Honda TRX 350FM Offroad Vehicle Owner's Manual

2000 TRX 350FM HONDA FOURTRAX 350 4 X4 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 information 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. 1999. No part of this publication may be reproduced without written permission from Honda Motor Co., Ltd. CONTENTS Page FOURTRAX SAFETY …..........……rrconvirenmrrerensenene an nrenmeren sente mare s annee nca nca n annee 1 Special Safety Messages .…..…..…...…..…..…..…-crcenessasersanrenanensaceceneneren reer 1 Warning Information.........e cies creer eee errr eae 6 PARTS LOCATION AND OPERATION ............emnereracrrenaronearenornenenanecanaeee 10 Parts Location ................_.....——_esesreicenerrerencainer eran enero nearenare ecc anen een 10 Parts Operation...........eenereceererererreccarecrerneereror ene nernrecrarnenerernrE tren eareAs 14 Power Controls ................es=esrrescareirerereere rec ereene ar eeearance nana ass a nee ree 14 LIghts........e....erereceneoencrermonenaroreaveane terme nene enema nene nero anannanen nen vnanEn NEC 21 Gearshift Controls... vuoi errr caer ra rans 29 Brake CONtrOIS...…....…...…rrcrraarrraneasennarencarrrccaneneecsana nana ee aan nec sren sean 31 Fuel Tank Controls …........…..rsseareserrenerensrecaree core cesanresnen san e sance seems 32 Engine Oil... na enr rrarasarente cer ree 35 Additional FEatUres ….…....…......….crirerersencrnrarcennreatasrerennanne nas re ane ren emma 36 RIDING YOUR FOURTRAX........... nee. eeeecarcenerereerereeeoeoenerneneemenrnererrenmanan. 42 Before Riding..................ee.ceesererecererercecaceaencereereneatrr een ne rear reee 42 Rider Preparation.…..…....…....…....…..rrcirercsrrconirensencasaressenessen career cena ena 42 Vehicle Preparation …......….....…..cucsersricseeserentenerenra sert enra sen sienne etre mec nn 44 Safe Riding RUl@S........…..……crrerconrarenenernnensacenraneccassane ner ann sea ren n ann 000 52 Rider ner eee oc rene ce ea san annee sara etes anse cen ONE n VE ce CEE 64 Starting the ENGgin@ ….….....…..…....…...cerserenasranensaranerennere nec eunen rares es sara ees 65 Shifting Gears ........................=ricerercacareracineoseriveraenerere ener en renace nes 69 Riding in Reverse.................e_e.ímececereerniancarerennearerorcero venere eneree enc. 70 Making Turns ..............e=e=ve.esereescererorerornacarerneranrerm rene venere nenee acen 72 Riding Up Hills ................e..2e.2eesevenrerrecencenar ene rcerarerarerane nene rnereneeeeo. 75 Riding Down Hills ................e.esmeseermenerere rs 82 Crossing Slopes ...............eeesesarceereinrrerareeneter erre cererarrerer care reatenereED eee 84 Making Turns on Slopes... cee, 85 Riding Over Obstacies.................e.eeee...22eenererreerer een enen Dee ee e. 86 Riding Through Water... rire 87 РагК!Ипд......ееееееееееенеенннннннннненненеенененннненненннннненнененннненненннненннееннноое. 88 (cont'd) CONTENTS Page MAINTENANCE AND REPAIRS..............ee.eeiorenerrerierorzerorceareorer near 89 Emission Requirements...................r..esevenervenorcereeconceneneranonentenrenanences 89 Maintenance Schedule ...............e.e..ecccarorerzenacre recen reaeo nera oe san 90 Maintenance Precautions ..................rree=íeíiierírerrca eee DDR 92 |. TT 93 Fuel System reece rere rere seer sree eran 94 LU DT CAT ON cece eee eee eee eee eee eee eee etree etree mete eee ratte treater era eneneen 106 ENGINE coer rere errr eer e reese ans 114 (6117) (0: O 116 Electrical System... rere erence reese serene rene 118 ST GE 125 Wheels and Tires.….…....….….....…...erccr resserre area rene r eee r a sea een aa ea a 135 Seat Removal .............e.e...remirereaenera ana anananernevera anar ae araratoavaTeTeVemaeneTeTe 140 Engine Guard and Skid Plates ....................ece.ereemeeeereeecienia inicie 141 Spark Arrester ………..…...........…errerreerenecenanena rer ern en rene rares area een eee nee mena 142 Driveshaft BOOtS ….…..................sccacscs caca cars naanons sas a se nana anne ane na naar ana à 144 TRANSPORTING YOUR FOURTRAX ....rrsrorrorenensensennan can annrranmanensa es 146 CLEANING YOUR FOURTRAX ….…............Lccsrsaesa es era aa nanas ans s ana na nan cannes 149 STORING YOUR FOURTRAX eee sera a rare ne aa aa caen nan na ne nana ne 151 SPECIFICATIONS er vé rene rrar cer area rare nee nee an sera a a can ee a nana aa sa ea 154 WIRING DIAGRAM .…..…..….....crrrcseca cree s eee a rene canne na nanas en anna nane sn n nan ane nca sa nee 156 CONSUMER INFORMATION... .……sr+srsenonenrerrenenrenrenaanenesena mena tenant nee 158 WARRANTY SERVICE..........….….rcrrerca near aan aa en een ane san ere sa casa nanas ananas 160 SERIAL NUMBERS AND COLOR LABEL... irene nese 161 INDEX teint eter seat se aea een ease een ta saasasaenenssnsnenssssnessenensensnsnsensnsnnensaransns 162 AUTHORIZED MANUALS .….....…resessenennenererennsensense semer ane ntane sam an arm aan an nue 169 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 maintenance 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 operating the ATV. + Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. * Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. * Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. * Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed. + Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. * Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible. * Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount and follow the procedures provided in this manual. * Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles 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 accessories. * 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). 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 e No > A WARNING 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 GEAR NO OPERATOR UNDER AGE 16 NEVER operate : e without proper training er instruction. #at spseds too fast for your skills or the conditions. ® on public roads - a calllsion can occur with THIS CATEGORY U (UTILITY) ATV IS FOR OFF ROAD USE another vehicis. ONLY. IT IS MAINLY FOR UTILITY USE BUT IT MAY ALSO e with a passenger - passengers affect balance BE USED FOR GENERAL RECREATION. and steering and increase risk of losing control. ALWAYS : TRAINING COURSES TO TEACH ATY RIDING SKILLS ARE * use proper riding techniques to avold vehicle AVAILABLE.FOR INFORMATION CONTACT YOUR DEALER. overturns on hills and rough terrain and in turns. @ avoid paved surfaces - pavement may seriously affect handiing and control. CHECK WITH YOUR DEALER TO FIND OUT ABOUT READ THE OWNER'S MANUAL STATE OR LOCAL LAWS REGARDING ATY OPERATION. FOLLOW ALL INSTRUCTIONS AND WARNINGS. « j THIS HANGTAG IS ХОТ ТО BE RZNOVED BEFORE SALE — | AWARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in MY SEVERE INJURY or DEATH. L ) | y =) RR ZA, IZ = FE ><> ZZ Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. improper tire pressure or overloading Never exceed the maximum front cargo limit can cause loss of control. of: 66165 (30kg). Loss of control can result in severe injury or death. Refer to instructions in the Owner's e Cold tire pressure, Manual. Front : 25+3kpa 0.25+0.03kgf/cm 3.6+0.4psi Rear | 25+3kpa 0.25+0.03kgtem 3.610.4psi ® Maximum weight capacity ; 220kg 485ibs. VASE Operating this ATV if you are under of severe injury or death. NEVER operate this ATV if you are ALWAYS USE NEVER USE NEVER CARAY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE EAR NEVER operate e without proper training or instruction, {+} ® at speeds too fast for your skills or the conditions. ® an public roads - a collision can occur with another vehicle. e with a passenger - passengers affect balance and steering and increase risk of Josing control. ALWAYS: * use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. ® avoid paved surfaces - pavement may seriously affect handling and control. BREAD THE OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. BRAKING INFORMATION With four-wheel drive operating any brake control causes braking at both the front and rear wheels. For detailed braking information, refer to the Cwner's Manual. the age of 16 increases your chance under ageif . —— Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum rear cargo limit (combined weight on the rear rack and in the storage area)of: 133Ibs (60kg}. Refer to instructions in the Owner's Manual. Towing an improperly loaded trailer can cause loss of control. ® Read owner's manual. Oe Tow weight limit: 3776N (385kgtf] 8501bs Tonque weight: 137N (14kgfl ° ong 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 (3) Reverse selector knob (4) Choke knob (5) Fuel gauge (6) Ignition switch (7) Throttle lever (8) Front brake lever (1) (2) (3) (4) y 7 (7) (8) = EN ДПО Fig. 2-1 Handlebars, from rider's point of view 10 (9) Flag pole bracket (10) Rear cargo rack (11) Seat lock lever (12) Fuel fill cap (13) Front brake fluid