Honda FourTrax Foreman ES Offroad Vehicle Owner's Manual 180 Pages

2001
TRX 450ES
HONDA FOURTRAX FOREMAN ES
OWNER'S MANUAL
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-throttle starts and rapid
acceleration.
For replacement parts and accessories, we recommend genuine
Honda products. They ve been specially designed for your vehicle and
manufactured to meet Honda's demanding standards.
This manual contains a Maintenance Schedule and information on
basic maintenance procedures. if you have the required skills and tools,
your Honda dealer can supply you with an Official Honda Service
Manual to help you perform more advanced maintenance and repairs.
When you need service, remember that your Honda dealer knows your
vehicle best and is interested in your complete satisfaction.
We wish you many years of safe and enjoyable riding.
While reading this manual, remember:
AWARNING Indicates a strong possibility that serious injury
or death may result if instructions are not
followed.
All information in this publication is based on the latest product infor-
mation available at the time of approval for printing. Honda Motor Co.,
Ltd. reserves the right to make changes at any time without notice and
without incurring any obligation.
© Honda Motor Co., Ltd. 2000. No part of this publication may be
reproduced without written permission from Honda Motor Co., Ltd.
CONTENTS
FOURTRAX SAFETY eerrerren nee EEE EEE ERRKERRRRRKRERARKERERTERERERRRERRURRER RE RER ARTE
Special Safety Message Sa R ER
Warning Informationen cers ene
PARTS LOCATION AND OPERATION ...............e.ee.ernereccececeoreen re rare.
Parts Location ............—.e......ereieeii irene nene nssarare sen ran sac enn ee nrana ananas nana
Parts Operation........... e .eserverereririnern eee ere ner orneraracrreracanenare
Power Controls ..............ce..reexerrrieeriiira rincon era ar eran rerereaare nana anna e
LIghts.................eeceeceeverenen ener encarar ere r een arar enero re eerrraarererereranrerneces
Gearshift Controls.......................e.eecerericenrear erre rarereerarerea reee.
Brake Controls...............e....eeenirrerecrii rare rene reee rana oareNrrrarereere.
Engine Oll...................emererreceececerrere arar c recen er eee eeearerererererrrrrarerremes
Additional Features .........................160eeumarerre e ae e
RIDING YOUR FOURTRAX................eeeeiesn nene eaneeneorerenerearemeeeeees
Before Riding....................eereverniinr aa reee enea rr ranenarereaorerarenes
Rider Preparation..................—..........e.eereer earn nracenrarraneeereeneme.
Vehicle Preparation .................e.reresereeiiri RR RR RAR eee eres
Safe Riding Rules...................e.eeerereieriiic e ee Re De e Dee.
RIQING .................urccrcccecconcsensana ne nacare nan ananenananaranaanaana nan terre nana nana caen
Starting the Engine .….……..…..….….…........eoreresmsmmmanten encecerrrrerreran re naar
Shifting GERAIS viii ccs ares ca casernes
Riding in REVErSE.…......….…...cercrrennererersrantanerrrnranene ere renense EEE L EEE
Making Turns ..............eee=ereerererracio ner e nene ren reee rarrernenerarercanenratanae
Riding Up HillS ….........…..…ercrrrrssssensaersrnrasranaanrarenenrane ass nca een nanas
Riding Down HillS …..….......…reseassssnsassnensennenearaanara ren rare era rene nan rare
Crossing Slopes.................e..vireeeeerrii eee ene e reee.
Making Turns on Slopes..................1esereerereniiire ee ee DDD.
Riding Over ODStACIES .….….….…..….….…rcrserararsrrarrrrarrerrrrarerran rene cacrrneannnen
Riding Through Water ….….….……rrsisieieseseeenenrersas rs er caca craanan nana
0 enr an ren en ae een een annee
(cont’d)
CONTENTS
Page
MAINTENANCE AND REPAIRS coerce re eens 95
Emission Requirements ...............e...ve.eemmienener nen IR. 95
Maintenance Schedule .................e.nse0rerorrircianconenrecacate reee renee ace 96
Maintenance Precautions ...............-..ererermererecierecen rene ee eee 98
Tool Kit.................e.srirceerracironzacerereeeecenarenra re nroncere nee enenante rre rnenenECanenNTe. 99
Fuel SYSTEM ceteris rere sears 100
LubriCatiON .….….……............csersrennsanenecera anne nser sans ras esa rennes eue rence sen en EEE 112
ENGÎNE ….…......………eccrrssrenrenerresateree ere n tante ten cena sen e eee teen EEE 120
Clutch er RAR rare ne nenren anse ns ce nana nano nee sr eee eee emma ane esrc nee 122
Electrical SYSTEM couric iene centres eres ete 124
TU Terna rncamecanes 131
Wheels and Tires.................=sieeereseceecerorienererencerrne reee vererereneanre E. 141
Seat Removal .............._...e.2i.esererevecenererrerererier rece remar ererT Erre. 146
Engine Guard and Skid Plates... rer H EEK E NEE EEE HENKE EHE 147
Spark Arrester .............=...=eemeeerinererrr ener ene nene 148
Driveshaft Boots..............._.-..e_-.ererveeererenrrne erro nceneaenrar ener ener 150
TRANSPORTING YOUR FOURTRAX .............. em. eeeecezererenenccorenerereecen. 152
CLEANING YOUR FOURTRAX ..............eeenenereorreencconceezcaioneorecerence ace. 155
STORING YOUR FOURTRAX …..…..rassssrrerenenienen anse na een ane ete ere c ec 157
SPECIFICATIONS ...........e.e....esrvcecerrereneerencanorerernaneavarecenerarennernerncanvene. 160
WIRING DIAGRAM .….....…......…recconmeeeecrannensse casses een ane nee sa sa cree menace ne NES 162
CONSUMER INFORMATION ............eeereeeccenireraereceniroreeacenenneneneerrenecnea. 163
WARRANTY SERVICE...............e..errerracorrrcanorercecatanonosccacearerenencerenenecTe 165
SERIAL NUMBERS AND COLOR LABEL.............e..esvceesnoneriaceccereccenerenee 166
INDEX TT O TATTOO 167
AUTHORIZED MANUALS -..........e.errecerrenenioencareanencecieanzcnneneencenentcenereeee 173
FOURTRAX SAFETY
SPECIAL SAFETY MESSAGES
AN ATV IS NOT ATOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently from other vehicles including motorcycles
and cars. A collision or rollover can occur quickly, even during routine
maneuvers such as turning and driving on hills or over obstacles, if
you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these
instructions:
* Read this manual and all labels carefully and follow the operating
procedures described.
* 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 hilis 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.
x 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 or pulling a trailer.
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).
California Proposition 65 Warning
WARNING: This product contains or emits chemicals known to the
State of California to cause cancer and birth defects or other
reproductive harm.
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
O
AL
Improper use of ATVs can result in SEVERE INJURY
or DEATH
THIS ATV IS FOR
UTILITY USE
ALWAYS USE NEVER USE NEVER CARRY NEVER USE OPERATOR ONLY-NO PASSENGERS
AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS
HELMET AND ROADS OR ALCOHOL
PROTECTIVE
NO OPERATOR UNDER AGE 16
NEVER operate :
® without proper training or instruction.
# at spesds too fast for your skills or tha conditions.
e on public roads - a collision can occur with THIS CATEGORY U (UTILITY) ATV IS FOR OFF ROAD USE
another vehicle. ONLY. IT IS MAINLY FOR UTILITY USE BUT IT MAY ALSO
® with a passenger - passengers affect balance BE USED FOR GENERAL RECREATION.
and steering and increase risk of losing control.
ALWAYS :
TRAINING COURSES TO TEACH ATV RIDING SKILLS ARE
© use proper riding techniques to avoid vehicle AVAILABLE.FOR INFORMATION CONTACT YOUR DEALER.
overturns on hills and raugh terrain and in turns.
® avoid paved surfaces - pavemant may seriously
affect handling and control,
READ THE OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
CHECK WITH YOUR DEALER TO FIND OUT ABOUT
STATE OR LOCAL LAWS REGARDING ATV OPERATION.
THS HANGTAG IS NOT TO BE REMOVED BEFORE SALE
Passengers can cause a
Overloading this ATV or carrying cargo
improperly can change handling, stability
and braking performance and can lead to an
accident.
Never exceed the maximum front cargo limit
of: E66lbs (30kg).
Refer to instructions in the Owner's
Manual.
loss of control, resulting in
SEVERE INJURY or DEATH.
| AWARNNG |
NEVER ride as a passenger.
A
Improper tire pressure or overloading
can cause loss of control.
Loss of control can result in severe
injury or death.
e Coid tire pressure,
Front: 25+3kpa 0.25+0.03kgl/cm 3.6+0.4psi
Rear | 25+3kpa 0.25+0.03kgf/cm 3.6+0.4psi
e Maximum weight capacity; 220kg 485165.
Operating this ATV if you are under
the age of 16 increases your chance
of severe injury or death.
NEVER operate this ATV if you are
under аде16 .
o A WARNING o |
Improper use of ATVs can result in SEVERE INJURY
or DEATH
ALWAYS USE NEVER USE MEYER CARRY NEVER USE
AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS
HELMET ANB ROADS OR ALCOHOL
PROTECTIVE
GEAR
NEVER operate
& without proper training or instruction.
(+) ® at speeds too fast for your skills or the conditions.
. on public roads - a collísion can occur with
another vehicle,
* 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.
® avoid paved surfaces - pavement may sariously
affect handling and control.
READ THE OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
BRAKING INFORMATION
With four-whgel drive operating any brake control
causes braking at both the front and rear wheels.
For detailed braking information, refer to the
Owner's Manual.
Overleading this ATV or carrying cargo
improperly can change handling, stability
and braking performance and can lead to an
accident.
Never exceed the maximum rear cargo limit
{combined weight on the rear rack and in
the storage area)of: 133|bs (80kg).
Refer to instructions in the Owner's
Manual.
Towing an improperly loaded
trailer can cause loss of
control.
@ Read owner's manual.
Tow weight limit: 3776N (385kgt)
o 9 850lbs
Tongue weight: 137N {14kgf}
® 9 9 30lbs
PARTS LOCATION AND OPERATION
PARTS LOCATION
(1) Rear brake lever
Parking brake
(2) Headlight switch
Engine stop switch
Headlight dimmer switch
Starter button
Upshift switch
Downshift switch
(3) Reverse selector knob
(4) Fuel gauge
(5) Choke knob
(6) Ignition switch
(7) Throttle lever
(8) Front brake lever
Fig. 2-1 Handlebars, from rider's point of view
10
(9) Reverse indicator
(10) Neutral indicator
(11) Oil high temperature indicator
(12) Multi-function display
® Speedometer
e Gear position indicator
e Odometer/Tripmeter
e Digital clock/Hourmeter
(13) Minute select button
(14) Hour select button
(15) Hourmeter/Digital clock select button
(16) Odometer/Tripmeter select button
(10)
(16) (15) (14) (13)
Fig. 2-2 Indicators and multi-function display, from rider's point
of view
11
(17) Flag pole bracket
(18) Rear cargo rack
(19) Seat lock lever
(20) Fuel fill cap
(21) Front brake fluid reservoir
(22) Helmet holder
(23) Front cargo rack
(24) Recoil starter (behind the right side cover)
(25) Right footpeg
(26) Rear brake pedal
(27) Assist headlight
(28) Headlights
(17) (18) (19) (20) (21) (22) (23)
(24) (25) (26) (27) (28)
Fig. 2-3 Right side of FOURTRAX
12
(29) Accessory socket
(30) Fuel valve
(31) Starting primer knob
(32) Storage compartment, containing:
Tool kit
Air pressure gauge
Owner's Manual
Gear change tool
(33) Oil filler cap/dipstick
(34) Left footpeg
(35) Trailer hitch
(30) (31)
(34)
(35)
(32)
Fig. 2-4
Left side of FOURTRAX
13
PARTS OPERATION
POWER CONTROLS
Ignition Switch
The ignition switch (Fig. 2-5) is in the center of the handlebars directly
in front of the seat.
