Honda TRX 300 FW Utility Vehicle Owner's Manual

1991 TRX 300 FW HONDA FOURTRAX 3004 x 4 OWNER'S MANUAL FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. it conforms to US EPA Noise Emission regulations, but does not conform to Federal Motor Vehicle Safety Standards or US EPA Ex- haust 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. 31HC5620 I 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. To get the best service from your FOURTRAX, we recommend that during the first few days you operate your vehicle so the engine does not labor or approach maximum rpm in any gear. Avoid full throttle operation, and shift gears frequently to vary engine speed. Careful break-in procedures will extend the service life of your engine. 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. 1990. No part of this publication may be reproduced without written permission from Honda Motor Co., Ltd. II CONTENTS Page FOURTRAX SAFETY L......ccevevacnennereracere cree n ven mona meme carre ce ne n acc cca ms 1 Special Safety Messages ...................eecsciesoorrnacecareeceneen core 1 Warning Information ............__...ew—.re-rreseseevenereneene rear eee ‚6 PARTS LOCATION AND OPERATION ................enenrorocccnnacorerecene. 10 Parts Location ............eeee.eesscaererczirze.eraresrecereconerccorrrrercarer ere. 10 Parts Operation ..............e...errmmrrrrererercocencionoenareecec nera ea. 13 Power Controls ............e.e...erenenaruereroocoreracaceacecacaroncoencocorecrA. 13 Lights ...........eerenerecererroriecorereeerrerera creer rca cenenaecear Terre 20 Gearshift Controls ..............eeecmercenoarourorararconmerecocerre nen nanecA. 23 Brake Controls ..............eeemrrcecererrcareverccoocaveoveroreravacanereneecaaaro 25 Fuel Tank Controls ...............eecconrnecorsrecoceranenenanenrenen e naneccnD. 26 Engine Oil ..................rermresocericioreccarcarenenconenereeoren naves. 28 Additional Features .................._eceeeeescercrmcocaccererrerranarocone 29 RIDING YOUR FOURTRAX -.........e.eeecoaraanocanerenvaccrnenencene o cea ce.. 34 Before Riding ................eeerererrccrervercicanaear e ncaneocororer nacen. 34 Rider Preparation ................re.eceeescorovercoccorecove near ener ener eee 34 Vehicle Preparation ...............eesesevererorcoronaos neuconeoenenerecanerT—. 36 Safe Riding Rules ...........eer.ere.eerercecenerrconvenranevarencooracereenenece. 44 Riding ...........-_-.——.ecesnorveveooraraanecocecaretrera ene vermacoacareiar nencocoreene. 56 Starting the Engine essen nee erre. 57 Shifting Gears POPPI 59 Riding in Reverse cuvette reas 60 Making Turns o.oo cic ct eerste ane nares 62 Riding Up HIS iii eccrine ees 65 Riding Down Hills ............….ssrsencsases sans s cena mere neue rame n ace 00 ra 000000 72 Crossing Slopes unite iii iii reece rears areas 74 Making Turns on Slopes ..............e-e-.-rrecerevevionerceneremencerere e. 75 Riding Over Obstacies ..................eeresererercaevearcacencaneorenneace 0e 76 Riding Through Water ..............._...eesrrenusaoiorererorenerenaro ea. 77 Parking ...........ee.rreecererrnorereceneoreroacerarmocontcarcorencarnen enero eres 78 MAINTENANCE AND REPAIRS ..............e.enenencanenonornenraenocoeceore. 79 Maintenance Schedule ................errreercereivonsncacccanererereatacone eee 79 Maintenance Precautions ............—_esr=ee.erreeeneocierarerencoonane acen. 80 Tool Kit ...............eecaccrorcceracrronaccai ra renerenmeneaoenenenenarreacecavenarenmes 82 Fuel System .............erreensraraceroacereooecacarencocrancacanoororarearereaeeteme. 84 Lubrication .............ec...eeereereccererrcenecerenenven ro erenenrorccon ener. 99 Engine oot ieee retainers 106 Electrical System ...........e.ee2nccorirmeoervenereretcanmeneaccaocivrnereeea nea. 110 Brakes .............eeooceccocararenocerrrcaceneeocavecanecnacernenerenmnncarenereeeee ee. 115 Wheels and e ocomene. 125 Seat Removal ............ee..eeerasorccaconecareocivareeneacorerrorecenvacanvenennee. 130 Engine Guard and Skid Plates ................e..reserecconaricneiienerererenec.. 131 Spark AV £13 (= GD 132 Driveshaft = {0 Lo ) £- JN 134 (cont'd) Hi CONTENTS (cont'd) TRANSPORTING YOUR FOURTRAX oii 136 STORING YOUR FOURTRAX -............e....eccrrevorccaracenarenceneen even. 138 SPECIFICATIONS irri ei tei rrr rrr as racer a eas 141 WIRING DIAGRAM ci rere eee 142 WARRANTY SERVICE iirc 143 SERIAL NUMBERS -.............e.srrencesorevercaonorentonecrererereoreco res. 145 INDEX ...........ecreonrcoacooranacacanoearereecaoarcanrevararcacacerrernenrecarcenvecn. 146 IV FOURTRAX SAFETY SPECIAL SAFETY MESSAGES AN ATV ISNOT ATOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motor- cycles 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—447—4700 to find out about the training courses nearest you. Always follow this age recommendation: À 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 shuld 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, and operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. Always inspect your ATV each time you use it to make sure itis 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 hilis. 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 Con- sumer Product Safety Commission at 1—800—638— 2772, or the ATV Distributors’ Safety Hotline at 1—800—852—5344. WARNING INFORMATION Your FOURTRAX comes with a hang tag 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. O 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: ® BEFORE YOU OPERATE THIS AYV, READ THE OWNER'S MANUAL AND ALL LABELS. ® NEVER OPERATE THIS ATV WITHOUT INSTRUCTION. Beginners should complete a certified training course. NEVER CARRY A PA » You increase your risk of losing control if you carry a passenger. : THIS ATV ON PAVED SURFACES. You increase your risk of losing control if you operate this ATV on pavement. NEVER OPERATE THIS ATV ON PUBLIC ROADS. You can collide with another vehicle if you operate this ATV on a public road. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. OR DRUGS before NEVER CONSUME ALCOHOL or while operating this ATV, e NEVER OPERATE THIS ATV AT EXCESSIVE : » You increase your risk of losing control if you operate this ATV at speeds too fast for terrain, visibility conditions, or your experience. e NEVER ATTEMPT WHEELIES, JUMPS, OR OTHER STUNTS. ' A WARNING THIS VEHICLE CAN BE HAZARDOUS TO OPERATE. U UTILITY MODEL THIS ATV iS FOR UTILITY USE OPERATOR ONLY-NO PASSENGERS NO OPERATOR UNDER AGE 16 THIS CATEGORY U (UTILITY) ATV IS FOR OFF ROAD USE ONLY. IT IS MAINLY FOR UTILITY USE BUT IT MAY ALSO BE USED FOR GENERAL RECREATION. TRAINING COURSES TO TEACH ATV RIDING SKILLS ARE AVAILABLE. FOR INFORMATION CONTACT YOUR DEALER. CHECK WITH YOUR DEALER TO FIND OUT ABOUT STATE OR LOCAL LAWS REGARDING ATV OPERATION. THIS HANGTAG IS NOT TG RF RÉMUVED BEFORE SALE A WARNING Riding as a passenger can cause the ATV to go out of control. Loss of control can cause a collision or rollover, which can result in severe injury or death. NEVER ride as a passenger. —— нана ® Read owner's manual e Balance load Improperly loading this cargo rack can cause loss of control which can e Weight limit result in severe injury or death. 