reservoir (14) Helmet holder (15) Front cargo rack (16) Recoil starter (behind the recoil starter cover) (17) Right footpeg (18) Rear brake pedal (19) Dipstick (20) Headlights (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) Fig. 2-2 Right side of FOURTRAX 11 (21) Accessory socket (22) Fuel valve (23) Starting primer knob (24) Storage compartment, containing: Tool kit Air pressure gauge Owner's Manual (25) Oil filler cap (26) Gearshift pedal (27) Left footpeg (28) Trailer hitch (22) (23) (24) Fig. 2-3 Left side of FOURTRAX 12 Multi-function Display (Canadian model only) (29) Reverse indicator (30) Neutral indicator (31) Oil high temperature indicator (32) Multi-function display e Speedometer e Odometer/Tripmeter ® Digital clock/Hourmeter (33) Minute select button (34) Hour select button (35) Hourmeter/Digital clock select button (36) Odometer/Tripmeter select button (29) 30) (31) » à Xx Е = PF A | 1 (35) Je \ (32) Fig. 2-4 Indicators and multi-function display, from rider's point of view PARTS OPERATION POWER CONTROLS Ignition Switch The ignition switch (Fig. 2-5) is in the center of the handlebars directly in front of the seat. (1) | QQ 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 can be turned on. The key can- (1) not be re- With the engine stop switch at moved. RUN (©) and the transmission in neutral, the engine can be started. 14 Engine Stop Switch The engine stop switch (Fig. 2-6 ) is next to the left handgrip, and it has three positions. When the switch is in the RUN (©) position, the engine will operate. When the switch is in either OFF ( 5% ) 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 (53), be sure to turn the ignition switch OFF ( © ) to prevent battery discharge. (1) Fig. 2-6 (1) Engine stop switch 15 Choke Knob The choke knob (Fig. 2-7) is located on the left side of the handlebar. 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. Fig. 2-7 (1) Choke knob (A) Fully ON (B) Fully OFF 16 Starter Button The starter button (Fig. 2-8) is below the engine stop switch. To start the engine, press the starter button (1), with the transmission in neutral, the ignition switch ON ( | ) and the engine stop switch (2) at RUN (©). Fig. 2-8 (1) Starter button (2) Engine stop 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. 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. 4 Unsnap and remove the recoil starter cover (2). Grasp the starter grip ( 1) firmly, then pull it out slowly approximately 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. (1) Fig. 2-10 (1) Recoil starter grip (2) Recoil starter 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 throttle. When pressure is released, spring tension automatically closes the throttle. Fig. 2-11 (1) Throttle lever (A) To open the throttle 20 LIGHTS Headlight and Dimmer Switches The headlight and dimmer switches (Fig. 2-12) are above the engine stop switch, next to the left handgrip. Turning the headlight switch (1) ON (3%) turns the headlight on. Use the dimmer switch (2) to select either high beam HI (ZD) or low beam LO ( £0). (1) — > (2) > SA > Cr - 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 switch is ON ( 1 ). 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 U.S. model Canadian model (1) (2) (3) E 179) D) Fig. 2-13 (1) Reverse indicator (3) Oil high temperature (2) Neutral indicator indicator 23 Multi-function Display (Canadian model only) (Ref. No.) Description Function {1) Multi-function display The display includes the following functions. (А) Speedometer Shows riding speed. (B)] Odometer Shows accumulated mileage. (page 26) Tripmeter Shows mileage per trip. (page 26) (C)| Digital clock Shows the time (hours and minutes). (page 28 ) Hourmeter Shows hours and tenths of hours of engine operation. (page 27 ) (2) Odometer/tripmeter select button Selects display of the odometer or tripmeter. Resets the tripmeter to zero (0). (page 26 ) (3) Digital clock/hourmeter select button Selects display of the hourmeter or digital clock. (page 27, 28) (4) Hour select button Advances the hour displayed by the digital clock. (page 28 ) (5) Minute select button Advances the minute displayed by the digital clock. (page 28 ) / (2) PR — (3) (4) (5) Fig. 2-14 24 Initial Display (Canadian model only) 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) RDAEA к BE") H 558888n (елке) (578) D Fig. 2-15 (1) Multi-function display 25 Odometer/Tripmeter (Canadian model only) Odometer When selected, the odometer (1) (Fig. 2-16) registers total distance traveled in kilometers while the ignition is ON ( | ). To change the display (2) from tripmeter to odometer, press and release the Odometer/Tripmeter select button (3). [ono/TRIF] [8/0] (5)(w) (3) Fig. 2-16 (1) Odometer (3) Odometer/Tripmeter select button (2) “ODO” display (2) Tripmeter When selected, the tripmeter (1) (Fig. 2-17) 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. Fig. 2-17 (1) Tripmeter (3) Odometer/Tripmeter select button (2) “TRIP” display 26 Hourmeter (Canadian model only) When selected, the hourmeter (1) (Fig. 2-18) 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). erm) (228) (A f (3) Fig. 2-18 (1) Hourmeter (3) Hourmeter/digital clock (2) Hourmeter mark select button 27 Digital Clock (Canadian model only) When selected, the digital clock (1) (Fig. 2-19) shows the time while the ignition is ON ( | ). To change the display from hourmeter to digital clock, press and release the hourmeter/digital clock select button (2). Fig. 2-19 (1) Digital clock (2) Hourmeter/digital clock select button Digital Clock Adjustment: Turn the ignition switch ON ( | ). Press and hold the hour select button (1). After two seconds, the hour display will begin advancing automatically. Release the button when the display reaches the desired hour (2). Press and hold the minute select button (3). After two seconds, the minute display will begin advancing automatically. Release the button when the display reaches the desired minute (4). (2) DO (1) Fig. 2-20 (1) Hour select button (3) Minute select button (2) Hour (4) Minute 28 GEARSHIFT CONTROLS Gearshift Pedal The gearshift pedal is near the left footpeg. One full stroke of the pedal shifts the transmission to the next higher or lower gear in the shifting sequence (Fig. 2-21). The pedal automatically returns to the horizontal position when released. Your FOURTRAX has five-forward gears (1, 2, 3, 4 and 5). To upshift to a higher gear, put the toe of your boot under the gearshift pedal and raise the pedal one full stroke. To downshift, step on the gearshift pedal and depress the pedal one full stroke. (For further operational instructions, see page 69.) UP SHIFTING SEQUENCE ( To reverse: use reverse selector knob DOWN SHIFTING SEQUENCE Fig. 2-21 Gearshifting sequence 29 Reverse Selector Knob The reverse selector knob (Fig. 2-22) (1) is on the rear brake lever. To shift into reverse, first bring the FOURTRAX to a complete stop and make sure the transmission is in neutral. While pushing the reverse selector knob (1) in, squeeze the rear brake lever (2), then depress the gearshift pedal. CAUTION: Bring the FOURTRAX to a complete stop before shifting the transmission into reverse. If the transmission is shifted into reverse while the vehicle is moving, the transmission will be damaged. (2) (1) Fig. 2-22 (1) Reverse selector knob (2) Rear brake lever 30 BRAKE CONTROLS Front Brakes The front brakes are operated by squeezing the front brake lever, near the right handgrip. Rear Brake The rear brake is operated either by depressing the brake pedal or by squeezing the rear brake lever (Fig. 2-23). 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. Fig. 2-23 (1) Rear brake lever/ (2) Lock lever Parking brake lever (A) To lock 31 FUEL TANK CONTROLS Fuel Gauge The fuel gauge (Fig. 2-24) (1) shows the approximate fuel supply available. At F (Full), the fuel tank capacity including reserve is: 3.43 US gal (13.0 2, 2.86 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: 0.85 US gal (3.2 2, 0.70 Imp gal) (2) (1) (3) A {IF i) ml / S Fig. 2-24 (1) Fuel gauge (2) Gauge needle (3) Red band 32 Fuel Fill Cap After refueling, be sure to tighten the fuel fill cap (Fig. 2-25) until it clicks. Insert the breather tube (2 ) into the handlebar cover hole (3). To refuel refer to page 94 . (1) Fig. 2-25 (1) Fuel fill cap (2) Breather tube (3) Handlebar cover hole 33 Fuel Valve The fuel valve (Fig. 2-26) is on the left side of the fuel tank, and it has three positions: OFF When the fuel valve is in the OFF position, fuel cannot flow to the carburetor. Turn the valve OFF whenever the FOURTRAX is not in use. ON When the fuel valve is in the ON position, fuel will flow from the main fuel supply to the carburetor. RES When the fuel valve is in the RES position, fuel will flow from the reserve fuel supply to the carburetor. Use the reserve fuel only when the main supply is gone. Refill the tank as soon as possible after switching to RES. The reserve fuel supply is: 0.85 US gal (3.2 2, 0.70 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 94—97. ON RES RES RES OFF © OFF ©) FUEL À FUEL — ON ON Fig. 2-26 (1) Fuel valve 34 ENGINE OIL Dipstick The dipstick (Fig. 2-27), on the right side of the front crankcase cover, is used to measure the oil level. The oil should be checked each day before operating the FOURTRAX and maintained between the upper level mark (2) and the lower level mark (3). For oil recommendations and instructions on checking, adding and changing oil, see pages 106 — 110. (1) Fig. 2-27 (1)Dipstick (2) Upper level mark (3) Lower level mark While reading this manual, remember: Indicates a strong possibility that serious injury or death may result if instructions are not followed. 