbon monoxide and hydrocarbons.
Exhaust Emission Control System
The exhaust emission control system is composed of lean carburetor
settings, and no adjustment should be made except idle speed
adjustment with the throttle stop screw.
The exhaust emission control system is separate from the crankcase
emission control system.
Crankcase Emission Control System
The engine is equipped with a closed crankcase system to prevent
discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air
cleaner and the carburetor.
143
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED:
U.S. federal law prohibits, or Canadian provincial laws may prohibit
the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person, other than for purposes of maintenance,
repair, or replacement, of any device or element of design
incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in
use; or (2) the use of the vehicle after such device or element of design
has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE
THE ACTS LISTED BELOW:
1. Removal of, or puncturing the muffler, baffles, header pipes or any
other component which conducts exhaust gases.
2. Removal of, or puncturing any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust
or intake system, with parts other than those specified by the
manufacturer.
Problems that May Affect ATV Emissions
If you are aware of any of the following symptoms, have the vehicle
inspected and repaired by your authorized Honda Motorcycle Dealer:
1. Hard starting or stalling after starting
2. Rough idle
3. Misfiring or backfiring during acceleration
4. After-burning (backfiring)
5. Poor performance (driveability) and poor fuel economy
144
WARRANTY SERVICE
Your satisfaction and goodwill are important to your Honda dealer. All
Honda warranty details are explained in the Distributors Limited
Warranty.
Normally, any problems with the product will be handied by your
dealer's service department. Sometimes, however, despite the best
intentions of all concerned, misunderstandings can occur. If your
problem has not been handled to your satisfaction, we suggest you
take the following action:
* Discuss your problem with a member of the dealership management.
Often, complaints can be quickly resolved at that level. If the
problem has already been reviewed with the Service Manager,
contact the owner of the dealership or the General Manager.
* If your problem still has not been resolved to your satisfaction,
contact the Motorcycle Customer Service Department of American
Honda Motor Co., Inc. The address is P. O. Box 2220, Torrance, CA
90509 —2220. Telephone: (310) 532—9811. [Canadian Vehicles: Refer
to the warranty booklet that was supplied with your vehicle.] We will
need the following information in order to assist you:
Your name, address, and telephone number.
The product model, year, and frame/VIN serial number.
Date of purchase.
Dealer's name and address.
The nature of your problem.
NUN
After reviewing all the facts, we will advise you of what action can be
taken. Please bear in mind that your problem will likely be resolved at
the dealership level, using the dealer's facilities, equipment and
personnel. So it is very important that your initial contact be with the
dealer.
We appreciate your purchase of a Honda FOURTRAX. We want to
assist you in every way possible to assure your complete satisfaction.
145
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 127).
KEY NO.
FRAME NO.
ENGINE NO.
COLOR
Fig. 5-1 (1) Key number (3) Engine number
(2) Frame number (4) Color label
146
INDEX
A
ACCESSOFIES TT TT 40
Age recommendatiON ……..…......….........…csaeeserenencenen antenne arec rare nane seen eue 32
Air cleaner