133tbs (80kg) в WCA-470 À WARNING improperly loading this cargo rack can cause loss of control which can result in severe injury or death. ® Read owner's manual e Balance load. e Weight timit 861bs (30kg) HC4-670 A WARNING improper tire pressure or overloading can cause lass of control. Loss of control can result in severe injury or death. e Coid tire pressure; Front : 4410.6 psi 0.30+0.03 kg/cm* Rear : 29+0.4 psi 0.20+0.03 kg/cm? e Maximum weight capacity: 4851bs.(220kg) NEC TO 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 Owner's Manual. HC5 670 AWARNING THIS VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fait to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: e BEFORE YOU OPERATE THIS ATV, READ THE OWNER'S MANUAL AND ALL LABELS. NEVER OPERATE THIS ATV WITHOUT PROPER INSTRUCTION. Beginners should complete a certified training course. NEVER CARRY A PASSENGER. You increase your risk of losing control if you carry a passenger. NEVER OPERATE THIS ATV ON PAVED SURFACES. You increase your risk of losing control if you operate this ATV on pavement. NEVER OPERATE THIS ATV ON PUBLIC ROADS, You can collide with another vehicle if you operate this ATV on a public road. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. + NEVER CONSUME ALCOHOL OR DRUGS before or while operating this ATV. NEVER OPERATE THIS ATV AT EXCESSIVE SPEEDS. You increase your risk of losing control if you operate this ATV at speeds too fast for the terrain, visibility conditions, or your experience. NEVER ATTEMPT WHEELIES, JUMPS, OR + OTHER STUNTS. [HF1-670 Operating this ATV If you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. RA A WARNING Towing an improperly loaded trailer can cause loss of control. e Read owner's manual. e Tow weight limit: 85Olbs (385 kg) e Tongue weight: 30 lbs (14 kg) HC4-670 PARTS LOCATION AND OPERATION PARTS LOCATION (1) Rear brake lever Parking brake (2) Reverse selector knob (3) Headlight switches Engine stop switch Starter button Choke lever (4) Reverse indicator lamp Neutral indicator lamp Oil temperature warning lamp (5) Ignition switch (6) Throttle lever (7) Front brake lever Fig. 2-1 Handlebars, from rider's point of view 10 (8) Flag pole bracket (9) Rear cargo rack (10) Fuel tank cap (11) 12 V DC receptacle and special plug (12) Front cargo rack (13) Kick starter (behind the right side cover) (14) Oil filler cap/dipstick (15) Right footpeg (16) Rear brake pedal (17) Headlights 1» ($ (5 46 17 Fig. 2-2 Right side of FOURTRAX 11 (18) (19) (20) (21) (22) (23) (24) Helmet holder Storage compartment, containing: Tool kit Air pressure gauge Owner's manual Gearshift pedal Fuel valve Left footpeg Starting primer knob Trailer hitch 20 2D 203 @ Fig. 2-3 Left side of FOURTRAX 12 PARTS OPERATION POWER CONTROLS Ignition Switch The ignition switch (Fig. 2-4) is in the center of the handlebars di- rectly in front of the seat. < Fig. 2-4 (1) Ignition switch Key . Key Position Function Removal The engine and headlights cannot be | | "© key OFF ngine and headlights cannot be | Can be operated. removed. The headlights can be turned on. The key ON With the engine stop switch at RUN cannot be and the transmission in neutral, the removed. engine can be started. 13 Engine Stop Switch The engine stop switch (Fig. 2-5) is next to the left handgrip, and it has three positions. When the switch is in the RUN position, the engine will operate. When the switch is in either OFF 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, be sure to turn the ignition switch OFF to prevent battery discharge. Fig. 2-5 (1) Engine stop switch (2) Starter button 14 Choke Lever The choke lever (Fig. 2-6) is next to the starter button. The choke has three positions: full choke (A), half choke (B), and off (C). To start a cold engine when air temperature is 50—90°F (10—35°C), move the choke lever left to the half choke position before pressing the starter button. At colder air temperatures, set the choke at the full choke position before pressing the starter button. As the engine warms, move the lever to the half choke position. After the engine is warm, move the choke right to the off position. CAUTION: Extended use of the choke may impair piston and cylinder wall lubrication and shorten the life of the engine. Fig. 2-6 (A) Full choke position (1) Choke lever (B) Half choke position (C) Off position 15 Starting Primer Knob The starting primer knob (Fig. 2-7) is on the carburetor float bowl on the left side of the FOURTRAX. To start the engine when air temperature is below 5°F (-15°C), push the knob in once or twice before pressing the starter button. Fig. 2-7 (1) Starting primer knob 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 at RUN. Fig. 2-8 (1) Starter button (2) Engine stop switch 16 Kick Starter The kick starter (Fig. 2-9) is on the right side of the FOURTRAX. It is used to start the engine when the battery is low. To operate the kick starter: 1. Unsnap and remove the right side cover (2). 2. Rotate the kick starter (1) outward. Fig. 2-9 (1) Kick starter (2) Right side cover 17 3. If the engine is cold, move the choke lever left to the full choke position (see Fig. 2-6). 4. Raise the decompression lever (Fig. 2-10), located on the right side of the engine, to the ‘’Decomp”’’ position (2). 5. Put your foot on the kick starter and depress the pedal from the top of the stroke all the way to the bottom with a rapid, con- tinuous motion. The decompression lever will automatically return to the lowered position. @ AR \ AO A ——— | ==3 P/N Fig. 2-10 (1) Decompression lever (2) ““Decomp” position 18 Throttle Lever The throttle lever (Fig. 2-11) is next to the right handgrip, and itis operated: by the thumb. Pressing the lever opens the throttle. When pressure is released, spring tension automatically closes the throttie. Fig. 2-11 (1) Throttle lever (A) To open the throttle 19 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 turns the headlights on. Use the dimmer switch (2) to select either high beam (HI) or low beam (LO). (1) TAN I SE ee =] - RE = 2 y Fig. 2-12 (1) Headlight switch (2) Dimmer switch Engine Oil Temperature Warning Lamp if the engine oil gets too hot, the engine oil temperature warning lamp (Fig. 2-13) will light. NOTE: The oil temperature warning lamp should come on when the ignition switch is turned ÓN. 