35 ADDITIONAL FEATURES Helmet Holder The helmet holder (2) (Fig. 2-28) 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. 2-28 (1) Handlebar (2) Helmet holder A WARNING 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. 36 Flag Pole Bracket The flag pole bracket (Fig. 2-29) 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. (1) Fig. 2-29 (1) Flag pole bracket (2) Optional flag pole 37 Trailer Hitch The trailer hitch is located on the rear axle housing. As illustrated in Fig. 2-30 , 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 47 — 49. 0) NN: Ds (2) UT | 1 a Fig. 2-30 (1) Trailer hitch (2) Trailer hitch ball 38 Storage Compartment The storage compartment (1) (Fig. 2-31) is below the rear cargo rack (2). To open the compartment, unhook the rubber strap (3). The owner's manual (4), tool! kit (5), and air pressure gauge (6) should be stored in the storage compartment (1). Be careful not to flood this area when washing your FOURTRAX or riding through water. Fig. 2-31 (1) Storage compartment (5) Tool kit (2) Rear cargo rack (6) Air pressure gauge (3) Rubber strap (7) Owner's manual bag (4) Owner's manual 39 Accessory Socket The accessory socket (1) (Fig. 2-32) is attached to the left side of the front fender (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 121— 123.) 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. Fig. 2-32 (1) Accessory socket (3) Cap (2) Front fender 40 While reading this manual, remember: NANI Indicates a strong possibility that serious injury or death may result if instructions are not followed. 41 RIDING YOUR FOURTRAX This part of the Owner's Manual discusses how to ride your FOURTRAX safely. Please review the special safety messages on pages 1—5 . While reading this manual, remember: Ze 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. 42 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. 43 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. A WARNING 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 106— 110). Check for leaks. 44 O ON 10. 11. 12. 13. _ Fuel level, Fill the fuel tank when necessary (pages 94—97 }. Check for leaks. Brakes. Check operation. Make sure there is no brake fluid leakage. If necessary, adjust free play (pages 125— 134). Tires. Check condition and pressure (pages 136— 138). Throttle. Check for smooth opening and closing in all steering positions. Headlight and headlight dimmer switches. Check for proper function (page 21 ). Engine stop switch. Check for proper function (page 15 ). Driveshaft boots. Check for damage (page 144). Nuts, bolts, fasteners. Check the wheels to see that the axle nuts are tightened. Check the security of all other nuts, bolts and fasteners. Steering. Check that the wheels turn properly as you steer the handlebars. Cargo. Check that all cargo is properly secured. Underbody and exhaust system. Check for, and remove, any dirt, vegetation or other debris that could be a fire hazard or interfere with the proper operation of the vehicle. Air cleaner housing drain tube. Check for deposits in the drain tube. If necessary, clean the tube (page102) and check the air cleaner case. GNC 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. 45 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 137). 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. 46 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 Ibs (220 kg) maximum (Combined weight of the rider, all accessories and all cargo) Front cargo rack weight limit 66 lbs (30 kg) maximum Rear cargo rack weight limit 133 Ibs (60 kg) maximum Tow weight limit 850 Ibs {385 kof! (Combined weight of the (3776 N) maximum trailer and all cargo in the trailer) Tongue weight = 30 lbs {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) 47 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. XD Do not place cargo anywhere on the FOURTRAX other than on the front and rear racks. Otherwise, operating stability may be adversely affected. Never ride with a passenger on the front or rear cargo racks. The FOURTRAX is not designed to carry a passenger. Do not tow another vehicle or a trailer with a rope or cable attached to the rear rack. Use the trailer hitch. Load cargo on the rear rack as far forward as possible. Make sure cargo on the front rack does not interfere with handlebar move- ment. Do not allow cargo to extend beyond the edges of either the front or rear racks. Make sure all cargo is secured before riding. When towing a trailer, take care to maintain balance and stability. Distribute cargo between the front and rear of the trailer to obtain the recommended tongue weight. NOTE: Tongue weight can be measured with an ordinary bathroom scale. Place the scale under the tongue, using either a tongue jack or other support to keep the trailer level. 8. 9. 10. 48 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. POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling, stability and braking which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load limits for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Use extra care when operating on hills and riding over obstacles. Never cross a slope when pulling a trailer. Always follow the instructions in this Owner's Manual for carrying cargo or pulling a trailer. 49 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, steering 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. 50 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: IVT: el Indicates a strong possibility that serious injury or death may result if instructions are not followed. 51 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. 52 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. 53 No Passengers This FOURTRAX is designed as an operator-only 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. A WARNING 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. 54 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. 55 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. A WARNING 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. 56 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. A WARNING 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. 57 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. 58 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. 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. 59 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. 60 No Stunts When riding, you should keep all four wheels of your FOURTRAX on the ground. Avoid “wheelies,” jumps and other stunts, as they could cause loss of control. POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off. Fig. 3-5 Never attempt wheelies or other stunts. 61 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 sometimes difficult to see obstructions.) Fig. 3-6 Be alert for changes in the terrain. AWARNING 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. 62 Never ride past your limit of visibility. Maintain a safe distance between your FOURTRAX and other off-road vehicles. Always exercise caution, and use extra care on rough, slippery and loose terrain. Fig. 3-7 Use extra care on rough terrain. POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. 63 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. A 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. 64 STARTING THE ENGINE Preparation 1. Select a level surface and lock the parking brake (page 31 ) 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. (2) (1) RES OFF ) FUEL À ON HoH в (#76) D Fig. 3-8 (1) Fuel valve (3) Engine stop switch (2) Ignition switch (4) Neutral indicator 65 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. Fig. 3-9 (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. 66 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). Fig. 3-10 (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 wall lubrication and shorten the life of the engine. * Do not race the engine during the warm-up period. Racing a cold engine wastes fuel and increases engine wear. 67 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 ( XX ). 