J
Tes
— a —
=
(1)
Fig. 2-5 (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 and assist The key can-
(1) headlight can be turned on. not be re-
moved.
With the engine stop switch at
RUN and the transmission in
neutral, the engine can be
started.
14
Engine Stop Switch
The engine stop switch (Fig. 2-6 ) is next to the left handgrip, and it has
three positions. When the switch is in the RUN (© ) position, the
engine will operate. When the switch is in either OFF ( & ) position, the
engine will not operate.
This switch is intended primarily as a safety or emergency control, and
it should normally remain in the RUN ( ©) ) position.
NOTE:
If you stop your FOURTRAX by turning the engine stop switch OFF
(Si), be sure to turn the ignition switch OFF ( O) to prevent battery
discharge.
=
(st Ye
(1)
Fig. 2-6 {1) Engine stop switch
15
Choke Knob
The choke knob (Fig. 2-7 } is located above the handlebar cover. The
choke has two positions: fully ON (A), and fully OFF (B).
To start a cold engine when air temperature is —15—35°C (5—95°F),
pull the choke knob up to the Fully ON position before pressing the
starter button. After the engine is warm, push the choke knob to the
fully OFF position.
CAUTION:
+ Extended use of the choke may impair piston and cylinder wall
lubrication and shorten the life of the engine.
+ Pushing the choke knob too hard to the OFF position may dislodge
the choke cable boot. If this happens, water and dirt may enter the
choke cable and cause corrosion. If the choke is hard to actuate, or
feels like it is sticking, check the cable boot.
Fig. 2-7 (1) Choke knob (A) Fully ON
(B) Fully OFF
16
Starter Button
The starter button (Fig. 2-8 ) is below the headlight switch (2). To start
the engine, press the starter button (1), with the transmission in
neutral, the ignition switch ON ( | ) and the engine stop switch (3) at
RUN (O).
(2)
Fig. 2-8 (1) Starter button (3) Engine stop switch
(2) Headlight switch
17
Starting Primer Knob
The starting primer knob (Fig. 2-9 ) is on the carburetor float bowl on
the left side of the FOURTRAX. To start the engine when air
temperature is below —15 °C (5 °F), push the knob in two or three
times before pressing the starter button.
(1)
ue
Fig. 2-9 (1) Starting primer knob
18
Recoil Starter
The recoil starter (Fig. 2-10) is on the right side of the FOURTRAX. It is
used to start the engine when the battery is low.
To operate the recoil starter:
1.
2.
3.
A
Unsnap and remove the right side cover (2).
Grasp the starter grip (1) firmly, then pull it out slowly approxi-
mately 4 in (100 mm).
Pull the grip up briskly and fully.
After the engine starts, allow the starter grip to return slowly.
If the starter grip does not return smoothly (because of dirt in the
assembly), see your Honda dealer.
Fig. 2-10 (1) Recoil starter grip (2) Right side cover
19
Throttle Lever
The throttle lever (Fig. 2-11) is next to the right handgrip, and it is
operated by the thumb. Pressing the lever opens the throttie. When
pressure is released, spring tension automatically closes the throttle.
(1)
Fig. 2-11 (1) Throttie lever (A) To open the throttle
20
LIGHTS
Headlight and Dimmer Switches
The headlight and dimmer switches (Fig.2-12) are above the starter
button, next to the gearshift switches.
Turning the headlight switch (1) ON (%:) turns the headlight and
assist headlight on. Use the dimmer switch (2) to select either high
beam HI (£0 ) or low beam LO ( £D ) for the headlights.
The dimmer switch will not change the assist headlight beam.
|| —_—
J (mp
(2)
nero
и nee
oi
UN)
(1)
Fig. 2-12
(1) Headlight switch (2) Dimmer switch
21
Reverse and Neutral Indicators
The reverse indicator (1) and the neutral indicator (2) (Fig. 2-13) are
located above the multi-function display.
The reverse indicator will light when the transmission is in reverse and
the ignition switch is ON ( | ). The neutral indicator will light when the
transmission is in neutral and the ignition switchis ON ( | ).
Oil High Temperature Indicator
If the engine oil gets too hot, the oil high temperature indicator (3) (Fig.
2-13) will light.
NOTE:
The oil high temperature indicator should come on when the ignition
switch is turned ON ( | ). This is not a problem. The light should go off
a few seconds after the engine is started.
CAUTION:
If the light does not come on with ignition switch ON ( | ), contact
your authorized Honda dealer for assistance if you cannot correct the
problem.
If the oil high temperature indicator comes on while you are riding,
immediately bring the vehicle to a stop, turn the engine off and let it
cool.
An electric fan is used to automatically provide sufficient air flow
through the oil cooler/before the engine oil temperature becomes too
high.
CAUTION:
* Failure to stop the engine immediately after the oil high
temperature indicator comes on will adversely affect the service life
of the engine.
* Do not carry or store articles on the front bumper. This may restrict
air flow through the engine oil cooler, causing it to overheat.
If the oil high temperature indicator comes on often, have your
FOURTRAX inspected by your Honda dealer.
22
[ooo/7RIP) | я / © ] (н) (м)
Fig. 2-13
(1) Reverse indicator
(2) Neutral indicator
(3) Oil high temperature
indicator
23
Multi-function Display
(Ref. No.) Description
Function
(1) Multi-function display
The display includes the following
functions.
(A) Gear position
indicator
Shows the gear position.
(page 27)
(B) Speedometer
Shows riding speed.
(С)! Odometer
Shows accumulated mileage.
(page 28 )
Tripmeter
Shows mileage per trip.
(page 28)
(D) Digital clock
Shows the time (hours and
minutes). (page 30 )
Hourmeter
Shows hours and tenths of hours
of engine operation. (page 29 )
(2) Odometer/tripmeter
select button
Selects display of the odometer or
tripmeter. Resets the tripmeter to
zero (0). (page 28)
(3) Digital clock/hourmeter
select button
Selects display of the hourmeter
or digital clock. (page 29, 30)
(4) Hour select button
Advances the hour displayed by
the digital clock. (page 30 )
(5) Minute select button
Advances the minute displayed by
the digita! clock. (page 30 )
24
Fig. 2-14
25
Initial Display
When the ignition switch is turned ON ( | ), the display (1) (Fig. 2-15)
will temporarily show all the modes and digital segments so you can
make sure the liquid crystal display is functioning properly.
The digital clock will reset if the battery is disconnected.
(1)
688888 wi
8 885888»
белки) (879) (9) (5)
Fig. 2-15 (1) Multi-function display
26
Gear Position Indicator
The gear position indicator (1) (Fig. 2-16) shows the gear position
when the ignition switch is in the ON ( | ) position and the engine is
running.
The indicator displays: N for neutral, R for reverse, and 1—5 for the
five forward speed gears.
When the engine is stopped, the indicator will display: N, R, 1, “---"" {if
the transmission is in 2nd, 3rd, or 4th gear), or 5.
(1)
we) (570) D
Fig. 2-16 (1) Gear position indicator
27
Odometer/Tripmeter
Odometer
When selected, the odometer (1) (Fig. 2-17) registers total distance
traveled in miles while the ignition is ON { | ). To change the display
(2) from tripmeter to odometer, press and release the Odometer/
Tripmeter select button (3).
Fig. 2-17 (1) Odometer (3) Odometer/Tripmeter select button
(2) “ODO” display
Tripmeter
When selected, the tripmeter (1) (Fig. 2-18) shows mileage per trip
while the ignition is ON ( | ). To change the display (2) from
odometer to tripmeter, press and release the Odometer/Tripmeter
select button (3). To reset the tripmeter to zero, press the Odometer/
Tripmeter select button and hold it in for at least two seconds.
ES (870) (#)()
(3)
(2)
Fig. 2-18 (1) Tripmeter (3) Odometer/Tripmeter select button
(2) “TRIP” display
28
Hourmeter
When selected, the hourmeter (1) (Fig. 2-19) shows accumulated hours
while the ignition is ON ( | ). The hourmeter provides accurate
service period information for initial and regular maintenance. To
change the display from the digital clock to the hourmeter mark (2),
press and release the hourmeter/digital clock select button (3).
(X В 05% Bn:
em de) MM
(3)
Fig. 2-19 (1) Hourmeter (3) Hourmeter/digital clock
(2) Hourmeter mark select button
(1)
(2)
29
Digital Clock
When selected, the digital clock (1) (Fig. 2-20) shows the time while the
ignition is ON ( | ). To change the display from hourmeter to digital
clock, press and release the hourmeter/digital clock select button (2).
E E WE
(2)
Fig. 2-20 (1) Digital clock (2) Hourmeter/digital clock select button
Digital Clock Adjustment:
Turn the ignition switch ON ( |).
To advance the hour display one unit at a time, press and release the
hour select button (1).
To advance the hour display automatically, press and hold the hour
select button. After two seconds, the hour display will begin advancing.
Release the button when the display reaches the desired hour (2).
To advance the minute display one unit at a time, press and release the
minute select button (3).
To advance the minute display automatically, press and hold the
minute select button. After two seconds, the minute display will begin
advancing. Release the button when the display reaches the desired
minute (4).
To zero the minute display, press and hold both the hour and minute
buttons simultaneously for two seconds.
(2) (4)
ro
Fig. 2-21 (1) Hour select button (3) Minute select button
(2) Hour (4) Minute
30
GEARSHIFT CONTROLS
Gearshift Switches
Two gearshift switches (Fig. 2-22) are located next to the left handlebar
grip: upshift ( {+ ) and downshift ( ).
Your FOURTRAX has five forward gears: 1, 2, 3, 4, and 5.
To upshift the transmission, press the upshift switch (1) once.
To downshift the transmission, press the downshift switch (2) once.
(For complete operational instructions, see page 71 ).
NOTE:
* The transmission cannot be upshifted from neutral to first gear or
neutral to reverse when the engine speed is above 3,000 rpm or the
ground speed is above 6 mph (10 km/h).
* The transmission cannot be downshifted from 1st gear to neutral
when the ground speed is above 2 mph (3 km/h).
UPSHIFTING SEQUENCE
DOWNSHIFTING SEQUENCE
(2) To reverse:
( use reverse selector knob
Fig. 2-22 (1) Upshift switch (A) Push
(2) Downshift switch
31
Reverse Selector Knob
The reverse selector knob (Fig. 2-23) (1) is on the rear brake lever.
To shift into reverse, first bring the FOURTRAX to a complete stop and
make sure the transmission is in neutral. While pushing the reverse
selector knob (1) in, squeeze the rear brake lever (2), then press the
downshift switch (3). To shift from reverse back to neutral, press the
upshift switch (4) once.
NOTE:
The transmission cannot be shifted from neutral back into reverse
when the engine speed is above 3,000 rpm or the ground speed is
above 6 mph (10 km/h).
CAUTION:
Bring the FOURTRAX to a complete stop before shifting the
transmission into reverse. If the transmission is shifted into reverse
while the vehicle is moving, the transmission will be damaged.
(1)
(2)
(3)
Fig. 2-23 (1) Reverse selector knob (3) Downshift switch
(2) Rear brake lever (4) Upshift switch
32
BRAKE CONTROLS
Front Brakes
The front brakes are operated by squeezing the front brake lever, near
the right handgrip.
Rear Brake
The rear brake is operated either by depressing the brake pedal or by
squeezing the rear brake lever (Fig. 2-24).
NOTE:
Although the front and rear brakes have separate controls, your
FOURTRAX's four-wheel drive interconnects all four wheels. So operat-
ing any brake control will cause braking at both the front and rear
wheels. For information on how to apply the brakes in various riding
situations, see pages 76 — 93.