Filter ................e..r.eniecionorieoinero narrar orar ere ree enero enter Ae te sr a 0 rene se ce nee nacre 87
Housing drain tube..............e.. ——..e ==... vereerecerconnerennrereno erre enen e rtecacanen nes 90
Apparel, recommended... coor eae 42
Authorized manuals................e. sree s sa rarer ees 153
B
Battery ................ee..receercccucecceraceneericaor eno eeacenmececareareeECeRTrErrnEnUrm ene nEC ATENTA 110
Brakes
Brake flUI................….ercrrerrenerrenaenneareeneneraaren area anrenerencanne nanas en tan anne 115
Front brakes
Brake lever ................erervereioririern e e e e e II O II II II IR RD GRO CR Ree 21
Brake pads...............e.eresesserereerercuceorermererre e nnenerereneerennerre rene NES 118
Parking brake.............e ieee reer eres eens 21
FAN [TUE {2 1=Y | COPPER 120
Rear brake
Brake pedal rr rec e case en ee0 17
Brake pads... erase eee 119
ToT a Fal oT fe To = To [0] =X SP ||
С
Carburetor
High altitude adjustment... reece eer renee 92
Idle speed adjustment... ...covciiiiiiiiii ieee rere 91
Choke
EEE 15
CIEANING.........….rrccrrrrcrererrennarerererecenarecenrantennanen mean nan s nec cran anse nca centre 135
Climbing HIllS ©…....….…srererrerecserenserensenee name senc ranenvane na anren ana a manne nee c een eee nea 63
Clutch adjustment... eect reee eee 107 — 108
Color label …..........…...….vescsseronrererennernanennanranea naar eneccrece mac can cc an en rate ssen anne 146
Consumer INFOrmation ….....…......…..…...cssrensencanrenner nana ananennan ares ana een canne 0e 143
Crossing Slopes............e.....eeesveerererrncon rene cenea nene cererrrr vea nene rerTE me 72
Customer Service ...............e...erersiiercionererce re eee ece eee nrnenerer erre. 145
147
D
Dimmer SWHCH aire ree erers 18
DIPSTICK eerie eee errr eens 24,94
Drive CNAIN cee eee nreneancarereeneneecenen are 101
E
Emission CONtro! SYSTEM ceive icteric errr rere rien ce reee 143
Engine
Idle speed adjustment..............e..e.e..=riierescerercereee essere eee 91
Break-in procedures....................everemmiirininer aria Ree rena H
Engine guard ..............e.esíereiiereee irene reese eee 128
Flooded engine ...................1seeeerrrierneinenee rei enee rre re Ren eren en rrrrnrenenenane. 58
Starting the ENGINE... rience reser renee 55
Engine oil
Changing Oil... errr 97
Checking oil level and adding Oil.................--e-.=.eeeeeeeeeener ener 94
Oil filler cap/dipstick..................—ee=—..—.e.eeerercerereneceren eee een 24, 94
Recommendations ...............eere.re.eereeererieereerecerececer erre reee renrerreneces 96
Engine stop SWitCH............e..—.e...mermererveeereeen nee rD ren TenenTe nene esr 14
Exhaust system
OT rcenecan eee aL ener arer Tere nenerneonrenene arre 35
LUT Co TT aT FOOT 130
F
Flag pole bracket... eee rs mens never 29
[Fe Yoo [=o I= To 11 5 T= JO 58
Fuel
Fuel recommendations ...............ecereseriererer reee Ree 84
FUE Fill CAP ceva ieee errr errr reese 22, 82
Fuel tank Capacity .…..….........eusersrenmercensssrenansenta scene ner re mana rence nn casa 82
Fuel VAÏVE....…............varresrencerrenrertanaren rares rence nree era nc nare ner ra ner re ec ane ne 00e 23
High altitude fuel mixture adjustment …….…....…...srarenanennennne 92
Refueling................e.e.eereicerer reee near ren ciCeen CeCe ne ereneneonrnrecaannerenenece. 82
Reserve fuel supply ...............-—-..—-.e=1ieseererermecerererr rr nee rReen ee 23
Fuse
Location ............-..e..ererecccroriercenerenrneereaeacan e rrenvenerareeeeneacananeenaererenm ren. 113
Replacement................—.eeeremcercenioioreeni earn enn Decee De reeee acen en on rnrene ae. 114
148
G
Gasoline (see Fuel)
Gearshift pedal... eee rrr areas 20