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: check the bulb and replace it if it is burned out. Contact your authorized Honda dealer for assistance if you cannot correct the problem. 20 If the oil temperature warning lamp comes on while you are riding, immediately bring the vehicle to a stop, turn the engine off and let it cool. CAUTION: * Failure to stop the engine immediately after the engine oil temperature warning lamp 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, causing it to overheat. If the oil temperature warning lamp comes on often, have your FOURTRAX inspected by your Honda dealer. To provide more air flow under adverse conditions, a heavy duty cooling fan is available as an optional part. 5e Fig. 2-13 (1) Reverse indicator lamp (2) Neutral indicator lamp (3) Engine oil température warning lamp 21 Reverse and Neutral Indicator Lamps The reverse indicator lamp and the neutral indicator lamp (Fig. 2-13) are next to the ignition switch. The reverse indicator lamp will light when the transmission is in reverse and the ignition switch is ON. The neutral indicator lamp will light when the transmission is in neutral and the ignition switch is ON. 22 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. 2-14). The pedal automatically returns to the horizontal position when released. Y our FOURTRAX has five forward gears (SL, 1, 2, 3 and 4). To upshift to a higher gear, put the toe of your boot under the gearshift pedal and raise the pedal one full stroke. To downshift, step on the gearshift pedal and depress the pedal one full stroke. (For further operational instructions, see page 59). UP SHIFTING SEQUENCE SL ı 23 4 To reverse: use reverse selector knob Gearshifting sequence 23 Reverse Selector Knob The reverse selector knob (Fig. 2-15) 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. << IT E SN ar с TR 17 Fig. 2-15 (1) Reverse selector knob (2) Rear brake lever 24 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. 2-16). NOTE: Although the front and rear brakes have separate controls, your FOURTRAX's four-wheel drive interconnects all four wheels. So operating any brake control will cause braking at both the front and rear wheels. For information on how to apply the brakes in various riding situations, see pages 60—77. 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 (1) until the lock lever releases. NOTE: Using the parking brake in freezing weather may cause the brakes to freeze In the locked position. Fig. 2-16 (1) Rear brake lever/Parking brake (2) Lock lever A) To lock ( o lock o FUEL TANK CONTROLS Fuel Tank Cap The fuel tank cap (Fig. 2-17) has a fuel cap vent lever (2) with ON and OFF positions. The lever should be turned to ON to allow fuel to flow when running the engine. Turn the vent lever to OFF to prevent fuel from flowing out the vent hole when transporting the FOURTRAX. Fig. 2-17 (1) Fuel tank cap (2) Fuel cap vent lever Fuel Valve The fuel valve (Fig. 2-18) 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. 26 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 0.7 gal (2.5 1). 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 84 — 87. Fuel valve 27 ENGINE OIL Oil Filler Cap/Dipstick The oil filler cap/dipstick (Fig. 2-19), on the right 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 99— 103. O Hb YN => > “4—2 “—(3 Fig. 2-19 | (2) Upper level mark (1) Oil filler cap/dipstick (3) Lower level mark While reading this manual, remember: AA INES Indicates a strong possibility that serious injury or death may result if instructions are not followed. 28 ADDITIONAL FEATURES Helmet Holder The helmet holder (Fig. 2-20) is a bracket near the left side of the handlebar cover (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. (1) Handlebar cover (2) Helmet holder AWARNING 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. 29 Flag Pole Bracket The flag pole bracket (Fig. 2-21) is on the rear cargo rack. Flag poles are optional equipment available from your Honda dealer. To mount a pole in the bracket, follow the instructions that come with the flag pole kit. NOTE: Flag poles are required in some riding areas. Check local regulations before riding. Fig. 2-21 (1) Flag pole bracket 142) An example flag pole Trailer Hitch The trailer hitch is located on the rear axle housing. As illustrated in Fig. 2-22, 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 manufacturers instructions. For load limits and operational guidelines, see pages 39—41. 30 Fig. 2-22 (1) Trailer hitch (2) An example ball Storage Compartment The storage compartment (Fig. 2-23) is behind the seat. To open the compartment, unhook the rubber straps (3) and lift the hinged section of the rear rack (4). The Owner's Manual (5), tool kit (6), and air pressure gauge (7) should be stored in the storage compartment. Be careful not to flood this area when washing your FOURTRAX. Fig. 2-23 (4) Rear rack section (1) Seat (5) Owner's manual (2) Storage compartment (6) Tool kit (3) Rubber straps (7) Air pressure gauge (For the rear rack section (8) Manual holder and the storage compartment) 31 12 V DC Power Supply The DC receptacle (Fig. 2-24) is attached to the right handiebar, near the handlebar cover (2). The receptacle provides 12 V DC power at a maximum of 180 watts (15 amps). If you exceed this limit, you may blow the fuse. (For information on fuses, and how to replace a fuse, see pages 113— 114.) NOTE: if your FOURTRAX is equipped with an optional cooling fan, the receptacle provides 12 V DC power at a maximum of 120 Watts (10 amps). 2) Fig. 2-24 (2) Handlebar cover (1) 12 V DC receptacle (3) Right handlebar Electrical accessories may be connected to the receptacle by using the special DC plug (Fig. 2-25) that comes attached to the receptacle. Be sure to use only accessories that are designed for 12 V DC power. To wire the special DC plug to an accessory: 1. Remove the cover (2) from the plug. 2. Thread the positive and negative accessory leads through the plug cover as indicated in Fig. 2-25. 3. Attach the leads to the plug (1). Make sure to connect the positive lead (3) and the negative lead (4) to the proper terminals. 32 NOTE: Use AWG18-AWG20 electrical wire for attaching an accessory to the special plug. Make sure the accessory leads are properly in- sulated, and keep them away from hot engine parts and sharp edges. CAUTION: | Use of an improper wire size may damage the system. Fig. 2-25 (2) Plug cover (1) Special DC plug (3) Positive lead (4) Negative lead 4. Replace the plug cover. 5. With the ignition switch OFF, insert the plug into the receptacle. Be careful not to twist the accessory leads. Make sure the leads extend from the bottom of the plug. CAUTION: To avoid possible damage to electrical components, make sure the ignition switch is OFF when inserting or removing the special DC plug. When the receptacle is not being used, cover it with the rubber cap attached to the receptacle to keep out dust, water and sand. 33 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: ANDES 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. 