Parking Brake
The rear brake lever has a lock which allows it to be used as a parking
brake.
To set the parking brake, squeeze the rear brake lever ( 1) and lock it
with the lock lever ( 2). Always set the parking brake when parking and
before starting the engine.
To unlock the parking brake, squeeze the rear brake lever until the lock
lever releases.
Using the parking brake in freezing weather may cause the brakes to
freeze in the locked position.
(2)
Fig. 2-24 (1) Rear brake lever/ (2) Lock lever
Parking brake lever (A) To lock
33
FUEL TANK CONTROLS
Fuel Gauge
The fuel gauge (Fig. 2-25) (1) shows the approximate fuel supply
available. At F (Full), the fuel tank capacity including reserve is:
3.17 US gal (12.0 2, 2.64 Imp gal)
When the gauge needle (2) enters the red band (3), fuel will be low
and you should refill the tank as soon as possible. The amount of fuel
left in the tank when the needle enters the red band is approximately:
0.79 US gal (3.0 2, 0.66 imp gal)
(2)
(3) |
—
SO JF
ГВ
Fig. 2-25 (1) Fuel gauge (2) Gauge needle
(3) Red band
34
Fuel Fill Cap
After refueling, be sure to tighten the fuel fill cap (Fig. 2-26) until it
clicks.
Insert the breather tube (2 ) into the handlebar cover hole ( 3).
To refuel refer to page 100.
(2)
(1)
Fig. 2-26 (1) Fuel fill cap (2) Breather tube
(3) Handlebar cover hole
35
Fuel Valve
The fuel valve (Fig. 2-27) 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:
0.71 US gal (2.7 2, 0.59 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
100 — 103.
RES
OFF FUE
x
NN
Fig. 2-27 (1) Fuel valve
36
ENGINE OIL
Oil Filler Cap/Dipstick
The oil filler cap/dipstick {Fig.2-28), on the rear crankcase cover, is
used to measure the oil level. The oil should be checked each day
before operating the FOURTRAX and maintained between the upper
level mark (2) and the lower level mark (3).
For oil recommendations and instructions on checking, adding and
changing oil, see pages 112— 116.
(1)
(2) ———
(3) — — >=
Fig. 2-28 (1) Oil filler cap/dipstick (2) Upper level mark
(3) Lower level mark
While reading this manual, remember:
NENE Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
37
ADDITIONAL FEATURES
Helmet Holder
The helmet holder (2) (Fig. 2-29) is located on the right side of the
handlebar ( 1). To use the holder, hang the D-ring on your helmet strap
over the bracket. Use the helmet holder only when the FOURTRAX is
parked.
Fig. 2-29 (1) Handlebar (2) Helmet holder
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.
38
Flag Pole Bracket
The flag pole bracket (Fig. 2-30) is on the rear cargo rack. Flag poles are
optional equipment available from your Honda dealer. To mount a
pole in the bracket, follow the instructions that come with the flag pole
kit.
NOTE:
Flag poles are required in some riding areas. Check local regulations
before riding.
(2)
(1) |
<a
OS
Fig. 2-30 (1) Flag pole bracket (2) Optional flag pole
39
Trailer Hitch
The trailer hitch is located on the rear axle housing. As illustrated in Fig.
2-31, to use the hitch, you'll need a proper size ball as specified by the
trailer manufacturer.
To attach the ball and properly hook up a trailer, follow the trailer
manufacturer's instructions. For load limits and operational guidelines,
see pages 49—51.
O
CS
> a
à » (1)
a“
-
EA
N
N
N A
—6) N © 6
Fig. 2-31 (1) Trailer hitch (2) Trailer hitch ball
40
Storage Compartment
The storage compartment ( 1) (Fig. 2-32) is below the rear cargo rack
(2). To open the compartment, unhook the rubber strap (3). The
owner's manual (4), tool kit (5), gear change tool (6), and air pressure
gauge (7) should be stored in the storage compartment (1).
Be careful not to flood this area when washing your FOURTRAX or rid-
ing through water.
Fig. 2-32 (1) Storage compartment (5) Tool kit
(2) Rear cargo rack (6) Gear change tool
(3) Rubber strap (7) Air pressure gauge
(4) Owner's manual
41
Accessory Socket
The accessory socket (1) (Fig. 2-33) is attached to the left side of the
assist headlight lower case (2). You can use the accessory socket to
power a trouble light, spotlight, CB radio, or cell phone, etc.
Do not plug in any heat-generating accessory such as an automobile
cigarette lighter because it can damage the socket.
To use the accessory socket, turn the ignition switch ON ( | ) to start
the engine. Then turn the headlights OFF, and open the accessory
socket cap (3).
Be sure the engine is on and the headlights are turned off before using
the accessory socket, otherwise you may drain the battery.
The accessory socket's rated capacity is DC 12V, 120 Watts (10A) or
less.
If you exceed this limit, you may blow a fuse. (For information on fuses,
and how to replace a fuse, see pages 127 — 130.)
When you are done using an accessory, unplug it, and cover the socket
with the cap.
Be careful not to flood this accessory socket when washing your
FOURTRAX.
(3)
Fig. 2-33 (1) Accessory socket (3) Cap
(2) Assist head light lower case
42
While reading this manual, remember:
INCI IIeR® Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
43
RIDING YOUR FOURTRAX
This part of the Owners Manual discusses how to ride your
FOURTRAX safely. Please review the special safety messages on
pages 1—5 . While reading this manual, remember:
NIN eN 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.
44
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.
45
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
112-116). Check for leaks.
46
N >
po
10.
11.
. Underbody and exhaust system. Check for, and remove, any dirt,
13.
Fuel level. Fill the fuel tank when necessary (pages 100—103).
Check for leaks.
Brakes. Check operation. Make sure there is no brake fluid leakage.
If necessary, adjust free play (pages 131— 140).
Tires. Check condition and pressure (pages 142— 144).
Throttle. Check for smooth opening and closing in all steering
positions.
Headlight and headlight dimmer switches. Check for proper func-
tion (page 21).
Engine stop switch. Check for proper function (page 15).
Driveshaft boots. Check for damage (page 150).
Nuts, bolts, fasteners. Check the wheels to see that the axle nuts
are tightened. Check the security of all other nuts, bolts and fasten-
ers.
Steering. Check that the wheels turn properly as you steer the
handlebars.
Cargo. Check that all cargo is properly secured.
vegetation or other debris that could be a fire hazard or interfere
with the proper operation of the vehicle.
Air cieaner housing drain tube. Check for deposits in the drain
tube. If necessary, clean the tube (page 108) and check the air
cleaner case.
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.
47
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 142).
A WARNING
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.
48
Loading
Load Limits
There are limits to how much weight can be carried on your
FOURTRAX and be pulled in a trailer.
NOTE:
The following weight limits apply to standard equipment only. Modi-
fying your FOURTRAX, using non-standard equipment or riding on
terrain that is not flat and smooth could further reduce these limits.
Maximum weight capacity 485 165 (220 Кд) maximum
(Combined weight of the rider, all accessories and all cargo)
Front cargo rack weight limit 66 Ibs (30 kg) maximum
Rear cargo rack weight limit 133 Ibs {60 kg) maximum
Tow weight limit 850 Ibs {385 kgf}
(Combined weight of the (3776 N) maximum
trailer and all cargo in the
trailer)
Tongue weight = 30 165 {14 kgf}
(Weight on the trailer (137 N) recommended
tongue)
Tongue and rear cargo weight = 133 Ibs (60 kg) maximum
(Combined weight on the
trailer tongue and on the
rear cargo rack)
49
Loading and Operational Guidelines
Carrying cargo or pulling a trailer will affect how your FOURTRAX
handles and greatly reduce its ability in accelerating, braking and
making turns and other maneuvers.
Be sure to observe the weight limits and follow these guidelines:
1.
Do not place cargo anywhere on the FOURTRAX other than on the
front and rear racks. Otherwise, operating stability may be ad-
versely affected.
2. Never ride with a passenger on the front or rear cargo racks. The
FOURTRAX is not designed to carry a passenger.
3. Do not tow another vehicle or a trailer with a rope or cable
attached to the rear rack. Use the trailer hitch.
4. Load cargo on the rear rack as far forward as possible. Make sure
cargo on the front rack does not interfere with handlebar move-
ment.
5. Do not allow cargo to extend beyond the edges of either the front
or rear racks.
6. Make sure all cargo is secured before riding.
7. When towing a trailer, take care to maintain balance and stability.
Distribute cargo between the front and rear of the trailer to obtain
the recommended tongue weight.
NOTE:
Tongue weight can be measured with an ordinary bathroom scale.
Place the scale under the tongue, using either a tongue jack or other
support to keep the trailer level.
8.
9.
10.
50
Allow extra room for starting, stopping and turning whenever you
carry cargo or pull a trailer.
Avoid riding on steep slopes when carrying cargo or pulling a
trailer.
Never cross a slope when towing a trailer.
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 hiils 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.
51
Accessories
Genuine Honda accessories have been specifically designed for and
tested on this vehicle. Because Honda cannot test all other accessories,
you are personally responsible for properly selecting, installing, and
using non-Honda accessories. Always follow the loading instructions
above, plus the following:
1. Carefully inspect the accessory to make sure it does not block any
lights, reduce ground clearance, or limit suspension travel, steer-
ing travel, or other controls.
2. Make sure the accessory does not interfere with your ability to
shift body position on the seat or operate hand and foot controls.
3. Do not add electrical equipment that will exceed the vehicle's
electrical system capacity. A blown fuse could cause a loss of
lights or engine power.
52
CN С` Те ЗВАННННННННННННИ
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:
PEN IDIEN Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
53
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.
54
AWARNING |
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.
55
No Passengers
This FOURTRAX is designed as an operator-onty vehicle. The long seat
is designed to allow the rider to change body position, not for carrying
a passenger. Never let a passenger ride on the seat or on the front or
rear cargo racks.
Fig. 3-2 Never carry a passenger on your FOURTRAX.
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this ATV.
Could cause an accident, resulting in harm to you and/or your
passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The long seat is to allow the operator to
shift position as needed during operation. It is not for carrying
passengers.
56
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.
57
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 control of the ATV, and may cause the vehicle to go out of
control.
HOW TO AVOID THE HAZARD
Never operate the ATV on any paved surfaces, including
sidewalks, driveways, parking lots and streets.
58
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.
59
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.
60
Keep Hands and Feet on Controls
Always keep both hands on the handlebars and both feet on the
footpegs when riding your FOURTRAX. This is important to maintain
your balance and to control the vehicle. If you put your feet on the
ground while the FOURTRAX is moving, they could come in contact
with the rear wheels, causing injury.
Fig. 3-5 (1) Footpeg
A WARNING
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.
61
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.
62
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.
EY 7. TT
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. 3-6 Never attempt wheelies or other stunts.
63
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. 3-7 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.
64
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. 3-8 Use extra care on rough terrain.
A WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on excessively rough,
slippery or loose terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle control, which could result
in an accident, including an overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose terrain
until you have learned and practiced the skills necessary to
control the ATV on such terrain.
Always be especially cautious on these kinds of terrain.
65
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.
——— WARNING _——[
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.
66
STARTING THE ENGINE
Preparation
1. Select a level surface and lock the parking brake (page 33) before
starting the engine.
2. Turn the fuel valve (1) and ignition switch (2) to ON.
3. Make sure the engine stop switch (3) is at RUN ( © ).
4. Make sure that the transmission is in neutral by checking that the
neutral indicator (4) lights.
(3)
y ane мн |
| 458 |
fr) (576) (HH
Fig. 3-9 (1) Fuel valve
(2) Ignition switch
(3) Engine stop switch
(4) Neutral indicator
67
Starting Procedure (After Preparation)
To restart a warm engine, follow the procedure for High Air Tempera-
ture.