Gearshifting.....................e_eiccroio ri ro nera errar enero anencarecerercarere rre nererere 20, 59
H
Headlight switches..................e.evvecenceceorcerorereree Teen nee eneam nene eee 18
Helmet holder... errr rea aan 28
High altitude fuel mixture adjustment.……..….............…...…..…oeressensiennensenses 92
Hills
Riding across SIOPES eevee iirc rrr ress essere ere e rns 72
Riding down RIlÍS.............. mec. .e_eeseiecinreererrerenaarnre ene nnenenrnecanenTenacecane Des 70
Riding up hillS................e.e.eeereererener US 63
Stopping On hills «cere reer ere 65
TUNING ON SIOPES cu cece erecta reser errs reser nase ens 73
I
Idle speed adjustment .......c.co iii eran 91
Ignition SWItCH................e=errerarervarecereenenereearacro rene arer reee EnenEn Ramen enmeCv. 13
Indicator
Indicator lamp
Neutral indicator lamp ..................eeeecesnceciercirerernerrence reee reee ran eas 19
Inspection, pre-ride............e.—.erermrraverrreorcerere reee rene nereerenemenee. 34
L
Lubrication
(see Engine oil)
Drive Chain. cece ra 101
M
Maintenance
PreCaULIONS cocci errr rere re rere essere seers seer ere e aera ne rnn aes 80
SCHECUIE UU 78
Modifications ..............e.—....r..eererrerareceeccererrarcerererre ercer eeree cerrar eee 42
149
N
Neutral indicator lAamp.......……........…….…creeececsercensereecensere rare canne rren arrete nue 19
Noise emission control system... re, 144
O
Obstacles, riding OVer..............—......-e-eemeririereriee re rene errata 74
Oil (see Engine oil)
Oil filler cap/dipstick ................e=.e....er.eserercenesrererce re e encarece 24,94
Owner's manual compartment...................eesrerrsiieceiererer Dee ae 30
P
A Tere ETerTe evaneree NONE arUrTANEEme en rUmea 76
Parts location.....................e=erieirerrnr eee Deere rene rece renereneenenrcacenercara 10
Parking brake..............e.......e.ereveneecenecceinerrrero rene recrear ree rre sers ere rca nee rence aa 21
AQjUStMENt ne nene eeenrereneenenrnerenerereceneNTUNUEa. 120
Passenger CArryING ..…...........…orericecerenmrrenerrersrrennenrenerre enr en encenrere seen 44
Pavement, NO riding ON cco KKKKKKKRKRRKKRKRAKREREENKRKRRKEREERRRRELULG 46
Tao | To FP 84
Pre-ride INSPECtION ui RKRERRRRRRERKRRERKERRERRARERKERKKARKEERAREEREEGGG 34
R
Rear brake pedal ...............e.e....ervercerernecencrieror ire eee rre eee rear 17
Rider training Course ...................-....1eíeicercireier eee areca 1,34
150
S
Safety messages, SpeCiAl 222202 II IO na ancan rares 1
Seat removal and installation ........................e.e0e e ee Ds 127
Serial NUMDEFS.......…........crerrerereneasasncaserssanrenrencerpesanesansaa are nne nanas 146
Shifting RAIS «circa 20, 59
SKiA platES ee R RER RR RER R RER RBRERERERR RER RER R RER E EEE 128
ele [|]: TT 62
Spark arrester................e..._eeeeeeeererrirener tee essence eee een ee eee ere aree ease anne 130
Spark KNOCK ccs eesti eee eee eee erecta eee ee aera ares es ananans 84
Spark plug .................—eeeeisermerareceeenoeo re rcerneneenerrereenenenTerT rre eee NA NeErrree ne nenes 105
Specifications............ ee... ener ene arerenerareree earn reee. 140
Stalling On a Aller eee ree Deer RER AREA 65, 68
Эка CT ll 0 TU Lu Coo JOUR 16
Storage compartment............e..weeseerereererree emer ann ennnnn sn nnnnssnsans 30
SY (oT aT alo lo] geTol=To IU] =: JURE 137
Suspension
FRONT ..........…cccccerrcrssrerrrerrenreneeren ms aanasaasenanten en pen en sense arena ana rene nee cer 25
(-]:] O GER EREREKERG 26
151
T
Throttle
aD corer reer eee e rere rear e rena eren 86
Lever..............e.eserrcoreenacarmenescaroervecoreronerneronveroneeneneore racer ere Ereeea 17,86
Tires
Inflation and air pressure .................e.e..eserrizereree ii ee RR RRA 123