2. Push the choke knob 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 page105). 68 SHIFTING GEARS After starting the engine and letting it warm up, follow these procedures: 1. With the transmission in neutral, release the parking brake, but continue squeezing the rear brake lever. 2. With the throttle closed, raise the gearshift pedal one full stroke to shift into 1st (first) 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 raising the gearshift pedal one full stroke. 5. Repeat this sequence to progressively upshift to 3rd, 4th and 5th (top) gear. 6. To downshift, reverse this sequence. Remember to close the POTENTIAL HAZARD throttle each time you shift to the next lower gear. Shifting gears without releasing the throttle. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always release the throttle when shifting gears. 69 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 procedures: 1. 2. 3. 4 Be sure there are no obstacles or people in the way. While pushing the reverse selector knob in, squeeze the rear brake lever, then depress the gearshift pedal (page 29). Release the rear brake lever. Open the throttle gradually and ride slowly. Do not open the throttle suddenly or make abrupt turns. To stop, close the throttle and gradually apply both the front and rear brakes. Do not abruptly apply the rear brake by itself. To shift out of reverse and into neutral, raise the gearshift pedal one stroke. While reading this manual, remember: ANDE Indicates a strong possibility that serious injury or 70 death may result if instructions are not followed. CL _AWARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly. POTENTIAL HAZARD Applying only the rear brake abruptly when operating in reverse gear. WHAT CAN HAPPEN The front wheels could lift off the ground and the ATV could overturn backwards. HOW TO AVOID THE HAZARD Carefully apply both the front and rear brakes when stopping in reverse gear. 71 MAKING TURNS To make a turn on level ground, steer the handlebars and lean your body toward the inside of the turn. (Fig 3-11) Leaning helps balance the vehicle, and it feels more comfortable. Leaning into a turn is an important 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 3-11), and lean inside, as you steer the handlebars. Shifting weight forward allows the rear wheels to turn easier, and it also improves front-wheel steering. Remember to shift your body forward to make sharp low-speed turns and whenever you turn while accelerating from a full stop. Apply the throttle slowly and gradually when you turn and start up at the same time. During other turns, use the throttle to maintain the desired speed throughout the turn. Practice these techniques on level ground until you are confident in making turns. 72 Fig. 3-11 Lean your body to the inside of a turn and forward. POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN The ATV can go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner's Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. 73 The terrain surface can be a major factor affecting turns. Skidding during a turn is more likely to occur on slippery surfaces, such as snow, ice, mud and loose gravel. If you skid on ice, you may lose all directional control. To avoid skidding on slippery terrain, keep your speed low and ride with caution. If your FOURTRAX skids sideways during a turn, steer in the direction of the skid. Avoid hard braking or accelerating until you have regained directional control. POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. 74 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. 75 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. 3-12 Shift weight forward when climbing hills. 76 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. 77 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. Thenassess 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. 3-13 If you roll backwards down a hill, don't apply either brake abruptly. 78 IY 7. TT 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. 79 If the hill is not too steep and you have good footing, you may be able to walk the FOURTRAX back down the hill. Make sure your intended path is clear in case you lose control of the FOURTRAX. If you decide you can walk the FOURTRAX safely: 1. Stand with your body facing downhill, beside the vehicle so you can reach the rear brake lever with your right hand (see Figure 3-14). Be sure your legs are clear of the wheels. Check your footing. Then slowly and carefully back the FOURTRAX down the hill using the rear brake lever to control speed. 5. If you lose control of the FOURTRAX, for your safety, get away from the vehicle. > WN If the hill is too steep or too slippery, or if you have any doubt whether you can safely walk the FOURTRAX back down the hill, leave the vehicle where it is and get help. If possible, block the wheels so the vehicle won't roll backwards. Fig. 3-14 Be sure your legs are Body position for backing clear of the wheels. down a hill. 80 While reading this manual, remember: NINE Indicates a strong possibility that serious injury or death may result if instructions are not followed. 81 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. 3-15 On downhills, shift your weight back. 82 AWARNING 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. 83 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. 7 7 17% Fig. 3-16 Shift weight uphill when crossing slopes. 84 MAKING TURNS ON SLOPES Compared to riding on level ground, you may need to shift more weight and lean more when making turns on slopes. Do not make turns on any slopes until you have first mastered the techniques for making turns on level terrain. Begin by practicing turning on gentle, smooth slopes before attempting turns on steeper or more difficult terrain. Avoid making turns on very steep, rough or slippery hills. A WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in this Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as described in this Owner's Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 85 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. A WARNING 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. 86 RIDING THROUGH WATER Your FOURTRAX is designed to travel through water up to approximately 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 134. AWARNING | 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. 87 PARKING Always choose a level place to park. After bringing your FOURTRAX to a stop, hold the brakes while you shift into neutral. Then set the parking brake and turn the ignition switch OFF ( O ). If you're through riding for the day, also turn the fuel valve OFF. While reading this manual, remember: УСА Indicates a strong possibility that serious injury or death may result if instructions are not followed. 88 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 right side of the frame. (1) Fig. 3-17 (1) Vehicle Emission Control Information Label 89 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 | — w|*| THROTTLE OPERATION | 98 т CARBURETOR CHOKE | 103 a AIR CLEANER (NOTE 1) С C | 99—101 Ш AIR CLEANER HOUSING | (NOTE 2) | | 102 < DRAIN TUBE e SPARK PLUG | | | 114—115 z VALVE CLEARANCE | | | 115 D ENGINE OIL R R R 35, = 106—110 Ш ENGINE OIL FILTER R R В |108—110 ENGINE IDLE SPEED | | | 104 90 C: Clean A: Adjust I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. R: Replace L: Lubricate FREQUENCY ITEMS Whichever comes first > INFTIAL MAINTENANCE REGULAR MAINTENANCE INTERVAL mi 100 600 1200 km 150 1000 2000 NOTE HOURS 20 100 200 Referto page DRIVE SHAFT BOOTS REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL (R: EVERY 2YEARS) 111—113 BRAKE FLUID (NOTES) 128 BRAKE SHOE WEAR (NOTE?) 133 BRAKE SYSTEM 125— 134 REVERSE LOCK SYSTEM 117 SKID PLATES, ENGINE GUARD 141 CLUTCH SYSTEM 116 Elx * SUSPENSION SPARK ARRESTER 142 NON EMISSION RELATED ITEMS NUTS, BOLTS, FASTENERS ** WHEELS/TIRES 135— 139 | * STEERING SHAFT HOLDER BEARINGS = |-- |= |) |— — dk STEERING SYSTEM * SHOULD BE SERVICED BY YOUR AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. REFER TO THE OFFICIAL HONDA SERVICE MANUAL. ** IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY NOTES: 1. Service more frequently when riding in dusty areas, sand or snow. BY YOUR AUTHORIZED HONDA DEALER. 2. Service more frequently after riding in very wet or muddy conditions. 3. Replace every 2 years. Replacement requires mechanical skili. 91 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. 92 TOOL KIT A tool kit (Fig. 4-1) is provided with your FOURTRAX and stored in the storage compartment below the rear cargo rack. The tools in the kit are sufficient to perform routine maintenance and simple repairs. Any extensive work requiring additional tools should 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 Fig. 4-1 (1) Tool kit While reading this manuai, remember: NENE Indicates a strong possibility that serious injury or death may result if instructions are not followed. 