The starter motor will operate only when the transmission is in neutral.
Normal Air Temperature
10° — 35 °C (50° — 95 °F)
1. Pull the choke knob (1) up all the way to fully ON (A) position, if
the engine is cold.
2. With the throttle closed, 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.
e
aL SNC
su
Fig. 3-10 (1) Choke knob (A) Fully ON
(B) Fully OFF
3. Immediately after the engine starts, operate the choke knob to
keep fast idle.
4. Continue warming up the engine until it runs smoothly and
responds to the throttle with the choke knob in the fully OFF (B)
position.
5. Ifidling is unstable, open the throttle slightly.
68
High Air Temperature
35 °C (95 °F) or above
1. Do not use the choke.
2. With the throttle slightly open, press the starter button (1).
TM |
Ze
at az
a AN
(1)
Fig. 3-11 (1) Starter button
Low Air Temperature
10 °C (50 °F) or below
Follow the procedure for “Normal Air Temperature”.
NOTE:
When air temperature is below — 15 *C (5 *F), push the starting primer
knob two or three times (page 18).
CAUTION:
* Extended use of the choke may impair piston and cylinder wali
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.
69
Flooded Engine
If the engine does not start after several attempts, it may have become
flooded with excess fuel. To clear the engine:
1.
Turn the engine stop switch OFF ( 3% ).
2. Move the choke lever to the OFF position.
3. Hold the throttle fully open and briefly press the starter button or
operate the recoil starter several times.
4. When the engine is cleared, wait 10 seconds. Then turn the engine
stop switch to RUN (© ) and repeat the normal starting
procedure, but don’t use the choke.
Low Battery
If the battery is low or dead, use the recoil starter (page 19) to start the
engine.
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 111).
70
SHIFTING GEARS
After starting the engine and letting it warm up, follow these proce-
dures:
1. With the transmission in neutral, release the parking brake, but
continue squeezing the rear brake lever.
2. With the throttle closed, press the upshift switch once to shift into
1st gear.
3. Release the rear brake lever and increase engine speed by
gradually opening the throttle.
4. When speed increases, release the throttle and shift to 2nd gear by
pressing the upshift switch once.
5. Repeat this sequence to progressively upshift to 3rd, 4th and 5th
(top) gear.
6. To downshift, press the downshift switch once. Remember to
close the throttle each time you shift to the next lower gear.
NOTE:
* The transmission cannot be upshifted from neutral to first gear when
the engine speed is above 3,000 rom or the ground speed is above
6 mph (10 km/h).
* The transmission cannot be downshifted from 1st gear to neutral
when the ground speed is above 2 mph (3 km/h).
* If the electric shift system malfunctions, the transmission cannot be
shifted by pressing the gearshift switches. See your Honda dealer.
(In an emergency, a gear may be selected manually so you may
move the vehicle. See Emergency Gear Selection & Operation, page
73 ).
I: ЕНОНАНННННя
POTENTIAL HAZARD
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.
71
If the Shift Switches Do Not Function
If one or both shift switches do not function, see the following
instructions. If proper function cannot be restored, see your Honda
dealer,
e When the engine is running:
1.
2.
3
Stop the FOURTRAX.
Turn the ignition switch to the “OFF” { O ) position.
After the engine stops, turn the ignition switch to the “ON” ( | )
position.
Press both shift switches and check that they are functioning.
If both switches are functioning, shift into neutral and restart the
engine.
If one or both switches are not functioning, see “Emergency Gear
Selection & Operation” on page 73.
e When the engine is stopped (ignition switch at “ON” ( | ):
wn =
Turn the ignition switch to the “OFF” (O ) position.
Turn the ignition switch to the “ON” ( | } position.
Press both shift switches and check that they are functioning.
If both switches are functioning, shift into neutral and restart the
engine.
If one or both switches are not functioning, see “Emergency Gear
Selection & Operation” on page 73.
@ When the battery is dead:
See “If the Battery is Dead” on page 75 .
72
Emergency Gear Selection & Operation
If the shift switches do not operate, use the following procedure to
manually select a gear so you may drive the vehicle to a location
where it can be loaded and transported to a Honda dealer.
1.
2.
3.
о с
90
Turn the ignition switch to the “ON” ( | ) position.
Remove the gear change tool from the storage compartment
(page 99).
Check the neutral indicator.
If the transmission is in neutral, go to step 4.
If the transmission is not in neutral, use the gear change tool to
shift to neutral so you will be able to start the engine, Refer to
“How to Shift Gears Manually” (page 74).
Apply the parking brake.
Press the starter button to start the engine.
Select the gear you want. For running on level ground: use 3rd or
4th gear. For mountainous roads: use 2nd or 3rd gear. Refer to
“How to Shift Gears Manually.”
Return the gear change tool to the storage compartment.
Get on the FOURTRAX. Drive it at a safe speed to a place where it
can be repaired or serviced.
73
How to Shift Gears Manually:
Fig. 3-12 How to shift gears manually
(A) Downshift (Counterciockwise)
(B) Upshift (Clockwise)
+ With the FOURTRAX unoccupied, align the hexagonal hole of the
gear change tool with the hexagonal end of the secondary spindle
which is located near the left footpeg.
* To downshift, turn the gear change tool counterclockwise (A ).
To upshift, turn the tool clockwise (B ).
* If the transmission does not shift, rock the vehicle back and forth and
try again.
* Return the gear change tool to the storage compartment.
Do not attempt to shift gears manually using the gear change tool
while driving.
NOTE:
If the transmission is shifted manually when the electric shift system is
functioning, the system will shutdown automatically and the shift
switches will not operate. To reactivate the system, turn the ignition
switch to the “OFF” (O) position, then turn it back to the “ON” ( |)
position.
74
If the Battery is Dead:
The electric shift system will operate even if the battery is dead, as
long as the engine is running. If the engine is not running, it may be
started using the recoil starter. See your Honda dealer to have the
battery recharged or replaced.
1.
2.
3.
Turn the ignition switch to the “ON” ( | ) position.
Remove the gear change tool from the storage compartment
(page 99 ).
Check if the transmission is in neutral by moving the vehicle back
and forth.
If the transmission is in neutral, the vehicle will move easily. Go to
step 4.
If the transmission is not in neutral, the vehicle will not move. Use
the gear change tool to shift to neutral so you will be able to start
the engine. Refer to “How to Shift Gears Manually’ (page 74 ).
Apply the parking brake.
Turn the ignition switch to the “OFF” (O) position, then turn it
back to the “ON” { | ) position.
Use the recoil starter (page 19 ) to start the engine.
75
RIDING IN REVERSE
To shift into reverse, first bring the vehicle to a complete stop and
make sure the transmission is in neutral. Then follow these proce-
dures:
1.
Be sure there are no obstacles or people in the way.
2. While pushing the reverse selector knob in, squeeze the rear brake
lever, then press the downshift switch once to shift into В”
(Reverse) gear.
3. Release the rear brake lever.
4. Open the throttle gradually and ride slowly. Do not open the
throttle suddenly or make abrupt turns.
5. To stop, close the throttle and gradually apply both the front and
rear brakes. Do not abruptly apply the rear brake by itself.
6. To shift out of reverse and into neutral, press the upshift switch
once to shift into “N”’ (Neutral) gear.
NOTE:
The transmission cannot be shifted from neutral back into reverse
when the engine speed is above 3,000 rpm or speed of your
FOURTRAX is above 6 mph (10 km/h).
While reading this manual, remember:
ENEE Indicates a strong possibility that serious injury or
76
death may result if instructions are not followed.
| A WARNING |
POTENTIAL HAZARD
improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacie or person behind you, resulting in
serious injury.
HOW TO AVOID THE HAZARD
When you select reverse gear, make sure there are no obstacies
or people behind you. When it is safe to proceed, go slowly.
| A WARNING |
POTENTIAL HAZARD
Applying only the rear brake abruptly when operating in reverse
gear.
WHAT CAN HAPPEN
The front wheels could lift off the ground and the ATV could
overturn backwards.
HOW TO AVOID THE HAZARD
Carefully apply both the front and rear brakes when stopping in
reverse gear.
77
MAKING TURNS
To make a turn on level ground, steer the handlebars and lean your
body toward the inside of the turn. (Fig 3-13) 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 (Fig 3-13), 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.
78
Fig. 3-13 Lean your body to the inside of a turn and forward.
CC NT CR
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.
79
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.
A WARNING
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.
80
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.
81
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.
Fig. 3-14 Shift weight forward when climbing hills.
82
CI TOR
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:
1. Using the front and rear brakes together, bring the FOURTRAX to
a stop with the vehicle pointed straight uphill.
83
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, carefully apply the front brakes first, then
carefully apply the rear brake as well. Do not apply either brake
abruptly if you are rolling backwards, or the vehicle may overturn.
NOTE:
Remember that operating any brake control with four-wheel drive will
cause braking at both the front and rear wheels,
If the FOURTRAX continues sliding backwards after you've applied the
brakes, get off and away from the vehicle.
Fig. 3-15 If you roll backwards down a hill, don't apply either brake
abruptly.
84
ee ———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 either brake abruptly while rolling backwards.
Apply the front brake first.
Then carefully apply the rear brake, and then lock the 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.
85
If the hill is not too steep and you have good footing, you may be able
to walk the FOURTRAX back down the hill. Make sure your intended
path is clear in case you lose control of the FOURTRAX.
If you decide you can walk the FOURTRAX safely:
1. Stand with your body facing downhill, beside the vehicle so you
can reach the rear brake lever with your right hand (see Figure
3-16).
Be sure your legs are clear of the wheels.
Check your footing.
Then slowly and carefully back the FOURTRAX down the hill using
the rear brake lever to control speed.
5. If you lose control of the FOURTRAX, for your safety, get away
from the vehicle.
но
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. 3-16 Be sure your legs are Body position for backing
clear of the wheels. down a hill.
36
While reading this manual, remember:
INGEN Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
87
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.
Do not downshift abruptly while descending a hill.
Use mainly the rear brake to control speed. Avoid using either the front
brake or rear brake hard or abruptly when riding down hills.
NOTE:
Remember that operating any brake control with four-wheel drive will
cause braking at both the front and rear wheels.
Remember, braking effectiveness is reduced on any hill with a loose
surface.
Fig. 3-17 On downhills, shift your weight back.
88
A WARNING
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.
89
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.
lp,
Fig. 3-18 Shift weight uphill when crossing slopes.
90
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.
91
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.
92
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.
Riding through water can make the brakes less effective than normal.
After leaving water, always test both the front and rear brakes. If
necessary, apply the brakes repeatedly until they dry out and operate
normally. If the brakes don’t regain effectiveness, stop your
FOURTRAX and follow the procedures on page 140.
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 linings.
93
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.
If it is necessary to start the engine when your FOURTRAX is stopped
on a grade in gear, rock the vehicle back and forth to allow shifting the
transmission into neutral.
While reading this manual, remember:
FAT Te Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
94
MAINTENANCE AND REPAIRS
EMISSION REQUIREMENTS (USA only)
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
rear fender below the seat.
(1)
Fig. 3-19 (1) Vehicle Emission Control information Label
95
MAINTENANCE SCHEDULE
Whichever INITIAL] REGULAR
FREQUENCY comes first MAINTENANCE] MAINTENANCE INTERVAL
> mi 100 600 1200 | Referto
ITEMS km 150 | 1000 | 2000 page
NOTE |HOURS 20 100 | 200
FUEL LINE | —
о THROTTLE OPERATION | 104
CARBURETOR CHOKE | 109
AIR CLEANER (NOTE 1) С С | 105—107
Lid AIR CLEANER HOUSING | (NOTE 2) | | 108
< DRAIN TUBE
a SPARK PLUG | 1 | 120-121
= VALVE CLEARANCE | | | 121
D ENGINE OIL R R R 37,
= 112—116
Lö ENGINE OIL FILTER R R R |112—116
ENGINE IDLE SPEED | | | 110
96
I: Inspect and Clean, Adjust,
Lubricate or Replace if necessary.