34 AWARNING 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. 35 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. AWARNING 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 1-800-447-4700. 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 99— 103). Check for leaks. 36 N . Fuel level. Fill the fuel tank when necessary (pages 84—87). Check for leaks. . Brakes. Check operation. Make sure there is no brake fluid leakage. If necessary, adjust free play (pages 115— 124). . Tires. Check condition and pressure (pages 126— 128). . Throttle. Check for smooth opening and closing in all steering positions. . Headlight and headlight dimmer switches. Check for proper function (page 20). . Engine stop switch. Check for proper function (page 14). . Driveshaft boots-check for damage (page 134). . Nuts, bolts, fasteners. Check the wheels to see that the axle nuts are tightened. Check the security of all other nuts, bolts and fasteners. 10. Steering. Check that the wheels turn properly as you steer the handlebars. 11. Cargo. Check that all cargo is properly secured. 12. 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. 13. Air cleaner Case Drain Tube. Check for, deposits in the Drain Tube. If necessary, clean the Tube (page 95) and check the air cleaner case. AWARNING POTENTIAL HAZARD O GO wood © 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. 37 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 air pressure (see pages 126—127). AWARNING 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. | 38 Loading Load Limits There are limits to how much weight can be carried on your FOUR- TRAX and be pulled in a trailer. NOTE: The following weight limits apply to standard equipment only. Modifying your FOURTRAX, using non-standard equipment or riding on terrain that is not flat and smooth could further reduce these limits. Maximum weight capacity (Combined weight of the rider, all accessories and all cargo) Front cargo rack weight limit Rear cargo rack weight limit Tow weight limit (Combined weight of the trailer and all cargo in the trailer) Tongue weight (Weight on the trailer tongue) Tongue and rear cargo weight (Combined weight on the trailer tongue and on the rear cargo rack) 485 Ibs (220 kg) maximum 66 Ibs (30 kg) maximum 133 Ibs (60 kg) maximum 850 Ibs (385 kg) maximum 30 Ibs (14 kg) recommended 133 Ibs (60 kg) maximum 39 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 above and follow these guidelines: 1. Do not place cargo anywhere on the FOURTRAX other than on the front and rear racks. Otherwise, operating stability may be adversely affected. 2. Never ride with a passenger on the front or rear cargo racks. The FOURTRAX is not designed to carry a passenger. 3. Do not tow another vehicle or a trailer with a rope or cable attached to the rear rack. Use the trailer hitch. 4. Load cargo on the rear rack as far forward as possible. Make sure cargo on the front rack does not interfere with handlebar movement. 5. Do not allow cargo to extend beyond the edges of either the front or rear racks. 6. Make sure all cargo is secured. 7. When towing a trailer, take care to maintain balance and stability. Distribute cargo between the front and rear of the trailer to obtain the recommended tongue weight. NOTE: Tongue weight can be measured with ordinary bathroom scales. Place the scales under the tongue, using either the tongue jack or other support to keep the trailer level. 40 8. Allow extra room for starting, stopping and turning whenever you carry cargo or pull a trailer. 9. Avoid riding on steep slopes when carrying cargo or pulling a trailer. 10. Never cross a slope when towing a trailer. | AWARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling, stability and braking which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load limits for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Use extra care when operating on hills and riding over obstacles. Never cross a slope when pulling a trailer. Always follow the instructions in this Owner's Manual for carrying cargo or pulling a trailer. 41 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. 42 AWARNING 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: AE NDIEN Indicates a strong possibility that serious injury or death may result if instructions are not followed. 43 No Modifications Modifying this FOURTRAX or removing original equipment may render the vehicle unsafe or illegal. Spark arresters and mufflers are required in most areas. Don't modify your exhaust system. Remember, excessive noise bothers everyone and creates a bad image for off-road vehicles. SAFE RIDING RULES Protective Apparel Always wear an approved motorcycle 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. AWARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket and long pants. 45 No Passengers This FOURTRAX is designed as an operator-only vehicle. The long seat is 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. AWARNING 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. 46 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. AWARNING 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. 47 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. AWARNING 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. 48 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. 49 FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. It 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. 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. 50 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. 51 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. AWARNING 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. 52 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. AWARNING 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. 53 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. Аве 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. 54 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. A WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. 55 RIDING For your initial riding practice, select a safe area free of obstacles with a level surface of dirt or sand. Practice at low speed until you are confident in shifting gears, braking, and making turns. AWARNING POTENTIAL HAZARD Running the engine in an enclosed ares. 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. 56 STARTING THE ENGINE Following are the procedures for starting a cold engine when air temperature is 50—95°F (10—35°C). (If you need help locating the controls, refer to pages 10—28 or the Index.) 