Repairing...........—————.—....esercererirenenerere rn enerererrernere ner en ene rrU Tener erTECe NeT 126
Specifications ….….…..........…errrrerserereenensen mea nanseener rene nr cree een sara 124
Tread CONITION oe. rrr reece rrr eee essere err eran 125
Tire pressure GAUGE .……....…...….…..…rrrrrrrrermensenemreerereereneeeene een e nee mere e ee ere nee nee 30
TOO! Kit .…........rcrrssrrecrensarenrenererenan sara mem saneeceseneee cena nere en e sas eee e nee e rence ere 81
Transporting procedures.................=..me.emecereneorere re DD 132
Turning
On level ground... eres reece eee eer eee 60
On slopes J rene ne rene onencen ar rerce nene roree one nee ene 73
V
Valve Clearance een reer eee etree ener eran e anaes 106
W
Warning labels ................—_ereercereroricererere rr e Deere reerereenecneracaraco eeeererene. 7
Warranty ServiCé........e...————--e—rsenorccccrrener Tener ceo cer nen erareanen ener ennre nece 145
Water
Riding through.............e.e==mre=eeeereeeerner es 75
Weight limits ............——.=.—...e..=.erereceacrennecer er enenacerenDerTenTRe eer 37
Wheel removal.................e..eerreecacarecorconcecoceecercarence cone rerrererere reee 122
Wiring diagram .............—..-.ee-2escerceriererencene rencor e nero reren enero nree enn cone eee. 142
152
AUTHORIZED MANUALS
The Service Manual (Publication Item No. 61HN100 ) used by your
authorized Honda dealer is available from Helm, Inc. (USA only,
Canada: See your Honda dealer to order authorized manuals.)
Also available, but not necessary, to service your model! is the Honda
Common Service Manual (Publication No. 61CM001), which explains
theory of operation and basic service information for various systems
common to all Honda motorcycles, motor scooters and ATVs.
These Honda manuals are written for the professional technician, but
most mechanically-capable owners should find them easy to use if
they have the proper tools and observe proper safety standards.
Special Honda tools are necessary for some procedures.
Publication Item No. Description Price Each’
61HN100 1999 TRX400EX Service Manual $40.00
61CM001 Common Manual $48.00
31HN 1600 1999 TRX400EX Owner's Manual $16.00
* Prices are subject to change without notice and without incurring obligation.
Order Toll Free: 1-888-CYCLE93 (1-888-292-5393)
(NOTE: For Credit Card Orders Only)
Monday — Friday 8:00 AM — 6:00 PM EST
OR
By completing this form you can order the materials desired. You can
pay by check or money order, or charge to your credit card. Mail to
Helm, Inc. at the address shown on the back of this order form (USA
only).
Canada: See your Honda dealer to order authorized manuals.
Publication Item Description Oty. Price Total
Item No. Each* Price
Sub Total
*Prices are subject to change without notice and without | Mich. Purchasers
incurring obligation. Add 6 % Sales Tax
Orders are mailed within 10 days. Please allow adequate | Handling Charge $4.00
time for delivery. Grand Total
153
NOTE: Dealers and Companies please provide dealer or company name, and also the name of the
person to whose attention the shipment should be sent.
Customer Name
Attention
Street Address Apartment Number
City State Zip Code
Daytime Telephone Number { )
| | Check or money order enclosed payable to Heim Inc. U. S. funds only. Do not send cash.
[| Check here if your billing address is different from the shipping address shown above.
|| VISA [| MasterCard
Account Number Expiration: Mo. Yr.
LIT LIE LE Luz
Customer Signature Date
These Publications cannot be returned for credit without reciving advance authorization within 14 days of delivery.
On returns, a restocking fee may be applied against the original order.
HELM P. O. BOX 07280, DETROIT, MICHIGAN 48207
154