C: Clean
A: Adjust
R: Replace
L: Lubricate
FREQUENCY Whichever INITIAL REGULAR
comes first MAINTENANCE MAINTENANCE INTERVAL
> mi 100 600 1200 | Referto
ITEMS km 150 1000 | 2000 page
NOTE (HOURS) 20 100 200
DRIVE SHAFT BOOTS | | —
REAR FINAL GEAR CASH (R: EVERY i 117 — 119
OIL AND DIFFERENTIAL 2YEARS)
= OIL
= BRAKE FLUID (NOTE3) | | 134
A BRAKE SHOE WEAR (NOTEN) | 139
E BRAKE SYSTEM | | | 131—140
=|* | REVERSE LOCK SYSTEM | | | 123
cc SKID PLATES,ENGINE | ) 147
5 GUARD
a *| CLUTCH SYSTEM | | i 122
= *| SUSPENSION | I —
> *| SPARK ARRESTER C С 148
© *| NUTS, BOLTS, FASTENERS ] | =
a WHEELS/TIRES i | | 141—145
x STEERING SHAFT HOLDER | —
BEARINGS
*% STEERING SYSTEM i —
* SHOULD BE SERVICED BY YOUR AUTHORIZED HONDA DEALER, UNLESS THE
OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY
QUALIFIED. REFER TO THE OFFICIAL HONDA SERVICE MANUAL.
** IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY
BY YOUR AUTHORIZED HONDA DEALER.
NOTES: 1. Service more frequently when riding in dusty areas, sand or snow.
2. Service more frequently after riding in very wet or muddy conditions.
3. Replace every 2 years. Replacement requires mechanical skill.
97
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.
A WARNING |
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.
98
TOOL KIT
À tool kit (1) (Fig. 4-1) and gear change tool (2) are provided with your
FOURTRAX and stored in the storage compartment below the rear
cargo rack.
The tools in the kit are sufficient to perform routine maintenance and
simple repairs. Any extensive work requiring additional tools shouid
be performed by your authorized Honda dealer.
The tool kit includes the following items:
* Standard/Phillips screwdriver * Spark plug wrench and
* Screwdriver handle handlebar
* 10 X 12 mm open end wrench * Pliers
* 14 X 17 mm open end wrench * Tool case
(1) ) (2)
Fig. 4-1 (1) Tool kit
(2) Gear change tool
While reading this manual, remember:
NENE Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
99
FUEL SYSTEM
FUEL
Refueling
The fuel tank capacity, including reserve, is:
3.17 US gal (12.0 2 , 2.64 Imp gal)
The reserve fuel supply 1s:
0.71 US gal (2.7 2, 0.59 imp gal)
To open the fuel fill cap (1), pull out the breather tube (2) from the
handie cover hole (3). Then turn the fuel fill cap counterclockwise.
Do not overfill (make sure there is no fuel in the filler neck (4 }).
After refueling, be sure to tighten the fuel fill cap firmly by turning it
clockwise until it clicks.
Insert the breather tube into the handie cover hole.
(4)
Fig. 4-2 (1) Fuel fill cap (4) Filler neck
(2) Breather tube
(3) Handlebar cover hole
100
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.
101
Fuel Recommendations
Your engine is designed to use any gasoline that has a pump octane
number of 86 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.
102
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.
103
THROTTLE
Throttle Cable and Lever
Check the condition of the throttle cable and the operation of the
throttle lever. Make sure the cable does not bind or interfere with
smooth operation of the throttle in any steering position. If the cable is
worn or kinked, have it replaced by your Honda dealer.
Throttle Free Play
Throttle free play, measured at the tip of the throttle lever (Fig. 4-3),
should be:
1/8— 5/16 in (3—8 mm)
To adjust throttle free play:
1. Slide the rubber sleeve (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.
7 (В
| 1/8—5/16 in
(2) (3 —8 тт)
(3)
(1)
(4)
Fig. 4-3 (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.
104
AIR CLEANER
Air Cleaner
The air cleaner accumulates dust and must be cleaned periodically. If
the FOURTRAX is ridden in dusty areas, the air cleaner must be
cleaned at more frequent intervals than specified in the Maintenance
Schedule.
If the FOURTRAX is submerged in water, the air cleaner should be
checked and water should be drained from the air cleaner housing
before starting the engine.
To clean the air cleaner:
1. Remove the seat by pulling up the seat lock lever (1) (Fig. 4-4).
2. Unlatch the four retainer clips (2) and remove the air cleaner hous-
ing cover (3).
(1)
Fig. 4-4 (1) Seat lock lever (2) Retainer clips
(3) Air cleaner housing
cover
105
3. Remove the screws (1) (Fig. 4-5) and remove the air cleaner
assembly (2) from the air cleaner housing.
4. Unscrew the clamp (3) and remove the mounting bracket (4).
5. Remove the air cleaner (5) from the air cleaner body (6).
(2) (1) (6) (5)
Fig. 4-5 (1) Screw (3) Clamp
(2) Air cleaner assembly (4) Mounting bracket
(5) Air cleaner
(6) Air cleaner body
(A) To release
6. Gently wash the air cleaner in clean, non-flammable (high flash
point) solvent such as kerosene — not gasoline.
Allow the air cleaner to dry throughly before applying oil. A wet air
cleaner will not fully absorb the oil.
A WARNING |
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.
106
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.
Dust cover
Do not push the dust cover (1) (Fig.4-6 ) into the breather joint (2).
If the dust cover is dirty, clean it.
(1) (2)
Fig. 4-6 (1) Dust cover
(2) Breather joint
107
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.
| Г (3)
a"
—
Fig. 4-7 (1) Drain tube (3) Air cleaner housing
(2) Clip
108
CARBURETOR
Choke Cable and knob
Check the condition of the choke cable (Fig. 4-8) and the operation of
the choke knob (2). If the cable is damaged or kinked, have it replaced
by your Honda dealer.
J (1)
| | ‘= |
N NO
= — >
NO
«
Fig. 4-8 (1) Choke cable (2) Choke knob
109
Adjusting Idle Speed
NOTE:
Do not try to compensate for faults in other systems by adjusting the
carburetor.
Before adjusting the idle speed and air-fuel mixture, unsnap the right
side cover. (Fig. 4-9)
To adjust the idle speed:
1. Warm up the engine. The engine must be warm for accurate idle
adjustment. Ten minutes of stop-and-go riding is sufficient.
2. Adjust idle speed by turning the throttle stop screw (Fig. 4-9).
Idle Speed:
1,400 = 100 rpm
Fig. 4-9 (1) Throttle stop screw
110
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.
111
LUBRICATION
ENGINE OIL
Checking Engine Oil Level and Adding Oil
Check the engine oil level each day before operating your FOURTRAX
and
add oil if needed.
To check the oil level:
1.
Make sure the vehicle is on level ground.
2. Start the engine in a well-ventilated area and let it idle for a few
minutes.
3. Stop the engine.
4. After a few minutes, remove the oil filler cap/dipstick (1) (Fig. 4-10)
from the rear crankcase cover and wipe it clean.
5. Insert the dipstick without screwing it in, then remove the dipstick
and check the oil level. The oil level should be between the upper
level mark (2) and the lower level mark (3) on the dipstick.
6. If required, add the specified oil into the filler cap hole, up to the
upper level mark on the dipstick. Do not overfill.
7. Reinstall the oil filler cap/dipstick.
CAUTION:
Running the engine with improper oil level can cause serious engine
damage.
(2) >
(3)— =
Fig. 4-10 (1) Oil filler cap/dipstick (2) Upper level mark
112
(3) Lower level mark
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 4-STROKE OIL OR AN EQUIVALENT.
For Canada:
USE HONDA 4-STROKE OIL OR AN EQUIVALENT.
Do not use oils with graphite or molybdenum additives. They may
adversely affect clutch operation.
Use only high detergent, premium quality motor oil certified to meet
API Service Classification 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
|
SAE 20W-40
ПОЛНО ПОЛН (НЛО
САЕ 10\/-40
IE DE он)
SAE IOW-30
Fig. 4-11 Recommended oil viscosities
113
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 crankcase while the engine is
still warm. This will ensure complete and rapid draining.
To change the oil and oil filter:
1.
2.
With the FOURTRAX on level ground, remove the oil filler cap/
dipstick from the rear crankcase cover (Fig. 4-10).
Place an oil drain pan under the crankcase and remove the oil
drain plug (Fig. 4-12).
GS
UD 7770
(1) <>
Fig. 4-12 (1) Oil drain plug
114
3. Remove the oil filter cover (1) (Fig. 4-13) by removing the bolts (2).
Let the remaining oil drain out.
Discard the oil filter (3).
4. Check that the oil filter cover O-rings (4) are in good condition and
then install a new oil filter. 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.
5. Install the filter with the rubber seal (5) facing out, away from the
engine. You will see the “OUTSIDE (TOWARDS FILTER COVER)”
mark (6) on the filter body, near the seal.
CAUTION:
Improper installation of the oil filter can cause serious engine damage.
6. Reinstall the oil filter cover (1), making sure the bolts (2) are
tightened securely.
Qil filter bolts torque:
7 Ibf-ft (10 N-m , 1.0 kgf-m)
(2)
Fig. 4-13 (1) Oll filter cover (5) Rubber seal
(2) Bolts (6) OUTSIDE mark
(3) Oil filter (7) Spring
(4) O-rings
115
7. Check that the drain plug sealing washer is in good condition, then
reinstall the oil drain plug securely. If necessary, replace the
sealing washer.
Oil drain plug torque:
18 Ibf-ft (25 N-m , 2.5 kgf-m)
8. Fill the crankcase with the recommended oil approximately:
2.2 US gt (2.12, 1.8 Imp at)
9. Reinstall the oil filler cap/dipstick.
10. Start the engine and let it idle for a few minutes.
11. Stop the engine and check the oil level. Make sure the oil is be-
tween the upper and lower level marks on the dipstick.
If necessary, add more oil but do not overfill.
CAUTION:
Running the engine with improper oil level can cause serious engine
damage.
NOTE:
* To protect the environment, please dispose of used engine oil
properly. We suggest you place used oil in a sealed container and
take it to your local service station for reclamation. Do not put it in
the trash or pour it on the ground.
* If a torque wrench was not used for installation, see your authorized
Honda dealer before operating the vehicle to verify proper assembly.
While reading this manual, remember:
ITY: Ill Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
116
REAR FINAL GEAR CASE OIL
Change the oil in the rear final gear case when specified by the Main-
tenance Schedule. Change the oil with the final gear case warm, and
the FOURTRAX on level ground to assure complete and rapid draining.
To change the rear final gear case oil:
1. To drain the oil, first place an oil drain pan under the oil drain plug
(Fig. 4-14).
2. Remove the oil filler cap (1) and the drain plug (2).
3. After the oil has completely drained, reinstall the drain plug.
Drain Plug Torque:
9 Ibf-ft (12 N.m , 1.2 kgf-m)
4. Fill the gear case with the recommended oil.
Rear final gear case oil:
3.0US 0z(90cm?, 3.2 imp 0z)
Recommended oil:
Honda shaft drive oil or equivalent HYPOID GEAR OIL SAE 80
Remove the oil level check bolt (3).
Make sure the oil level reaches the oil level check hole (4).
5. Install the oil filler cap and oil level check bolt.
(4)
— 7
Fig. 4-14 (1) Oil filler cap (3) Oil level check bolt
(2) Drain plug (4) Lower edge of oil level
check hole
117
DIFFERENTIAL OIL
Change the oil in the differential when specified by the Maintenance
schedule. Change the oil with the differential warm, and the
FOURTRAX on level ground to assure complete and rapid draining.