93 FUEL SYSTEM FUEL Refueling The fuel tank capacity, including reserve, is: 3.43 US gal (13.0 2, 2.86 Imp gal) The reserve fuel supply is: 0.85 US gal (3.2 £ , 0.70 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 handle cover hole. (4) Fig. 4-2 (1) Fuel fill cap (4) Filler neck (2) Breather tube (3) Handlebar cover hole 94 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. 95 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. 96 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 emissions. 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 “Gasoho!”. 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 oxygenates mentioned above are not covered under warranty. 97 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. — LN | 1/8—5/16 in (3—8 mm) (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. 98 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 housing cover (3). (1) (3) Fig. 4-4 (1) Seat lock lever (2) Retainer clips (3) Air cleaner housing cover 99 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). 5. Remove the air cleaner (4) from the air cleaner body (5). (1) (3) Fig. 4-5 (1) Screw (3) Clamp (2) Air cleaner assembly (4) Air cleaner (5) Air cleaner body 100 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. POTENTIAL HAZARD Using gasoline or low flash point solvents for cleaning ATV parts. WHAT CAN HAPPEN A fire or explosion could result. HOW TO AVOID THE HAZARD Use only a nonflammable or high flash point solvent to clean ATV parts. 7. Soak the air cleaner in Pro Honda Foam Filter Oil or an equivalent [Canadian Vehicles; gear oil (SAE 80—90)] until saturated, then squeeze out the excess oil. CAUTION: Twisting the air cleaner when squeezing out excess oil could damage the air cleaner. 8. Reassemble by reversing the disassembly sequence. 101 Air Cleaner Housing Drain Tube The air cleaner housing drain tube (Fig. 4-6) should be serviced in accordance with the Maintenance Schedule. (Riding through water may require more frequent inspection.) If deposits can be seen in the drain tube, the tube must be cleaned before starting the vehicle. To clean the drain tube: 1. Remove the drain tube (1) by removing the clip (2). 2. Drain the deposits. 3. Reinstall the drain tube, securing it with the clip. (3) Fig. 4-6 (1) Drain tube (3) Air cleaner housing (2) Clip 102 CARBURETOR Choke Cable and knob Check the condition of the choke cable (Fig. 4-7) and the operation of the choke knob (2). If the cable is damaged or kinked, have it replaced by your Honda dealer. (2) Fig. 4-7 (1) Choke cable (2) Choke knob 103 Adjusting Idle Speed NOTE: Do not try to compensate for faults in other systems by adjusting the carburetor. To adjust the idle speed: 1. Warm up the engine. The engine must be warm for accurate idle adjustment. Ten minutes of stop-and-go riding is sufficient. 2. Adjust idle speed by turning the throttle stop screw (Fig. 4-8). Idle Speed: 1,400 + 100 rom (1) TN Fig. 4-8 (1) Throttle stop screw 104 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. 105 LUBRICATION ENGINE OIL Checking Engine Oil Level and Adding Oil Check the engine oil level each day before operating your FOURTRAX and add oil if needed. To check the oil level: 1. Make sure the vehicle is on level ground. 2. Start the engine in a well-ventilated area and let it idle for 5 minutes. If the air temperature is below 10 °C (50 °F), let the engine idle for an additional 5 minutes (a total of 10 minutes). An engine that is not warmed sufficiently may give an inaccurate (low) oil level reading. 3. Stop the engine. 4. After a few minutes, remove the dipstick (1) (Fig. 4-9 ) from the front crankcase cover and wipe it clean. 5. Insert the dipstick without screwing it in, then remove the dipstick and check the oil level. The oil level should be between the upper level mark (2) and the lower level mark (3) on the dipstick. 6. If required, remove the oil filler cap (4) from left side of the crankcase and 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 and dipstick. CAUTION: Running the engine with improper oil level can cause serious engine damage. 2) — (3) — Fig. 4-9 (1) Dipstick (3) Lower level mark (2) Upper lever mark (4) Oil filler cap 106 Engine Oil Recommendations Recommended Oil Viscosity: SAE 10W-40. Other viscosities shown in Fig.4-10 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 I SAE 20W-40 | ооо нано ан SAE 10W-40 A o ан SAE 10W-30 Fig. 4-10 Recommended oil viscosities 107 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. With the FOURTRAX on level ground, remove the oil filler cap (1) from left side of the crankcase (Fig. 4-11). 2. Place an oil drain pan under the crankcase and remove the oil drain plug (2). (2) Fig. 4-11 (1) Qil filler cap (2) Oil drain plug 108 3. Remove the oil filter cover (1) (Fig. 4-12) 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. Oil filter bolts torque: 7 tbof-ft (10 N-m , 1.0 kgf-m) (2) Fig. 4-12 (1) Oil filter cover (5) Rubber seal (2) Bolts (6) OUTSIDE mark (3) Oil filter (7) Spring (4) O-rings 109 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: 2.1 US qt (2.0 2, 1.8 Imp at) 9. Reinstall the oil filler cap. 10. Start the engine and let it idle for 5 minutes. 11. Stop the engine and after a few minutes, check the oil level. Make sure the oil is between 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: NT UN TNEN Indicates a strong possibility that serious injury or death may result if instructions are not followed. 110 REAR FINAL GEAR CASE OiL Change the oil in the rear final gear case when specified by the Main- tenance Schedule. Change the oil with the final gear case warm, and the FOURTRAX on level ground to assure complete and rapid draining. To change the rear final gear case oil: 1. To drain the oil, first place an oil drain pan under the oil drain plug (Fig. 4-13). 2. Remove the oil filler cap (1) and the drain plug (2). 3. After the oil has completely drained, reinstall the drain plug. Drain Plug Torque: 9 lbf-ft (12 N-m , 1.2 kgf-m) 4. Fill the gear case with the recommended oil. Rear final gear case oil: 2.9 US oz (85 em? , 3.0 Imp oz) 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) ЭГ Fig. 4-13 (1) Oil filler cap (3) Oil level check bolt (2) Drain plug (4) Lower edge of oil level check hole 111 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. 2. 3. 112 To drain the oil, first place an oil drain pan under the oil drain plug (Fig. 4-14). Remove the oil filler cap (1) and the drain plug (2). After the oil has completely drained, reinstall the drain plug. Drain Plug Torque: 9 Ibf-ft (12 N-m, 1.2 kgf-m) Fill the differential with the recommended oil. Differential oil: 8.2 US oz (241 cm? , 8.5 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). Install the oil filler cap. (1) a a u N Let ee (3) A he e SN E ZZ А = (2) Fig. 4-14 (1) Oil filler cap (3) Lower edge of (2) Oil drain plug inspection hole 113 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) CAUTION: Using a spark plug of incorrect size or heat range can cause serious engine damage. Toc heck and change the spark plug: 1. 2. 3. 4 114 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. 4-15) 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. (3)— 1 0.03 — 0.04 in (0.8— 0.9 mm) | (2) NIT Fig. 4-15 (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. 115 CLUTCH Clutch Adjustment To adjust the clutch: 1. Make sure the ignition switch is OFF (©). 2. Loosen the lock nut (Fig. 4-16), 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. Fig. 4-16 (1) Lock nut (2) Clutch adjuster 116 Reverse Lock System Measure the reverse assist lever (2) free play. Free play, measured at the lever (2) end near the cable (Fig. 4-17), should be approximately: 1/16 — 3/16 п (2 — 4 тт) 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. (2) 1/16—3/16 in (2—4 mm) (3) (4) ©) Fig. 4-17 (1) Rear brake lever (3) Rubber sleeve (2) Reverse assist lever (4) Adjusting nut (5) Lock nut While reading this manual, remember: NN ENDE Indicates a strong possibility that serious injury or death may result if instructions are not followed. 117 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. 118 Battery Removal 1. Make sure the ignition switch is OFF (O). 2. Remove the seat (page 140). 3. Toremove the rear fender lid (1), remove the clips (2) (Fig. 4-18 ). 4. Release the rings and remove the rubber band (4). (Fig.4-19) 5. Disconnect the negative (—) terminal lead (5) from the battery (3) first, then disconnect the positive (+) terminal lead (6). 6. 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. Fig.4-18 (1) Rear fender lid (2) Clips 119 (4) o (5) Negative (—) terminal lead (6) Positive (+) (3) Battery (4) Rubber band Fig. 4-19 terminal lead 120 FUSE As illustrated in Fig. 4-20, the fuse box (1) is located in the battery compartment. The main fuse, sub fuses and spare fuses are located in the fuse box. The specified main fuse is: 30A 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) Fuse box (2) Fuse box cover 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. 