1. Lock the parking brake, and make sure the transmission is in neutral. (The starter will not operate unless the transmission is in neutral.) 2. Turn the fuel valve, the fuel cap vent lever and the ignition switch ON. 3. Turn the engine stop switch to RUN. 4. Set the choke lever at the half choke position. Keep the throttle fully closed. 5. 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. 6. After the engine has warmed up, turn the choke OFF. If the engine is already warm, or if air temperature is above 95°F (35°C), do not use the choke, but open the throttle slightly before pressing the starter button. If air temperature is below 50°F (10°C), move the choke lever to the full choke position before starting the engine. Keep the throttle fully closed. As the engine warms, move the choke to the half choke position. When the idle is smooth, turn the choke OFF. When air temperature is below 5°F (-15°C), push the starting primer knob once or twice before pressing the starter button. 57 If the engine doesn’t start after pushing the starter button several times, use the kick starter. Flooded Engine If the engine does not start after several attempts, it may have become flooded with excess fuel. To clear the engine: . Turn the engine stop switch OFF. . Move the choke lever to the OFF position. . Hold the throttle fully open and briefly press the starter button or operate the kick starter several times. . When the engine is cleared, wait 10 seconds. Then turn the engine stop switch ON and repeat the normal starting procedure, but don't use the choke. BD wm 58 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 SL (super low) 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 1st gear by raising the gearshift pedal one full stroke. 5. Repeat this sequence to progressively upshift to 2nd, 3rd and 4th (top) gear. 6. To downshift, reverse this sequence. Remember to close the throttle each time you shift to the next lower gear. AWARNING POTENTIAL HAZARD Shifting gears without releasing the throttle. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always release the throttle when shifting gears. 59 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: . 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. . Release the rear brake lever. . Open the throttle gradually and ride slowly. Do not open the throttle suddenly or make abrupt turns. 5. To stop, close the throttle and gradually apply both the front and rear brakes. Do not abruptly apply the rear brake by itself. 6. To shift out of reverse and into neutral, raise the gearshift pedal one stroke. + N While reading this manual, remember: A WARNING Indicates a strong possibility that serious injury or death may result if instructions are not followed. 60 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. AWARNING POTENTIAL HAZARD Applying 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. 61 MAKING TURNS To make a turn on level ground, steer the handlebars and lean your body toward the inside of the turn. (Fig 3-8) 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 3-8), 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 throttie to maintain the desired speed throughout the turn. Practice these techniques on level ground until you are confident in making turns. 62 Fig. 3-8 Lean your body to the inside of a turn and forward. AWARNING 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. 63 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 direc- tion of the skid. Avoid hard braking or accelerating until you have regained directional control. AWARNING 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. 64 RIDING UP HILLS The FOURTRAX's ablility 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. A WARNING 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. 65 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. 3-9 Shift weight forward when climbing hills. 66 AWARNING 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. 67 2. Get off the FOURTRAX while you continue holding the brakes. 3. Set the parking brake, shift into neutral and turn the engine off. 4. Then assess the situation. If the FOURTRAX starts rolling backwards before you begin braking, keep your weight uphill, carefully apply the front brakes first, then carefully apply the rear brake as well. Do not apply either brake abruptly if you are rolling backwards, or the vehicle may overturn. NOTE: Remember that operating any brake control with four-wheel drive will cause braking at both the front and rear wheels. If the FOURTRAX continues sliding backwards after you've applied the brakes, get off and away from the vehicle. Fig. 3-10 If you roll backwards down a hill, don't apply either brake abruptly. 68 AWARNING 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. 69 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 3-11). . 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. BON 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. 7 UA К N = A = Г TA | ~ , Ty Fig. 3-11 Be sure your legs are Body position for backing clear of the wheels. down a hill. 70 While-reading this manual, remember: IN NINEN Indicates a strong possibility that serious injury or death may result if instructions are not followed. 71 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 low gear, sit back on the seat with 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 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. Also, remember, braking effectiveness is reduced on any hill with a loose surface. Fig. 3-12 On downhills, sit back on the seat. 72 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. 73 CROSSING SLOPES To maintain balance and stability when riding across a slope, you need to shift weight toward the uphill side of the vehicle. To do this, move your body off the center of the seat and lean toward the uphill side. On a slippery or loose surface, you may also need to steer slightly uphill to maintain a straight course across the slope. Avoid crossing hills that are excessively steep, slippery or rough. Fig. 3-13 Shift weight uphill when crossing slopes. 74 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. AWARNING 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. 75 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. AWARNING 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. 76 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 124. 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. 77 PARKING Always choose a level place to park. After bringing your FOUR- TRAX to a stop, hold the brakes while you shift into neutral. Then set the parking brake and turn the ignition switch OFF. If you're through riding for the day, also turn the fuel valve and the fuel cap vent lever OFF. While reading this manual, remember: INDIE Indicates a strong possibility that serious injury or death may result if instructions are not followed. 