To change the differential oil:
1. To drain the oil, first place an oil drain pan under the oil drain plug
(Fig. 4-15).
2. Remove the oil filler cap (1) and the drain plug (2).
3. After the oil has completely drained, reinstall the drain plug.
Drain Plug Torque:
9 Ibf-ft (12 N-m, 1.2 kgf-m)
4. Fill the differential with the recommended oil.
Differential oil:
6.4 US 0z (190 cm?, 6.7 imp oz)
Recommended oil:
Honda shaft drive oil or equivalent HYPOID GEAR OIL SAE 80
Make sure the oil level reaches the lower edge of the inspection
hole (3).
5. Install the oil filler cap.
118
(2)
Fig. 4-15 (1) Oil filler cap (3) Lower edge of
(2) Oil drain plug inspection hole
119
ENGINE
SPARK PLUG
The
standard spark plug is: DPR7EA-9 (NGK)
or X22EPR-U9 (DENSO)
For cold climate (Below 5 °C, 41 °F): DPR6EA-9 (NGK)
or X20EPR-U9 (DENSO)
For extended high speed riding: DPR8EA-9 (NGK)
or X24EPR-U9 (DENSO)
CAUTION:
Using a spark plug of incorrect size or heat range can cause serious
engine damage.
To check and change the spark plug:
1.
2.
3.
4
120
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. 4-16) should have a flat tip and sharp edges, and
the side electrode (3) 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:
0.03—0.04 in (0.8—0.9 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.
CAUTION:
The spark plug must be securely tightened. An improperly tightened
plug can become very hot and possibly damage the engine.
—= 0.03—0.04 in
— = (0.8—0.9 mm)
Fig. 4-16 (1) Spark plug cap (2) Center electrode
(3) Side electrode
VALVES
Valve clearance should be:
0.006 in (0.15 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.
121
CLUTCH
Clutch Adjustment
To adjust the clutch:
1. Make sure the ignition switch is OFF (©).
2. Loosen the lock nut (Fig. 4-17), and turn the clutch adjuster (2)
counterclockwise until you feel slight resistance.
3. Then turn the adjuster 1/4 turn clockwise, and tighten the lock nut
to hold the adjuster in this position.
4. After adjustment, start the engine and test ride the FOURTRAX to
be sure the clutch is operating properly.
(1) (2)
Fig. 4-17 (1) Lock nut (2) Clutch adjuster
122
Reverse Lock System
Measure the reverse assist lever (2) free play. Free play, measured at
the lever (2) end near the cable (Fig. 4-18), should be approximately:
1/16—3/16 in (2—4 mm)
To adjust the free play:
Slide the rubber sleeve (3) back to expose the adjusting nut (4).
Loosen the lock nut (5) and turn the adjusting nut to obtain the correct
free play.
Tighten the lock nut and reinstall the sleeve.
Other Checks:
Check the reverse assist lever and cable for loose connections or other
damage. If the cable is worn or kinked, have it replaced by your Honda
dealer.
1/16—3/16in (1)
(2— 4 mm)
Fig. 4-18 (1) Rear brake lever (3) Rubber sleeve
(2) Reverse assist lever (4) Adjusting nut
(5) Lock nut
While reading this manual, remember:
INARI Iel Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
123
ELECTRICAL SYSTEM
BATTERY
Your FOURTRAX battery is located in a compartment under the seat.
The battery is sealed, so it is not necessary to check the electrolyte
level or add distilled water. If the battery seems weak, see your
authorized Honda dealer for information on recharging or replacement.
If you replace the battery, choose one that is sealed and equivalent to
the original. Be sure to read and follow all safety precautions indicated
on the battery.
CAUTION:
Do not attempt to remove the caps from the battery cells as this may
damage the battery.
Although the battery is sealed, it vents explosive gases and should be
handled with appropriate care.
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.
WARNING: Battery posts, terminals and related accessories contain
lead and lead compounds. Wash hands after handling.
124
Battery Removal
1. Make sure the ignition switch is OFF (O).
2. Remove the seat (page 146).
3. Remove the battery holder (1), (Fig. 4-19) 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.
* After installing the battery, check to see if the battery cables are
routed correctly.
125
(2)
Fig. 4-19 (1) Battery holder (4) Battery
(2) Mount bolts (5) Positive (+)
(3) Negative (—) terminal lead
terminal lead
126
FUSE
As illustrated in Fig. 4-20, the main fuse (1), main fuse (electric shift
motor) (2) and the sub fuses (3) are located in the battery
compartment.
The specified main fuse is:
30 A, 30 A (Electric shift motor)
The specified sub fuses are:
15A X 2,10A x 2
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. 4-20 (1) Main fuse (3) Sub fuses
(2) Main fuse (Electric shift motor)
To replace the main 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.
127
2. Remove the seat (page 146).
3. Remove the fuse case (1).
4. Open the fuse case cover (2).
5. Replace the old fuse.
6. Reinstall the fuse case cover and fuse case.
7. Install the seat.
(2)
E ID
Ш 4 NS
; |
= =a)
J 77
< JN
uy
l— N |
ZN
(4) J (3)
Fig. 4-21 (1) Fuse case (3) Spare fuse
(2) Fuse case cover (4) Main fuse
To replace the main fuse (Electric shift motor):
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.
128
Remove the seat (page 146).
Open the fuse holder cover (1).
Replace the old fuse.
Reinstall the fuse holder cover.
Install the seat.
OOTP WN
(1)
(3)
Fig. 4-22 (1) Fuse holder cover (3) Spare fuse
(2) Main fuse
To replace the sub fuses:
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.
129
2. Remove the seat (page 146).
3. Remove the sub fuse box cover.
4. Pull the old fuse out of the clips.
5. Push a new fuse into the clips and install the fuse box cover.
6. Install the seat.
(2)
(1)
ИЕ
Terre (Ir
CE REE IE a 1
[=] "1
| |
Fig. 4-23 (1) Sub fuses (2) Spare fuses
A WARNING
POTENTIAL HAZARD
Improperly replacing a fuse.
WHAT CAN HAPPEN
Serious damage to the electrical system, which could cause a fire
or a loss of lights or engine power, which could lead to an
accident.
HOW TO AVOID THE HAZARD
Never use a fuse with a different rating from that specified in this
Owner's Manual.
Do not pry the clips open to get a fuse out, as a loose fuse could
cause damage to the electrical system or start a fire.
130
BRAKES
FRONT BRAKES
This FOURTRAX has hydraulic front drum brakes on both front wheels.
Each day before riding you should check the brake lever free play and
inspect the system for fluid leaks. The brake fluid level should be
checked frequently, and the brake shoe linings should be inspected
periodically.
To check lever free play and shoe lining clearance:
1. Measure the distance the brake lever (Fig. 4-24) moves before the
brakes start to take hold. Free play, measured at the tip of the front
brake lever (1) should be:
1—1 3/16 in (25—30 mm)
(1)
1—1 3/16 in
О (25 — 30 mm)
Fig. 4-24 (1) Front brake lever
131
2. Remove the inspection hole plug (Fig.4-25) and measure the
lining thickness (2) on both front wheels.
Lining Thickness:
Standard: 0.16 in (4.0 mm)
Service Limit: 0.04 in (1.0 mm)
if either lining is worn beyond the limit, both brake shoes must be
replaced by an authorized Honda dealer.
3. If the brake lever free play and the brake shoe lining thicknesses
are within the recommended limits, reinstall the inspection hole
plugs, seating them into the inspection holes as shown in Fig. 4-24.
4, If the brake lever free play is excessive but the linings are not worn
beyond the service limit, adjust the brake lining clearance.
(2)
1
ZN,
Fig. 4-25 (1) Inspection hole plug (3) Front brake drum
(2) Lining thickness (4) Front wheel rim
While reading this manual, remember:
ATAN eN Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
132
To adjust the brake lining clearance:
1. Squeeze the brake lever firmly two or three times then release it.
2. Raise the front and rear wheels off the ground by placing a
support block under the vehicle.
3. Beginning with either the left or right front wheel, remove the
inspection hole plug (Fig. 4-25) and line up the hole with one of the
brake adjusters (Fig. 4-26).
4. Using a screwdriver, turn the brake shoe adjuster (1) in the
direction of the arrow until the front brake locks.
(1) |
Fig. 4-26 (1) Brake adjusters
5. Back the adjuster off three clicks, then squeeze the brake lever
several times. Spin the wheel manually to make sure the brake
does not drag.
6. Line up the inspection hole with the second adjuster and repeat
steps 3 through b.
7. Reinstall the inspection hole plug, seating it into the inspection
hole as shown in Fig. 4-25.
8. Follow steps 3 through 7 to adjust the other front brake.
9. Recheck the brake lever free play. If free play is still excessive after
adjusting the brake lining clearance, there is probably air in the
brake system and it must be bled out. See your authorized Honda
dealer for this service.
133
To check the brake fluid level:
Brake fluid must be added to the reservoir (Fig. 4-27) whenever the
fluid level approaches the lower level mark (1). Use only DOT 3 or 4
brake fluid and have it added by an authorized Honda dealer.
NOTE:
If the fluid level approaches the lower level mark (1), the brake system
should be inspected by your authorized Honda dealer. A low fluid level
may indicate fluid leakage. Brake failure may occur if this condition
exists and is not corrected.
CAUTION:
* To prevent damage to the brake system, use only fluid from a
sealed container. Never allow contaminants (dirt, water, etc.) to
enter the brake fluid reservoir.
+ Brake fluid can damage paint and plastic, so handle the fluid with
care. When adding brake fluid, be sure the reservoir is horizontal
before removing the cover to prevent accidental spilling.
134
Fig. 4-27 (1) Lower level mark
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.
Other Checks:
1. Make sure there are no fluid leaks.
2. Check the condition of brake hoses and fittings. If the hoses are
worn or cracked, have them replaced by an authorized Honda
dealer.
135
REAR BRAKE
This FOURTRAX has a single mechanical drum brake on the rear axle
housing. Each day before riding you should check the operation of
both the rear brake pedal and the rear brake lever. You should also
periodically check the brake shoes for wear.
To check and adjust brake pedal free play:
Measure the distance the rear brake pedal moves before the brake
starts to take hold. Free play, measured at the end of the pedal (Fig.
4-28), should be:
9/16— 13/16 in (15—20 mm)
(1)
Cy
En
= В,
|
9/16 — 13/16 т
(15—20 тт)
Fig. 4-28 (1) Rear brake pedal
136
То adjust the free play, turn the brake pedal adjusting nut ( 1), (Fig.
4-29 ), located on the brake operating rod at the rear of the frame.
Make sure the cut-out on the adjusting nut is properly seated on the
brake arm pin (3).
(3)
Fig. 4-29 (1) Brake pedal adjusting nut
(2) Brake lever adjusting nut
(3) Brake arm pin
137
To check and adjust brake lever free play:
Measure the distance the rear brake lever moves before the brake
starts to take hold. Free play, measured at the tip of the brake lever (Fig.
4-30 ), should be:
9/16— 13/16 in (15— 20 mm)
To adjust the free play, turn the brake lever adjusting nut (2), (Fig.
4-29 ), located on the brake operating rod at the rear of the frame.
Make sure the cut-out on the adjusting nut is properly seated on the
brake arm pin (3).
9/16 — 13/16 in
(15— 20 mm)
Fig. 4-30 (1) Brake lever
138
To check rear brake shoe wear:
When the brake is applied, an arrow (3) attached to the brake arm (2)
moves toward a reference mark (4) on the brake panel (see Fig. 4-31).
if the arrow aligns with the reference mark on full application of the
brake, the brake shoes must be replaced. See your authorized Honda
dealer for this service.