121 Remove the seat (page 140). Remove the rear fender lid (page 119). Remove the fuse box cover (page 121). Pull the old fuse out of the clips. Push a new fuse into the clips and install the fuse box cover. Install the rear fender lid. Install the seat. NAD SON (1) (= 7 7 Tol E Fig. 4-21 (1) Main fuse (2) Spare 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. 122 Remove the seat (page 140). Remove the rear fender lid (page 119). Remove the fuse box cover (page 121 ). Pull the old fuse out of the clips. Push a new fuse into the clips and install the fuse box cover. Install the rear fender lid. Install the seat. о носов Bl | | ез З0 2 || 910 = В 15 а Ta mal Ly FS A Xx (1) Fig. 4-22 (1) Sub fuses (2) Spare fuses 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. 123 While reading this manual, remember: PTE NIN Indicates a strong possibility that serious injury or death may result if instructions are not followed. 124 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. 4-23) 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) O 1—1 3/16 in (25 — 30 mm) Fig. 4-23 (1) Front brake lever 125 2. Remove the inspection hole plug (Fig.4-24) 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. (3) as E 5 (1) Р19. 4-24 (1) Inspection hole plug (3) Front brake drum (2) Lining thickness (4) Front wheel rim While reading this manual, remember: INVA: [Ie Indicates a strong possibility that serious injury or death may result if instructions are not followed. 126 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. 4-24) and line up the hole with one of the brake adjusters (Fig. 4-25). 4. Using a screwdriver, turn the brake shoe adjuster (1) in the direction of the arrow until the front brake locks. Fig. 4-25 (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 5. 7. Reinstall the inspection hole plug, seating it into the inspection hole as shown in Fig. 4-24. 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. 127 To check the brake fluid level: Brake fluid must be added to the reservoir (Fig. 4-26) 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. 128 Fig. 4-26 (1) Lower level mark 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. 129 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. 4-27), should be: 9/16 — 13/16 in (15—20 mm) 9/16— 13/16 in (15— 20 mm) Fig. 4-27 (1) Rear brake pedal 130 To adjust the free play, turn the brake pedal adjusting nut (1), (Fig. 4-28 ), 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). (2) (1) (3) Fig. 4-28 (1) Brake pedal adjusting nut (2) Brake lever adjusting nut (3) Brake arm pin 131 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. 4-29 ), should be: 9/16 — 13/16 п (15—20 гпт) To adjust the free play, turn the brake lever adjusting nut (2), (Fig. 4-28 ), 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 (1) (15—20 mm) Y Fig. 4-29 (1) Brake lever 132 To check rear brake shoe wear: When the brake is applied, an arrow (1) attached to the brake arm (2) moves toward a reference mark (3) on the brake panel (see Fig. 4-30). 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. Fig. 4-30 (1) Arrow (2) Brake arm (3) Reference mark Other Checks: Check the condition of the brake cables. If there are kinks or signs of wear that could cause sticking or failure, have the cables replaced by an authorized Honda dealer. Make sure the brake arm, spring, and fasteners are in good condition. 133 DRAINING WATER FROM BRAKES Make sure the engine is off and the parking brake is set. Then remove the inspection hole plug (Fig. 4-31) from the front brakes, and the drain bolt (Fig. 4-32) 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. 4-31 (1) Front brake inspection hole plug Fig. 4-32 (1) Rear brake drain bolt 134 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. 4-33) 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 \bf-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. 135 NOTE: If a torque wrench was not used for installation, see your authorized Honda dealer before operating the vehicle to verify proper assembly. Fig. 4-33 (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. 4-34. 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. 136 FRONT REAR TIRE SIZE AT24 x 8-12 XxX АТ24 X 9-11 ЖЖ TIRE BRAND DIRT HOOKS DIRT HOOKS BRIDGESTONE BRIDGESTONE RECOMMENDED | 3.6 psi (25 kPa, 0.25 | 3.6 psi (25 kPa, 0.25 o | PRESSURE kgf/cm?) kgf/cm?) QO Z | MAXIMUM 4.0 psi (28 kPa, 0.28 | 4.0 psi (28 kPa, 0.28 5 PRESSURE kgf/cm?) kgf/cm?) = MINIMUM 3.2 psi (22 kPa, 0.22 | 3.2 psi {22 kPa , 0.22 PRESSURE kgf/cm?) kgf/cm?) O = © | RECOMMENDED | 3.6 psi (25 kPa, 0.25 | 3.6 psi (25 kPa, 0.25 = & | PRESSURE kgf/cm?) kgf/cm?) Fig. 4-34 Tire specifications 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. 137 Tire Tread Condition To check the condition of a tire tread, measure the groove depth (1) (Fig.4-35) 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. 4-35 (1) Groove depth (3) Wear indicator (2) Wear indicator location mark 138 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. 139 SEAT REMOVAL To remove the seat (Fig. 4-36), 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. (1) (2) Fig. 4-36 (1) Seat (3) Prongs (2) Seat lock lever (4) Hooks (5) Studs 140 ENGINE GUARD AND SKID PLATES The engine guard (Fig. 4-37) 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 90—91). 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. 4-37 (1)Engine guard — (2) Skid plates 141 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. 4-38) 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. Pa ых АМ Fig. 4-38 (1) Bolt 142 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. 143 DRIVESHAFT BOOTS Check the rubber driveshaft boots (1) for damage or leaking grease. If necessary, have your authorized Honda dealer replace them. Fig. 4-39 (1) Driveshaft boots 144 While reading this manual, remember: LED Indicates a strong possibility that serious injury or death may result if instructions are not followed. 145 TRANSPORTING YOUR FOURTRAX When you transport your FOURTRAX, we recommend that you carry the vehicle in its normal operating position (on all four wheels) and follow these procedures: 1. Setthe parking brake and place the transmission in gear. 2. Turnthe fuel valve OFF. 3. Secure the vehicle with “tie downs” in the areas shown (Fig. 4-40). 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. 4-40 Points to secure (1) Front cargo rack FOURTRAX with tie downs 146 (2) \ (3) Fig. 4-41 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. Follow steps 1 and 2 on the previous page. 2. Place a suitable container under the carburetor drain tube. 3. Turn the drain screw counterclockwise and drain the fuel from the carburetor. 4. After draining the carburetor, turn the drain screw clockwise until itis tight. 5. Pour the drained fuel into the fuel tank. 6. Tilt the vehicle and secure properly. Do not tow your FOURTRAX behind a car or other vehicle. 147 A WARNING POTENTIAL HAZARD Inclining this ATV without first draining fuel from the carburetor. WHAT CAN HAPPEN The fuel could explode or ignite. HOW TO AVOID THE HAZARD Always drain fuel from the carburetor before inclining this ATV. Always handle fuel in a well-ventilated area with the engine off. Do not smoke or allow flames or sparks in the area where fuel is handled. If any fuel is spilled, make sure the area is dry before starting the engine. 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. 148 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. 149 1. Rinse the FOURTRAX thoroughly with cool water to remove loose dirt. 2. Cleanthe FOURTRAX with a sponge or soft cloth using cool water. Avoid directing water to muffler outlets and electrical parts. 3. After cleaning, rinse the FOURTRAX thoroughly with plenty of clean water. Detergent residue can corrode alloy parts. NOTE: The inside of the headlight lens may be clouded immediately after washing the ATV. Moisture condensation inside the headlight lens will disappear gradually by lighting the headlight in high beam. Run the engine while keeping the headlight on. 4. Dry the FOURTRAX. 5. Start the engine and let it run for several minutes. 6. Test the brakes before riding the FOURTRAX. Several applications may be necessary to restore normal braking performance. Braking efficiency may be temporarily impaired immediately after washing the FOURTRAX. Anticipate longer stopping distances to avoid a possible accident. 150 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. 151 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. 