78 MAINTENANCE AND REPAIRS MAINTENANCE SCHEDULE INITIAL REGULAR I: Inspect and Clean, Adjust, Lubricate SERVICE . SERVICE or Replace if necessary. PERIOD Refer to EVERY PERIOD C: Clean R: Replace ) (Every 30 page ; . (First week ; A: Adjust L: Lubricate . operating of operation) days) * | FUEL LINE YEAR | — * | FUEL STRAINER SCREEN YEAR C 88, 89 * | THROTTLE OPERATION i | 91 * | CARBURETOR CHOKE | 96 AIR CLEANER (NOTE 1} С 92—94 AIR CLEANER CASE DRAIN TUBE (NOTE 2) | 95 SPARK PLUG | 106, 107 * | VALVE CLEARANCE | i 107 28, ENGINE OIL R R 99_ 103 ENGINE OIL FILTER R R 101 — 103 * | CARBURETOR IDLE SPEED | i 96—98 YEAR |, FINAL DRIVE OIL 2 YEARS R 104, 105 BRAKE FLUID (NOTE 3) | 118, 119 79 REGULAR I: Inspect and Clean, Adjust, Lubricate INITIAL SERVICE . SERVICE or Replace if necessary. PERIOD Refer to EVERY PERIOD C: Clean R: Replace . (Every 30 page . (First week A: Adjust L: Lubricate . operating of operation) days) YEAR | 115—117 * К EAR BRAKE SHOE W {NOTE 2) 120—123 BRAKE SYSTEM | ! 25, 115—124 * | REVERSE LOCK SYSTEM | | 109 * [CLUTCH SYSTEM | | 108 ENGINE GUARD, SKID PLATES i 131 * | SUSPENSION i —— * | SPARK ARRESTER (NOTE 4) С 132, 133 * | NUTS, BOLTS, FASTENERS | | — ** | WHEELS/TIRES | | 125—129 * * | STEERING SHAFT HOLDER BEARINGS YEAR **| STEERING SYSTEM YEAR | —— * SHOULD BE SERVICED BY YOUR AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND 15 MECHANICALLY QUALIFIED. REFER TO THE OFFICIAL HONDA SERVICE MANUAL. ** IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY YOUR AUTHORIZED HONDA DEALER. NOTES: 1. Service mare frequently when riding in dusty areas, sand or snow. 2. Service more frequently after riding in very wet or muddy conditions. 3. Replace every 2 years. Replacement requires mechanical skill. 4. USA only. 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 in- structed. If you need to replace any parts, remember to use only new genuine Honda parts or their equivalents. 80 AWARNING 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. AWARNING 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. TOOL KIT A tool kit (Fig. 4-1) is provided with your FOURTRAX and stored in the storage compartment behind the seat. 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 Screwdriver handle 10 x 12 mm open end wrench 14 x 17 mm open end wrench Pliers Spark plug wrench and handlebar Tool case * x x x * kk Fig. 4-1 (1) Tool kit 82 While reading this manual, remember: OTIS indicates a strong possibility that serious injury or death may result if instructions are not followed. 83 FUEL SYSTEM FUEL Refueling Fuel tank capacity is 3.3 US gal (12.5 {), including 0.7 US gal (2.5 £) in the reserve supply. To refuel, remove the fuel tank cap (Fig. 4-2) by twisting it counterclockwise. Do not overfill (make sure there is no fuel in the filler neck). After adding fuel, tighten the fuel tank cap firmly by turning it clockwise. Align the arrow (2) on the cap with the reference mark (3) on the fuel tank. Fig. 4-2 (2) Arrow (1) Fuel tank cap (3) Reference mark (4) Filler neck 84 AWARNING 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 tank cap is closed properly and securely. If any fuel is spilled, make sure the area is dry before starting the engine. AWARNING 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. 85 Fuel Recommendations Your engine is designed to use any gasoline that has a pump octane number (25) of 86 or higher, or a research octane number of 91 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. 86 Gasolines Containing Alcohol If you decide to use a gasoline containing alcohol (gasohol), be sure its octane rating is at least as high as that recommended above. There are two types of gasohol: One contains ethanol, and the other contains methanol. Do not use gasohol that contains more than 10% ethanol. Do not use gasohol that contains methanol (methyl or wood alcohol) unless it also contains cosolvents and corrosion inhibitors for methanol. Never use gasoline containing more than 5% methanol, even if it has cosolvents and corrosion inhibitors. NOTE: * Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is not yet complete. Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol. If it does, confirm the type and percentage of alcohol used. If you notice any undesirable operating symptoms while using a gasoline that contains alcohol, or one that you think contains alcohol, switch to a gasoline that you know does not contain alcohol. 87 FUEL STRAINER SCREEN The fuel strainer (Fig. 4-3) is in the fuel valve. The strainer has a fine mesh screen (2) which prevents dirt from entering the carburetor passages. Dirt which accumulates in the screen must be removed periodically, or the fuel flow will eventually be restricted. To clean the fuel strainer screen: 1. Turn the fuel valve OFF. 2. Remove the fuel strainer cup (1). 3. Remove the strainer screen (2). 4. Wash the screen in nonflammable or high flash point solvent. AWARNING 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. 88 5. Reassemble by reversing the disassembly sequence. 6. Turn the fuel valve and fuel cap vent lever ON, and check for leaks. Correct if necessary. Fig. 4-3 (2) Strainer screen (1) Fuel strainer cup (3) O-ring While reading this manual, remember: IAA Ne Indicates a strong possibility that serious injury or death may result if instructions are not followed. 89 While reading this manual, remember: AZ NVEN Indicates a strong possibility that serious injury or death may result if instructions are not followed. 90 THROTTLE Throttle Cable and Lever Check the condition of the throttle cable and the operation of the throttle lever. Make sure the cable does not bind or interfere with smooth operation of the throttle in any steering position. If the cable is worn or kinked, have it replaced by your Honda dealer. Throttle Free Play Throttle free play, measured at the tip of the throttle lever (Fig. 4-4), should be maintained at 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. 1/8—5/16 in (3—8 mm) Fig. 4-4 (3) Lock nut (1) Rubber sleeve (4) Throttle lever (2) Cable adjuster (A) To decrease free play (B) To increase free play 91 AIR CLEANER Air Cleaner Filter The air cleaner filter accumulates dust and must be cleaned periodically. If the FOURTRAX is ridden in dusty areas, the filter must be cleaned at more frequent intervals than specified in the Maintenance Schedule. To clean the air cleaner filter: 1. Remove the seat by pulling up the seat lock lever (Fig. 4-5). 2. Unlatch the four retainer clips (2) and remove the air cleaner cover (3). Fig. 4-5 (2) Retainer clips (1) Seat lock lever (3) Air cleaner cover 92 3. Remove the screws (Fig. 4-6) and remove the air cleaner assembly (2) from the case. 4. Unscrew the clamp (3) and remove the mounting bracket (4). 