(2)
> \
Co
(>
7 \
Ce mi (1)
(4)
(3)
Fig. 4-31 (1) Brake lever adjusting (3) Arrow
nut (4) Reference mark
(2) Brake arm
Other Checks:
Check the condition of the brake cables. If there are kinks or signs of
wear that could cause sticking or failure, have the cables replaced by
an authorized Honda dealer. Make sure the brake arm, spring, and
fasteners are in good condition.
139
DRAINING WATER FROM BRAKES
Make sure the engine is off and the parking brake is set. Then remove
the inspection hole plug (Fig. 4-32) from the front brakes, and the drain
bolt (Fig. 4-33) from the bottom of the rear brake cover. If any water
drains, the brake seals must be replaced by your Honda dealer as soon
as possible.
Fig. 4-32 (1) Front brake inspection
hole plug
(1)
Fig. 4-33 (1) Rear brake drain bolt
140
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 vehicle.
2. Loosen the wheel nuts (Fig. 4-34) 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).
A WARNING
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.
141
NOTE:
If a torque wrench was not used for installation, see your authorized
Honda dealer before operating the vehicle to verify proper assembly.
Za
Fig. 4-34 (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. 4-35.
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.
+ A 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.
142
FRONT REAR
TIRE SIZE АТ25 X 8-12 %k AT25 x 10-12 XxX
TIRE BRAND KT401C DUNLOP KT405C DUNLOP
RECOMMENDED | 3.6 psi (25 kPa, 0.25 | 3.6 psi (25 kPa , 0.25
© PRESSURE kgf/cm?) kgf/cm?)
OO
< | MAXIMUM 4.0 psi (28 kPa , 0.28 4.0 psi (28 kPa , 0.28
5 PRESSURE kgf/em?) kgf/em?)
=
MINIMUM 3.2 psi (22 kPa, 0.22 | 3.2 psi (22 kPa, 0.22
PRESSURE kgf/cm?) kgf/cm?)
= © RECOMMENDED | 3.6 psi (25 КРа ‚ 0.25 | 3.6 psi (25 kPa, 0.25
= & | PRESSURE kgf/cm?) kgf/cm?)
Fig. 4-35 Tire specifications
- SA WARNING
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.
143
Tire Tread Condition
To check the condition of a tire tread, measure the groove depth (1)
(Fig.4-36) 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.
Fig. 4-36 (1) Groove depth (3) Wear indicator
(2) Wear indicator location mark
144
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.
145
SEAT REMOVAL
To remove the seat (Fig. 4-37), pull up the seat lock lever (2) at the
right side of the seat and lift it up.
To reinstall the seat, insert the prongs (3) into the hooks (4) on the
frame, and press the studs (5) into the grommets on the battery holder.
Press the seat down until it locks. Check that the seat is locked securely
by lifting up on the rear of the seat after reinstalling it.
(2)
Fig. 4-37 (1) Seat (3) Prongs
(2) Seat lock lever (4) Hooks
(5) Studs
146
ENGINE GUARD AND SKID PLATES
The engine guard (Fig. 4-38) protects the engine crankcase.
The skid plates (2) protect the frame and rear final gear case. Check
the guard and plates for cracks, damage or looseness at intervals
shown in the Maintenance Schedule (page 96— 97).
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. 4-38 (1) Engine guard (2) Skid plates
147
SPARK ARRESTER
The exhaust system must be periodically purged of accumulated
carbon.
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.
The use of safety glasses is recommended for this procedure.
Because of the possible fire hazard, check that there are no
combustible materials in the area before purging the spark arrester.
To purge the system:
1. Select a well-ventilated area free of combustible materials and
make sure the exhaust pipe is cool.
2. Remove the bolt. (Fig. 4-39)
3. Start the engine and rev it up approximately twenty times while
momentarily creating exhaust system back pressure by blocking
the end of the muffler with a shop towel.
4. Stop the engine and allow the exhaust pipe to cool.
5. Reinstall the bolt securely.
Fig. 4-39 (1) Bolt
A WARNING
POTENTIAL HAZARD
Improperly purging the exhaust system.
WHAT CAN HAPPEN
Could injure the eyes.
Could cause burns.
Could cause carbon monoxide poisoning, possibly leading to
death.
Could start a fire.
HOW TO AVOID THE HAZARD
When purging the exhaust system:
Always wear eye protection, and make sure no one stands behind
the vehicle.
Always let the exhaust system cool before performing this
operation.
Never run the engine in an enclosed area.
Make sure there are no combustible materials in the area.
149
DRIVESHAFT BOOTS
Check the rubber driveshaft boots (1) for damage or leaking grease. If
necessary, have your authorized Honda dealer replace them.
Fig. 4-40 (1) Driveshaft boots
150
While reading this manual, remember:
NUNES Indicates a strong possibility that serious injury or
death may result if instructions are not followed.
151
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. 4-41).
Suitable “tie downs’ are available from your Honda dealer.
Ordinary rope is not recommended because it can stretch under
load.
CAUTION:
Using tie downs in any other areas can damage your FOURTRAX.
Fig. 4-41 Points to secure (1) Front cargo rack
FOURTRAX with
tie downs
152
3
(3)
Fig. 4-42 Points to secure (2) Rear cargo rack
FOURTRAX with (3) Trailer hitch
tie downs
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
itis 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.
153
————ARNING
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.
A WARNING
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.
154
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.
155
1. Rinse the FOURTRAX thoroughly with cool water to remove loose
dirt.
2. Clean the FOURTRAX with a sponge or soft cloth using cool water.
Avoid directing water to muffler outlets and electrical parts.
3. After cleaning, rinse the FOURTRAX thoroughly with plenty of
clean water. Detergent residue can corrode alloy parts.
Dry the FOURTRAX.
Start the engine and let it run for several minutes.
Test the brakes before riding the FOURTRAX. Several applications
may be necessary to restore normal braking performance.
DR
Braking efficiency may be temporarily impaired immediately after
washing the FOURTRAX.
Anticipate longer stopping distances to avoid a possible accident.
156
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. Drain the fuel tank and carburetor. Be sure to drain the fuel in a
well-ventilated area, not in a garage.
157
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.
A WARNING
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.
158
3. Remove the spark plug and pour one tablespoon (10 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
(Я ) before pressing the starter button.)
4. Remove the battery (page 125) 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.
AWARNING
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.
5. Wash and dry the FOURTRAX, and wax all painted surfaces.
6. Inflate the tires to their recommended pressures.
7. Place the FOURTRAX on blocks to raise all four tires off the ground.
159
SPECIFICATIONS
DIMENSIONS
Overall length 77.2 in (1,961 mm)
Overall width 45.5 in (1,156 mm)
Overall height 45.0 in (1,144 mm)
Wheelbase 50.0 in (1,271 mm)
WEIGHT
Dry Weight 586 Ibs (266 kg)
CAPACITIES
Engine oil 2.9 US at (2.7 2 , 2.4 Imp at)
Fuel tank 3.17 US gal (12.0 2, 2.64 Imp gal)
Fuel reserve 0.71 US gal (2.7 2, 0.59 Imp gal)
ENGINE
Bore and stroke 3.54 x 2.68 in (90.0 x 68.0 mm)
Compression ratio 8.5:1
Displacement 26.39 cu-in (432.6 cm°)
Engine idle speed 1,400 = 100 rpm
Spark plug, standard DPR7EA-9 (NGK)
X22EPR-U9 (DENSO)
Spark plug gap 0.03— 0.04 in (0.8— 0.9 mm)
Valve clearance 0.006 in (0.15 mm)
CHASSIS AND SUSPENSION
Caster angle 3.0
Trail length 0.3 in (7 mm)
Tire size, Front AT25 X 8-12 %%
Rear АТ25 Хх 10-12 ЖЖ
160
POWER TRANSMISSION
Primary reduction 2.103
Secondary reduction 2.100
Final reduction Front: 3.153
Rear: 3.153
Gear ratio 1st 4.083
2nd 2.388
3rd 1.608
4th 1.178
5th 0.848
Reverse gear ratio 4.781
ELECTRICAL
Battery 12V—12 Ah
Generator 0.31 kW/5,000 rpm
LIGHTS
Head light (Low/High) 12 V 25/25 W X 2
Assist headlight 12 V 45 W
Taillight 12V5W X 2
Neutral indicator LED
Reverse indicator LED
Oil high temperature indicator LED
FUSE
Sub fuse 15A x 2,10A X 2
Main fuse 30 À
Main fuse {Electric shift motor) 30 À
161
WIRING DIAGRAM
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162
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.
163
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
164
WARRANTY SERVICE
Your satisfaction and goodwill are important to your Honda dealer. All
Honda warranty details are explained in the Distributor's Limited
Warranty.
Normally, any problems with the product will be handled 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.
о в о юн
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.
165
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 upper side of the rear
crankcase.
The color label (4) is attached to the frame below the seat (page 146 ).
KEY NO.
FRAME NO.
ENGINE NO.