152 3. Remove the spark plug and pour one tablespoon (15—20 cc) of clean engine oil into the cylinder. Operate the starter for a few seconds to distribute the oil, then reinstall the spark plug. (Make sure the engine stop switch is OFF (51 ) before pressing the starter button.) 4. Remove the battery (page 119) and store it in an area protected from freezing temperatures and direct sunlight and out of the reach of children, slow charge the battery once a month. POTENTIAL HAZARD Allowing open flames or sparks near the battery. WHAT CAN HAPPEN Gases may explode and possibly cause injury. HOW TO AVOID THE HAZARD Do not allow open flames or sparks near the battery. 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. 153 SPECIFICATIONS DIMENSIONS Overall length 78.1 in (1,983 mm) Overall width 45.0 in (1,143 mm) Overall height 44.5 in (1,130 mm) Wheelbase 49.1 in (1,246 mm) WEIGHT Dry Weight 523.6 Ibs (237.5 kg) CAPACITIES Engine oil 2.6 US gt (2.5 2, 2.2 Imp qt) Fuel tank 3.43 US gal (13.0 2 , 2.86 Imp gal) Fuel reserve 0.85 US gal (3.2 2 , 0.70 Imp gal) ENGINE Bore and stroke Compression ratio Displacement Engine idle speed Spark plug, standard Spark plug gap Valve clearance 3.09 X 2.68in {78.5 X 68.0 mm) 8.8 : 1 20.08 си-т (329.1 ст?) 1,400 + 100 rpm DPR7EA-9 (NGK) X22EPR-U9 (DENSO) 0.03— 0.04 in (0.8— 0.9 mm) 0.006 in (0.15 mm) CHASSIS AND SUSPENSION Caster angle Trail length Tire size, Front Rear 4.0° 0.7 in (17 mm) АТ24 X 8-12 ЖЖ AT24 x 9-11 xXx 154 POWER TRANSMISSION Primary reduction 2.188 Secondary reduction 1.933 Final reduction Front: 3.769 Rear: 3.692 Gear ratio 1st 3.455 2nd 1.933 3rd 1.333 Ath 0.966 5th 0.720 Reverse gear ratio 4.600 ELECTRICAL Battery 12V—12 Ah Generator 0.245 kW/5,000 rpm LIGHTS Head light (Low/High) 12 V 30/30 W X 2 Taillight 12V5W X 1 Neutral indicator 12 \ 1.7 МУ Хх 1......... USA LED ...........eecacenrraroocma Canada Reverse indicator 12V 1.7 W Xx 1......... USA DE Dessen Canada Oil high temperature indicator 12V 1.7 W X 1......... USA LED ...........evcscenereceno Canada FUSE Main fuse 30 A Sub fuse 15 À x 2, 10 À X 2 155. WIRING DIAGRAM U.S. model 00Z9-SNH-Z0£00 waa] 22 | [ame] m а MACE 330 | |o+—-O | н | [ # [16 [rare] 3 NOVIVANOOUS OS Усс oo [Hna] [o+o | nn Loto | 440 33H4 440 oto | с) НО-РО | №0 16 [ceive eu [rive IH 107 | (H) (1H)| 11 leiva HOUMS HOLIMS H3lUYLS dOLS NONI HOLIMS HIPIWIO HOLIMS ONLLHDIT HOLIMS NOLLIND! 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HOLIMS PAY IND NOILINEH JUINDYH LEVLS 157 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 contro! 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. 158 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 159 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. RUN 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. 160 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 140 ). KEY NO. FRAME NO. ENGINE NO. COLOR Fig. 5-1 (1) Key number (3) Engine number (2) Frame number (4) Color label 161 INDEX A AÄCCESSOTIES ee R RER errr eet tsar eres ate tas serrata eae rerasats eens rernernnses 50 ACCESSOIY SOCKET. citi iii reer eres RE ae. 40 Age recommendation ...................reeeecreern cer Dee eee e DR Ia. 42 Air cleaner TTD 99 Housing drain tube..........................e.e.erereecerecearrerereea erroneo cenar. 102 Air pressure gauge ............e.e..eseimiriieeracacer cero ER eR De cera. 39 Apparel, recommended......................eeeeneiriierermeiee e e eee eee e 52 Authorized Manuals... eee reer bares 169 B Battery RRR eue 118 Brakes Brake Cables... rer 133 ВгаКе 1 LT TD 128 Front brakes Adjustment.…................…..…..…crrrimrerrenssensanece nca sererere serre nenrene cena nas 125 Brake lEVEr cuit eer aa emer eres 31 Brake lever free Play eee eer TR III 125 Brake shoes................ereeeccerceerrenceeneeicoro reee rene nene eee. 125 Parking brake... coco ere rer revere eee 31 Rear brake Brake le VE essen reer er rae aera era naan 31 Brake lever free play ................reececereccereoccorer ear ere RR DEA 132 Brake pedal .................e.escerrriiorereoeeeeneoacenore a rerearerencare arena ran 31 Brake pedal free play... ren 130 Brake SOS cc. rrr aaa 133 Break-in procedures... viii eerie eee een reee ren re Rene eee ercer Il С Carburetor High altitude adjustment... errr en 105 Idle speed adjustment... cries 104 Cargo carrying Loading and operational guidelines........................esreseierie ree 48 Weight limit... creer reer errr rem reer Er. 47 Choke Cable ...................eveerorerierercereeceeareoreneneceneneeaoaeeceoseerere eat nacer ecemenee 103 Knob...............e.esercenienararirercrrenenororeancorearcoraaraoeneereaenereoaTatarear enn 16, 103 Cleaner ieee reer er eece acero nrereree rre arrre rea tanenceanenveEme 149 Climbing hills cee rrr rrr rarer eN. 75 (OF [V7 (od a TF: To FTV E31 0 | SPP c ace c cer 116 Consumer information .........e......er.erearesrereeer errr renee eas 158 CrOSSING SIOPES..….........…..ncserrercrnsecrcansansrceenaarennenrenenten rnere ee ss cree cree annees 84 Customer ServiCe .............erervererriiercrrecrercerererrareerararrare Tener Errr emanan ranma 160 D Differential Oil... eee verre rere ree rere aan 112 Digital clock (Canadian model Only) iim erre 28 Dimmer SWITCH... riers rrr errr reese srr nee ne rtanrremenere reee 21 Di eeaaere re aa a 37,106 Display (see Multi-function display) (Canadian model only)................ 24 Driveshaft boots...............e... .reeeererriiiricirererer reee ener renato rarer ee 144 E Emission control system ..............=.eee.sssiaamrreeecer eee 158 Engine Idie speed adjustment................—..-—...eeeeeeeeereriener re 104 Break-in procedures................e.esireiereierreeeenere nee eee ena e erase nase anes i Flooded ENGINE... rene ice eee ene ener ee nen reneenenacen 68 Starting the engine ....................-eeeerereeee rene eran 65 Engine guard and skid plates ...............e...eeeereeeresrnereee reee ereenee eee 141 Engine oil Changing Oil... eee ERC ee. 108 Checking oil level and adding Ola 106 DE ena as 37, 106 N 108 Oil filter ….….…......…..errencerensrentenersananreneerasarrareenenasrenren entree e ec encens 108 Oil high temperature indicator ….….…....…..…...…..….ecssercessercenmenceneae none unes 22 Recommendations ............... seers risers reves ener eens 107 Engine stop SWIitch …….…...….........ereecrsrsensenrenenseneaneren sa rsn sen aecena sance nana cc eee 15 Exhaust system ORT =F T aT 4 To eme e ne sre ce caea ren V ne 45 a USO ere c ecran eee cc 142 163 F Final gear case Oil essen R RE EEUERRRRERKKRREERAKEKARGKKEUEUERURKKEEKEG 1 Flag pole Bracket... eee eee eee Flooded engine ...............ese=errercecenertenacreee ne cen er ranee ree ere rene enerereemenere Une Fuel A ener nraceneeerrrareen re oreneareNETENUaCrre 33, Fuel gauge ..................i.esererrerereinerenrr enc caneeee ener ronererererreNEENeEn area nrertUNes Fuel recommendations ..............em.eneeeereeeere rre Deere e Fuel tank capacity .................._e.e...eereerererreirr aran erre eee rere erees Fuel valVve...............—e_eíveiernenrriiernenerererecenena tene reacrerenceeeartetecnatEcareEDene High altitude fuel mixture adjustment ...............—e...re.eveeeeereee 1 REfUEIING.........….......rrereccocreseeereresrenrerenenaresseranra ren ren en enr esse ses en nee Reserve fuel SUPPIY..........….....…rreressansrensanenaassanrra nan ersancenre nana annee Fuses Location ...............—...ererecererenreenneenereeerere rare errrenerE e erenrerereNenerereemErE Neve 1 Replacement, main fuse ...............eserererierereereee eee eee ENTERA 1 Replacement, sub fUSEes..................e..2viiiierceceeeecenee ee eemea rincones 1 G Gasoline (see Fuel) Gearshift pedal...................-...-e..irereseriiere ener nenee ner rente rerereramer ener. CT encara rDenerreneneeennerecamerermen eee eae 29, Gearcase oil Rear final gear Case Oil... eee 1 H Headlight SWitch@S.…...…..…...….…….rrerecccrensaren canine ne nrrena cena ssa case san ere eme rennes [=X Fa a T= a Lo] = cS High altitude fuel mixture adjustment ...........ccociiiiriin cere, 1 Hills Riding across SIOPes ......................svecerieserenceneneereece recae ener erre nene: Riding down hills............................eeeererarrrcacanen ene a ree cenane eater reee. Riding up hills................———......eeeimesreeere eee ricerinineneDe een ener eN One eee Stopping ON hills eee reese eee rae Turning ON SIOPES iii erences errr esse neem es Hourmeter (Canadian model only) ceiver vv e 164 Idle speed adjustment .............e.e.....e.eesenciireerer e eee eee eee reser eens 104 IGNITION SWITCR cece rere terse eee ee aera eens 14 Indicator Neutral indicatO TE 22 Oil high temperature IndicatOr ee RI IDA 22 Reverse INQICAÏON...….........ucssssrsececenerenreerranerrecenaan sa nanas ee een en eee 22 INSPECtION, PrE-F1Q@ …..…................cecsssssrrsrernerena re snensara rer ane en en sa an saane naar 44 L Loading Loading guidelines and procedures.….….…..….……ss-rrrcccssrrrccrarre nn snanerees 48 Weight liMitS.…...........