5. Remove the filter (5) from the air cleaner body (6). Fig. 4-6 (4) Mounting bracket (1) Screws (b) Filter (2) Air cleaner assembly (6) Air cleaner body (3) Clamp (A) To release 93 6. Wash the filter in nonflammable or high flash point solvent and allow it to dry thoroughly. AWARNING 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 for cleaning ATV parts. 7. Soak the filter in clean gear oil (SAE 80—SAE 90) until saturated, then squeeze out the excess oil. CAUTION: Do not twist the filter element when squeezing out excess oil. Twisting could damage the filter. 8. Reassemble by reversing the disassembly sequence. 94 Air Cleaner Case Drain Tube The air cleaner case drain tube (Fig. 4-7) should be serviced in accordance with the Maintenance Schedule. 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. Fig. 4-7 (2) Clip (1) Drain tube (3) Air cleaner case 95 CARBURETOR Choke Cable and Lever Check the condition of the choke cable (Fig. 4-8) and the operation of the choke lever (2). If the cable is damaged or kinked, have it replaced by your Honda dealer. = Fig. 4-8 (1) Choke cable (2) Choke lever Adjusting Idle Speed and Air-Fuel Mixture NOTE: Do not try to compensate for faults in other systems by adjusting the carburetor. To adjust the idie speed: 1. Warm up the engine. The engine must be warm for accurate idle adjustment. Ten minutes of stop-and-go riding is sufficient. 96 2. Adjust idle speed by turning the throttle stop screw (Fig. 4-9). Idle Speed: 1,400 + 100 rpm. To adjust the air-fuel mixture: 1. Turn the pilot screw (2) clockwise until you hear the engine miss or decrease in speed. 2. Then turn the screw counterclockwise until the engine misses or decreases in speed again. 3. Center the pilot screw exactly between the two extreme positions. Usually, the correct setting (between extremes of rich and lean) will be found at 1-3/4 turns open from a fully closed position. 4. If idle speed changes after adjusting the fuel mixture, readjust the throttle stop screw. | ra XA 2) Fig. 4-9 (1) Throttle stop screw (2) Pilot screw 97 High Altitude Adjustment When operating this FOURTRAX 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 (see the table below). 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. Altitude range Main jet Pilot screw O— 5,000 feet (O— 1,500 m) No. 125 Factory preset 3,000 — 8,000 feet Screw in 3/4 turn or higher No. 120 from factory preset (1,000— 2,500 m) 98 LUBRICATION ENGINE OIL Checking Engine Oil Level and Adding Oil Check the engine oil level each day before operating your FOUR- TRAX and add oil if needed. To check the oil level: 1. Make sure the vehicle is on level ground and the engine is off. 2. Remove the oil filler cap/dipstick (Fig. 4-10) from the right crankcase cover and wipe it clean. 3. 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. 4. If required, add the specified oil into the filler cap hole, up to the upper level mark on the dipstick. Do not overfill. 5. Reinstall the oil filler cap/dipstick. CAUTION: Running the engine with improper oil level can cause serious engine damage. AN / \Z O D \ #09 Fig. 4-10 (2) Upper level mark (1) Oil filler cap/dipstick (3) Lower level mark 99 Engine Oil Recommendations Recommended Oil Viscosity: SAE 10W-40. Other viscosities shown in Fig. 4-11 may be used when the average temperature in your riding area is within the indicated range. USE HONDA GN4 4-STROKE OIL OR AN EQUIVALENT. Use only high detergent, premium quality motor oil certified to meet or exceed US automobile manufacturer's requirements for 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 recomended. * Do not use oils with graphite or molybdenum additives. They may adversely affect clutch operation. SAE 20W-50 SAE 20w-40 0 20 40 60 80 100 °F L | 1 | À | В -20 -10 о 10 20 30 40 “C Fig. 4-11 Recommended oil viscosities 100 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/dipstick from the right crankcase cover (Fig. 4-10). 2. Place an oil drain pan under the crankcase and remove the oil drain plug (Fig. 4-12). Fig. 4-12 (1) Oil drain plug 101 3. Remove the oil filter cover (Fig. 4-13) by removing the screws. Let the remaining oil drain out. Discard the oil filter (2). 4. Check that the oil filter cover O-rings (3) are in good condition and then install a new oil filter. Use the proper Honda oil filter or equivalent. Other filters may not filter impurities from the oil property. 5. Install the filter with the rubber seal facing out, away from the engine. You will see ‘’OUT-SIDE‘’ 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 are tightened securely. Fig. 4-13 (2) Oil filter (4) Rubber seal (1) Oil filter cover (3) O-rings (5) OUT-SIDE mark 102 7. Check that the drain plug sealing washer is in good condition, then reinstall the oil drain plug securely. 8. Fill the crankcase with approximately 2.2 US gt (2.1 {) of the recommended oil. 9. Reinstall the oil filler cap/dipstick. 10. Start the engine and let it idle for a few minutes. 11. Stop the engine and check the oil level. Make sure the oil is 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. 103 GEAR CASE OIL Change the oil in the gear case when specified by the Maintenance schedule. Change the oil with the gear case warm, and the FORTRAX on level ground to assure complete and rapid draining. To change the gear case oil: 1. To drain the oil, first place an oil drain pan under the oil drain plug (Fig. 4-14). 2. Remove the oil filler cap (1) and the drain plug (2). 3. After the oil has compleltely drained, reinstall the drain plug. Drain Plug Torque: 9 ft-Ib (12 N-m, 1.2 kg-m) 4. Fill the gear case with the recommended oil. Front/Rear final gear case oil: 6.4 US oz (190 cc)/3.0 US oz (90 cc) Recommended oil: Honda shaft drive oil or equivalent HYPOID GEAR OIL SAE 80 Front gear case oil: 6.8 US oz (200 cc) Recommended oil: SAE 10 W— 40 Make sure the oil level reaches the lower edge of the inspection hole (3). 5. Install the oil filler cap. 104 Front gear case Front final gear case Fig. 4-14 (1) (2) (3) (4) (5) (6) Oil filler cap Oil drain plug Lower edge of inspection hole Left front shock absorber O-ring Oil level check bolt 105 ENGINE SPARK PLUG The standard spark plug is DPR8EA-9 (NGK) or X24EPR-U9 (ND). CAUTION: Using a spark plug -of incorrect size or heat range can cause serious engine damage. To check and change the spark plug: . 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 square edges, and the side electrode (2) should not be eroded. If the electrodes and in- sulator tip appear unusually fouled or burned, we suggest that you contact your authorized Honda dealer. 5. Discard the spark plug if there is apparent wear or if the in- sulator is cracked or chipped. 