COLOR
Fig. 5-1 (1) Key number (3) Engine number
(2) Frame number (4) Color label
166
INDEX
A
ACCESSOTies ...............eervervinrrerarecaoaraconaenecenrenererarare reee ea ern aa tern a nena 52
Accessory SOCKET... tierce cies teers eee ee eecee en cecen ner 42
Age recommendation ............mr.eeemeeeniierniee nee enero arena. 44
Air cleaner
CE 105
Housing drain tube... rere reese rene 108
Air pressure gauge..............reseveeeerriineneeee e eee enero eeceneneeeenene teme 41
Apparel, recommended... ia Ie Re DAD 54
Authorized manuals............e..e._eeeeneiiiierneec eee e ee ercer". 173
B
BattErY TE 124
Brakes
Brake cablEsS...…....….......…...crrerccerenreranrancanarenrarernansenrenerennansacen tan cen ane 139
SC na 000 134
Front brakes
Adjustment.……......…............….….….….. sanessrete sance stone sente sente sa etes De ne se ne nace Tame 131
Brake lEVEr ..……......…....…..........…erecrconransrcananviensantirrrrananren can anarenrensenneneues 33
Brake lever free Play... eee ees 131
Brake Shoes... irene rere 131
Parking brake...................— re. .eereenariercarererrererverereronacererrenanveararercaree nace. 33
Rear brake
Brake lever ..................r.evesceroiorceacarerrarareeroroetereanervareree nen ate nacen renace. 33
Brake lever free play... rrr 138
Brake pedaAl ee reer eens 33
Brake pedal free play... rca eee 136
Brake Shoes..................eresmereinererrareanereevermevereeorenevarervereanarerrerenTareTTe 139
Break-in procedures................eennnrnorieererer ee eee e erre. Il
C
Carburetor
High altitude adjustment.................... reer ee 111
Idle speed adjustment... er 110
Cargo carrying
Loading and operational guidelines................e......esenenrercere e 50
Weight limit a arre nen ene nata reese cee 49
Choke
Cable ...........e.ei.eeeraieerenieenesararnereneeceareemannevecararcereeoetcarerervanasnaveterermvenee 109
Qe] Pa 16, 109
167
ClEANING............…rerercrrrerrrrarerencersranrenssnanenrenenenrenra enter en rene ses E nee ee 155
Climbing hills ...............e.e.eeeereecerereen e RC nene Rene naceCenArUeDererrenereee. 81
Clutch adjustment.…..…........…..….…errerereeeenentenensensnnnnnannnnnnnnnnnnnn 122
Consumer information .................-—e....ee.ererre e RR RIERA. 163
Crossing slopes.................-...-+ ercer ener reee eee reee nectcereerUrnerar nacer. 90
Customer Service ..............e.ererrescicararicrcereranerrernrrereece ere eee eran 165
D
Differential Oil...................eeereeceecercenererereeneererne erre rneeerrrnUeerTrUme. 118
Digital clock .................-m.meneeercineercaneno ne nne acero nene rereeneonemenenereve recaen. 30
Dimmer switch .................esmeercacersirariereriererveneeeee reee re eremarenarennrenanerecmane. 21
DipstiCk .............ermm..eeeeiorerern enero enrneronranorTecareEDeFONONaNO NON FUCNeNUCNUCmUNCes 37,112
Display (see Multi-function display) ….....…....……rrrerrencenneenesennnenennn 24
Driveshaft boots...................eeeeeessiirecerereneareree re reee nee reee 150
E
Emergency gear selection & operation .………….......………sserirrersseneenmesnstesn 73
Emission control SYSTEM …............….....csrerenressementensar cree mere arme na rennes 163
Engine
Idle speed adjustment... rre nene aee eee. 110
Break-in procedures.................erereeccerccccerni rene D ere eee nene enero il
Flooded engine.............e...emverereenereernr narrar anar nee re rTereeee menea eanenororenee. 70
Starting the engine..............—-.-———--.e==meeeeereene enn ena ce aereo eas 67
Engine guard and skid plates ..............................e.eesmeeivererarrenererrecrenvee 147
Engine oil
Changing Oil... ese net 114
Checking oil level and adding Oll...................e....eeeseneacenoicc eee Dee 112
Oil filler cap/dipstick...............rercersresserenrentenereneene RA 37, 112
Oil filter .............. ce _.ecenieroveecerercercacerren errar rene reee rarcenare nene arre nTenDes 114
Oil high temperature indicator .................=.........eeeeeercecerore ere 22
Recommendations ..............e.-re==-eeem=íicereicerein recen ere serre senc nene 113
Engine stop SWitCh.........----__.eeseserereenerar reee ener ree er ce rerTeD. 15
Exhaust system
O1 101101 re neen e as ar ere n mn erencencem teen ren came ere Vanne 47
PUFGING......….….…......rerensonsermensentenensessaneresesrererenenece ecran ce te sert c Are ne teen 148
168
F
Final gear case 0 11 EU 117
Flag pole bracket.….…..….....…......…......crcrresrarsirnraneeneecrneareneananrenensnenenten sen en rene 39
Flooded engine .................e.eeeceeeeerreerier eee ee ene ere areee ree neaneareree pen reecme 70
Fuel
Fuel fill cap................essurereiriierereare recae ce nene er near racer 35, 100
UTC Be FTF oO mare 34
Fuel recommendations... rr creer 102
Fuel tank Capacity courier eters e reese seem emmn eras 100
FUBI VaIVE certs erase ease res neanseans 36
High altitude fuel mixture adjustment ...................... rre ns 111
A ere ene e nereneenn ena erenenrnaereneenan rr anererrUre 100
Reserve fuel supply.................er2eemme2iiierriie ie RI DR II IR TÉE IR II III IR IRRADIA 36
Fuses
LOCATION O 127
Replacement, main fUse ..............e-....esvecenvrerioeconcene een eee 127
Replacement, main fuse (Electric shift motor)... 128
Replacement, sub fUSes...........e.....veee20sariiencereacar nene ee eee Rei 129
G
Gear change tool....................—.....eneerereeeecercernanac erre encee ce nenenee ener. 74, 99
Gasoline (see Fuel)
Gearshift switch
DOWNShIft SWITCH cu. errs ere rns 31,71
Upshift SWITCH een rrr eras 31,71
GeaArSNITING EN 31,71
Gearcase oil
Rear final gear case Oil..................erereieirrivicer errr 117
Gear position indicator .............e.-e.........2ererresecerriie DI II essa sera O 27
H
Headlight switches..................e..svevececerivancerrvire Re Rea eee eee 21
Helmet holder....................e.ererereecercernercere en RR RT aba babar 38
High altitude fuel mixture adjustment…….……....…......……rrersrserenencasannes 111
Hills
Riding across SIOopes ...............er=.ereesvacerrscecenearecenee eee arena eee reee 90
Riding down Rills..............._.ere==.esiverereacarecarereeea rre reeeeoeorereenerr ee. 88
Riding up hills..................——.eeereiiere riera erre rr rene creer as 81
Stopping on hills ...............e=ereremsuierrerenerare reee eee era rue 83
IPT oT] a¥e lod I=] eo] oT J0 carecer recen 91
Hourmeter ..............._.esiicascacarareccernanercaracoccarreverarre o renare ren rarar ener reee 29
Idle speed adjustment aan. rennen nr RD 110
IgNItioN SWILCH cc. A Ren ene e erncae can eee 14
Indicator
Gear position indicator ....................=...e.e. eee RD 27
Neutral indicator.................eee. re. .ereesmerrriirrercer erre enc Deere. 22
Oil high temperature indicator .....................ereremrererere een nee nnenes 22
AY = 01 16 [167-1 Co] rare oe einer ner reee. 22
Inspection, pre-rid@..….....…....….…..…....…ceeeneeecennmmnsnnnnnnnnnnnnnmnnnnnnnnnmnnnnnmnn 46
L
Loading
Loading guidelines and procedures....................2.-=esnieermene 50
Weight limits..................erexreerernerenneeren econ Ne ee enearenerenne recente. 49
Lubrication
(see Engine oil, Gear case oil and differential oil)
M
Maintenance
Precautions ..................—..esermecercerercoverreneranece re Der rn nerarnanerorenenenercacnane 98
Schedule ..............e..eevercoriricerecacerecenereee ene rarerTere e rereecanenerernerenenerereaTe 96
Modifications .............-......e.eeesverercererceneeocare rar nrraaria en ne nectar catar Dareeee 54
Multi-function display ...........---—....e.-.esexarreserorereenenoernanenene tere nenatancenene. 24
N
Neutral indicator ..................=rverereececiirerer rr cercare cenreraer nece erreneeeees 22
Noise emission control system.............e=.....ermeerraccorcirenernnenee econ ere 163
O
Obstacles, riding OVéer.................----===ieimerseoriecarcacarererornenacanerrarerrernerrecece 92
Odometer ............e..........ieciermicicorerreceneaceoracereneenerenence nn re nran ener ener Dare. 28
Oil (see Engine oil, Gear case oil and differential oil)
Oil filler cap/dipstick ..................-.eeeereiieeerieeee rene rec rece rater se nee 37,112
Oil filter, changing...............--—=r=e====erireererercececce cer aer De rer eran tere nnene reee. 114
Oil high temperature indicator... iii, 22
Owner's manual compartment.................---.e.e.....eerecececernene nera 41
170
A tate enna ae ee ees 94
Parts location.....................rereccecercere rei ee e reee nee ere arar ear re 10
Parking Drake. eee eerie rarer anne 33
Passenger carrying ..............e=Ñveeeecereveceroirerornener e renearo Eee DerarEne reee enero. 56
Pavement, no riding on ..................veerereereeze e e ere Re eee eee eee 58
PINging........... e... me reerrireceea inananarenTenennenen erre narenerveme arena enema name neam eones 102
Pre-ride INSPECtION ...............…rrrrerrenceneersensenenransara sacre nan ananas 46
R
Rear final gear Case Oil .….…..….…..….......rrrrereanenmrnsrenennassennreeannensennennenenaanees 117
RECOII Starter …....…..…...........…rcccrrrrrensenae sara nm aarrenaanane sara ne manan ea nen en Dana ne Aa nanas 19
Reverse
ASSIST CADE cco TT 123
ASSISTIEVES iii eee erie ee sea serene rman 123
Gear, shifting into..................—e..recerercerei reir Dee RR Re 31,71
Indicator............. RKRRERRRKKARREREREEKKRERKARKRKRRRARARERKERARKERAKRRRRRKELEKERG 22
Riding in reverse .................-.eserrariarrrneenacerecennee no rior reee. 76
Selector knob............e.....r.eserrerireirenrnr enana nene ernee ee ererrerreenerTea 32
Rider training course ..................eveniceeeeei R RAR ERKRRKREREEREEDEBRRKKERRREKAEG 1, 46
S
Safety messages, SpeCaAl rr 1
Seat removal and installation ..........ccoviiiiiiiiii een 146
Serial numbers and color label .....................e....e.emmemmeno rere 166
Shifting gears ..................resecenenrececcener e een er erreneererrrrrEenenreTarEEN. 31,71
Switch
Downshift SWItCh ..….........…..rersressessa ca csan san nra nan ean cena una care ra an nanas 31, 71
Upshift SWitcCh............e=..ereceeeeneororarerene eres re rear nenoarerreracenorerEErenON ra 31,71
Skid plate J RUTTER 147
Skiddin Orr reeeescr errr reese rer res erases eres rasa rere sr arr sees 80
Socket, ACCESSOrY ities rrr rere seer seta cesses serene 42
Spark arr@stEr.….……..........…rerrierenssarererencersensenenessanancenenn amener rene na ananas annees 148
Spark KNOCK .....…........….osereccorrececennransrranansaresenanenrenmaseneama ER eercarEeEm a 102
Si rene ere rene Re einer neta erre 120
Specifications.............ee.....re_eseereierrercecerreranrere rre ereare recaen rrrnenean eran. 160
Stalling On à hill... cosserrrererasssrrenaanne nada ue annee aan een aaa nana aa anna nana 83
Starter DUTTON …....….......………erccecceccrrenerrenrensanararenrenennrananrrrananensana ee sean an sance 17
Starting primer KNOD.........…...…...ercrersssserarnanarenren<arananrn anse nvan anse ace man RI III 18
Storage COMpartment.….…....….....…..vrererenserenreneanirennanssnave nano area mareeanee name 41
Storing procedures ...............ree.eeecierieieizerorneeurer nr enero cerenerereenenrecemes 157
T
Throttle
CADE NT 104
LE VOTE RE RERRERTRRRRRKRRRARAKKRRRARARARARRARAKRARARKREREREARRUAUEREEREKUEUEG 20, 104
Tires
Inflation and air pressure .....................esmiserermeie re eee ne 142
Repairing..............—._.eserereereeeerearieeren ene eraser rrr rar rere rear serra 145
Specifications ...................eserererierreeere RR IRON RD RD Ree ees 143
Tread CONGItION .…................crrsssererrsenrenencencanaanenerrer en serre rere Ne 144
TOO Kit.…........….evreccrerecerarennaseneen rence anse ren aee ana sae een arece mm sace nana ce Dane a ace c Ven 99
Trailer hitch ...........e.......eee.ssriermereeer reee rene nene Der cearecanececarenenereenenene 40
Trailer towing
Operational guidelines.…....….….........…..….…rreserserserrencenceneenasrenerne rene eee 50
Weight limitS..................ssorcermeniarennensnsa nr asanrne msn anrene es sas sens a dA nec ec can e 49
Transporting procedures..............e.er.eeeeeerereriiie III III III IEA 152
Tripmeter.................emerineeeeorerernerernenenen enana nene rrrennennemene ena nTEnANANNeNeNemenerevna 28
Turning
OU ere mea me ne 0eme 78
OS 91
V
Valve clearancCe .................esrecececcerreiceiorererrereare eran rene rareanacarecanereanDee. 121
W
Warning labels coor ncenerenerarmene ena ecoarenee 7
Warranty SerViCé ..............——_erecennereroricenzier encore nee ceca estate eternos 165
Water
Draining from brakes ....................-.....rererereeenenener ener rene ere name neue 140
Riding through... corres ern 93
Weight limits coerce 49
Wheel removal... coerce eres essere eee semester eens 141
Wiring diagramM 0 UOTE aan 162
172
AUTHORIZED MANUALS
The Service Manual (Publication Item No. 61HN003 ) 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 motorcycies, 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”
61HN003 2001 TRX450S/ES Service Manual $40.00
61CM001 Common Service Manual $48.00
31HN0730 2001 TRX450ES Owner’s Manual $16.00
“Prices are subject to change without notice and without incurring obligation.
Also available in Spanish:
Publication tem No. Description Price Each”
65HN001 2001 TRX400FW/TRX450S/450ES $60.00
Service Manual
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174