…cercrreccencenearaansa rase era neneen sean sena rene nan e eee ne n ne 47 Lubrication (see Engine oil, Gear case oil and differential oil) M Maintenance Lud 171 61 «© à [AREAS ET 92 SCHEQUIE …..…...........…russsraseasasnanenaransanaananannararra nan an area nana ee an enr e nan ara en 90 Modifications ...............=.e.e.eeeeeerieren or enana enae rene erearareneeren aretes 52 Multi-function display (Canadian model only) ......................eevevee 24 N Neutral indicator .................===.ereerereiae ce errar nnen canne e ane ananas 22 Noise emission control system .....................reeiriereriereeD e De e rans 159 O Obstacles, riding OVer............e.e.e2eeicereear e IR RR III IIA araasenaanaacese 86 Odometer (Canadian model ONY)... eee eee eee EN 28 Oil (see Engine oil, Gear case oil and differential oil) Oil filler cap -................ eee essere te trates eee e ee ee eee e anes 106 OT EEE 108 ОН high temperature indicator...................— e... reee De 22 Owner's manual compartment....................._......... e renerrr ce nece cone. 39 165 EEE 88 Parts location...................—.e..erercererrrceneren rene ren E Erre NE EEerer Tener rerereenerraneTe 10 Parking brake................. e. cenenace cen cere rete Deere rer ero ececenercenacae 31 Passenger carrying ...........—.——..==.rmesereernerere reine e eee Deere enero 54 Pavement, no riding ON coor rere errr ees 56 Pinging............ e e-ereemeeiieiaene ren een ener cero renene acento reeveeeenenemencaraceraenene 96 Pre-ride inspection ............_..-e..—-..e.erieiciner o reee eee ca cea roo rereenec. 44 R Rear final gear case Oil .................e=ierercerenonerconcerne nn nera re cen. 111 Recoil starter ................e..eeeervererereccorrerercerenerrerere rene rene rnenerane rre reNTe ne. 19 Reverse Assist cable .....................esceervereeneeereccacarrereneTerDenDerernrnre e cacacerenereneTe 117 ASSISt IEVEF TA 117 Gear, shifting intO.….....…............……orcersserrrrenereasenrren eee rDe REE. 29, 69 INAÎCALON …..........….....rrrsrrencressassenrene rene er ana cena senasere ne nren ve ce nee na crane 22 Riding in revErSE ….….........……essssanmensrnserenrentenerensansesraa cac cete stat cn annees 70 Selector knob.................e=..eiierermerrecernecararer arenero reee rccacerar enero rene. 30 Rider training COUrse ...........-..---.eviverererercercecacecrencaneearro error Tercera 1,44 S Safety messages, special ….....….….….….sssssssssninneenensentenennrerencensesee nec c encens 1 Seat removal and installation .…....….......…..….….-....eccssssansenenensensenareeem ane 140 Serial numbers and color label ................--———.---e_eeeriiererrerorere 161 Shifting gears ..................e.erereeeeccenerience nene eee nene state menaces crc 29, 69 Skid plates OUP En reS 141 110 [0 [1019 ORTOP 74 Socket, accessory .............em_r...e2erverrrreronenenen ise saa r ease reser sense nan aa aes 40 OY 0: LE 1-1] (PPO en ecran 142 Spark knock.................-...=meesereeiriiiee ner ec Der ercer eeccereeeen enero rene eee. 96 Spark PlIUQ USP 114 Specifications..................eiereeeer e De O Roncero e reencenec eee neenanTe. 154 Stallingon a hill .................ee=e.eecereeeeieii ceca cr rr er ernen een erre rnecerer ere. 77 Starter button .................e.eeeceererrerermerr TON 17 Starting primer knob..............——.-..r.vsserererverereeeerer nece 18 Storage compartment...............e.eem.ereimininiie ri RR eran nera 39 Storing procedures ...............=e.ee0eeiiiiieenie iii ren eee eee ncen rene. 151 166 T Throttle CADIE reer earn 98 LeVer.........emnerernerinancaeaaceeenereararenearaaneemareocareacare oro Eten ne an ere sacre re 20, 98 Tires Inflation and air Pressure ….….….…....rrererccraeccessanres ce ssaran na ran ace nanas 136 Repairing............——_..e=ererercererrerneerecacecrorrererorrererereeanerene rene enernenrnrEme enn. 139 Specifications ..........e..-..erereseerecerereececre reo errar Errar e ree eee. 137 Tread condition ................. me. eeeceserercererreerareneeorarecerarereecarareraneeTT. 138 Tool Kit.................ererenennanracenenenecanace e tararareneneanenaareaaementeneraren nene roer AreeneEA Ne 93 Trailer HICH .............. ee... sieceranrecerren een area ta era rear es 38 Trailer towing Operational guidelines...................eresrercererciorrereo reee reee ereDerre eeeee 48 Weight limits............_..—..—esmevarsrarcororrerorneverererarreo re rnereraneeeere enana reeEErm re 47 Transporting procedures....................eeeesenecierrireceie e ein e e rar erene 146 Tripmeter (Canadian model only) ..................-.-..eeeeeeeee einer rne nee 26 Turning On level ground...............e-_eee. e. ererereerereneere tner en cercare rears rer erens 72 ON Sl OPES citi rere saree rer rrr 85 167 V Valve CIlEarancC@.…...….….....…...rrerrerserareccasncecenrenrerennsener nr eaan rene cran rence ane 115 W Warning !абе!5$ ......нннннескскеннненннннненееененненннннссеенеенненнененннененнннненннннннееенне) 7 Warranty SerViCé .................es=mercicitecc ener eDer er enereeeee rene eee renencereceret. 160 Water Draining from brakes ..............----.—..rmeseccreirerece oe ener ee 134 Riding thrOUGN............………rirsenrereeseneeneenrenre terra sentence na ensa sente res e ne ne re 87 Weight limitS ..…........….….….rcercreneereeneerennenenenrene rene e rene nee center e terre 47 Wheel removal …..….....….......rssircecrrcansensentanrre ns sance rene nca sen encre nn san c msn ane 135 Wiring diagram .............m=e=-.—-resererenerererceceericito rie e era cececcenencenerer core 156 168 AUTHORIZED MANUALS The Service Manual (Publication Item No. 61HN400 ) used by your authorized Honda dealer is available from Helm, Inc. (USA only, Canada: See your Honda dealer to order authorized manuals.) Also available, but not necessary, to service your model is the Honda Common Service Manual (Publication No. 61CM001), which explains theory of operation and basic service information for various systems common to all Honda motorcycles, motor scooters and ATVs. These Honda manuals are written for the professional technician, but most mechanically-capable owners should find them easy to use if they have the proper tools and observe proper safety standards. Special Honda tools are necessary for some procedures. Publication Item No. Description Price Each* 61HN400 2000 TRX350TM/TE/FM/FE Service $48.00 Manual 61CM001 Common Service Manual $48.00 31HN5600 2000 TRX350FM Owner's Manual $16.00 "Prices are subject to change without notice and without incurring obligation. Order On-line: www.helminc.com Order Toll Free: 1-888-CYCLE93 (1-888-292-5393) (NOTE: For Credit Card Orders Only) Monday — Friday 8:00 AM — 6:00 PM EST OR By completing this form you can order the materials desired. You can pay by check or money order, or charge to your credit card. Mail to Helm, Inc. at the address shown on the back of this order form (USA only). Canada: See your Honda dealer to order authorized manuals. Publication Item Description ty. Price Total Item No. Each* Price Sub Total “Prices are subject to change without notice and without | Mich. Purchasers incurring obligation, Add 6 % Sales Tax Orders are mailed within 10 days. Please allow adequate | Handling Charge $4.00 time for delivery. Grand Total 169 NOTE: Dealers and Companies please provide dealer or company name, and also the name of the person to whose attention the shipment should be sent. Customer Name Attention Street Address Apartment Number City State Zip Code Daytime Telephone Number ( ) || Check or money order enclosed payable to Helm Inc. U. S. funds only. Do not send cash. || Check here if your billing address is different from the shipping address shown above. | | visa | | MasterCard Account Number Expiration: Mo. Yr. (rrr (ET (AS LE | — Customer Signature Date These Publications cannot be returned for credit without reciving advance authorization within 14 days of delivery. On returns, a restocking fee may be applied against the original order. HELM Pr. 0. BOX 07280, DETROIT, MICHIGAN 48207 170

Honda TRX 350FM Offroad Vehicle Owner's Manual 174 Pages

Honda TRX 350FM Offroad Vehicle Owner's Manual

Key Features

Frequently Answers and Questions

What is the minimum recommended age for operating the TRX 350FM?

What are some of the safety features on the TRX 350FM?

What are some of the maintenance procedures that should be performed on the TRX 350FM?

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Honda TRX 350FM Offroad Vehicle Owner's Manual 174 Pages

Honda TRX 350FM Offroad Vehicle Owner's Manual

Key Features

Frequently Answers and Questions

What is the minimum recommended age for operating the TRX 350FM?

What are some of the safety features on the TRX 350FM?

What are some of the maintenance procedures that should be performed on the TRX 350FM?

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