6. Using a wire-type feeler gauge, make sure that the spark plug gap is 0.031—0.035 in (0.8—0.9 mm). If adjustment is necessary, bend the side electrode carefully. 7. With the plug washer attached, thread the spark plug in by hand to prevent cross-threading. 8. After threading by hand, tighten a new spark plug 1/2 turn with the spark plug wrench to compress the washer. If you are reus- ing a plug, it should only take 1/8— 1/4 turn after the plug seats. Dd WN 106 CAUTION: The spark plug must be securely tightened. An improperly tightened plug can become very hot and possibly damage the engine. O { 0.031—-0.035 in (0.8—0.9 mm) 1 al Fig. 4-15 (1) Center electrode (2) Side electrode VALVES Valve clearance should be maintained at 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 ad- justed by an authorized Honda dealer. 107 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 108 Reverse Lock System Measure the reverse lever free play. Free play, measured at the lever end near the cable (Fig. 4-17), should be within 1/16—1/8 in (2—4 mm). To adjust, loosen the lock nut (1) and turn the adjusting nut (2). Tighten the lock nut securely. Other Checks: Check the reverse lever and cable for loose connections or other damage. If the cable is worn or kinked, have it replaced by your Honda dealer. 1/16— 1/8 in (2—4 тт) Fig. 4-17 (1) Lock nut (2) Adjusting nut 109 ELECTRICAL SYSTEM BATTERY Your FOURTRAX battery is located in a compartment under the seat. The battery is sealed, so itis not necessary to check the elec- trolyte 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. AWARNING POTENTIAL HAZARD Allowing open flames or sparks near the battery. WHAT CAN HAPPEN Gases may explode and possibly cause injury. HOW TO AVOID THE HAZARD Do not allow open flames or sparks near the battery. When the FOURTRAX 1s to be stored for an extended period, remove the battery from the vehicle and charge it fully. Then store it in a cool, dry place. If the battery is to be left on the vehicle, disconnect the negative cable from the battery terminal. 110 Battery Removal с > W N — O . Make sure the ignition switch is OFF. . Remove the seat (page 130). . Remove the battery box cover (1) by removing the mount bolts (2). . Remove the battery holder (3) by removing the mount bolts (4). . Disconnect the negative (-) terminal lead (5) from the battery (6) first, then disconnect the positive (+)terminal lead (7). . Remove the battery. * Install in the reverse order of removal. * After installing the battery, check to see if the battery cables are routed correctly as shown on the label (8). * Check all bolts and other fasteners are secure. 111 Fig. 4-18 112 Battery box cover Mount bolts Battery holder Mount bolts Negative (—) terminal lead Battery Positive (+) terminal lead Caution label FUSES As illustrated in Fig. 4-19, the main fuse (1), the sub fuse (2) and the spare fuse (3) are located in the battery compartment. Both the main fuse and the sub fuse are 15 A. (The main fuse is connected to the red wire.) If a fuse fails frequently, it usually indicates a short circuit or an overload in the electrical system. See your authorized Honda dealer for repair. Fig. 4-19 (1) Main fuse (Red wire) (3) Spare fuse (2) Sub fuse (Pink wire) (4) Fuse holder To replace a fuse: 1. Make sure the ignition switch is OFF. CAUTION: Turn the ignition switch OFF before checking or replacing the fuse to prevent accidental short-circuiting which could damage the electrical system. 113 2. Open the fuse holder (Fig. 4-20) and lift out the fuse with the clips (2). 3. Slide the old fuse out of the clips and discard it. 4. Slide the clips onto the ends of the new fuse, push them back into the fuse holder, and close the fuse holder. REMOVAL INSTALLATION Fig. 4-20 (1) Fuse holder (2) Clips AWARNING 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. 114 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. 4-21) moves before the brakes start to take hold. Free play, measured at the tip of the front brake lever (1) should be within 1— 1-1/4 in (25—30 mm). 1—1-1/4 in (25— 30 mm) Fig. 4-21 (1) Front brake lever 115 2. Remove the inspection hole plug (Fig. 4-22) 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. 4-22. A. if the brake lever free play is excessive but the linings are not worn beyond the service limit, adjust the brake lining clearance. Fig. 4-22 (2) Lining thickness (1) Inspection hole plug (3) Front brake drum (4) Front wheel rim 116 To adjust the brake lining clearance: 1. 2. 3. Squeeze the brake lever firmly two or three times then release it. Raise the front and rear wheels off the ground by placing a support block under the vehicle. Beginning with either the left or right front wheel, remove the inspection hole plug (Fig. 4-22) and line up the hole with one of the brake adjusters (Fig. 4-23). . Using a screwdriver, turn up the brake shoe adjuster (1) until the front brake locks. Fig. 4-23 (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. . Line up the inspection hole with the second adjuster and repeat steps 3 through 5. . Reinstall the inspection hole plug, seating it into the inspection hole as shown in Fig. 4-22. . Follow steps 3 through 7 to adjust the other front brake. . 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. 117 To check the brake fluid level: Brake fluid must be added to the reservoir (Fig. 4-24) whenever the fluid level approaches the lower level mark (5). Use only DOT 3 or 4 brake fluid. NOTE: If the fluid level approaches the lower level mark (5), 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. 1. Remove the screws (1), reservoir cap (2), diaphragm plate (3) and diaphragm (4). 2. Fill the reservoir with the recommended brake fluid up to the upper level mark (6). 3. Reinstall the parts in the reverse order of removal. 118 Fig. 4-23 (4) Diaphragm (1) Screws (5) Lower level mark (2) Reservoir cap (6) Upper level mark (3) Diaphragm plate AWARNING 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. 119 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. 4-25), should be 5/8— 3/4 in (15—20 mm). 5/8— 3/4 in (15—20 тт) Fig. 4-25 (1) Rear brake pedal 120 To adjust the free play, turn the brake pedal adjusting nut (Fig. 4-26), located on the brake operating rod at the rear of the frame. NOTE: Make sure the cut-out on the adjusting nut is properly seated on the brake arm pin (3). Fig. 4-26 (1) Brake pedal adjusting nut (2) Brake lever adjusting nut (3) Brake arm pin 121 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. 4-27), should be within 5/8— 3/4 in (15—20 mm). Minor adjustments can be made with the adjuster (2) on the brake lever. Loosen the lock nut (3) and turn the adjuster. Major adjustments should be made using the brake lever adjusting nut on the brake arm (Fig. 4-28). 5/8— 3/4 in (15—20 mm) I, TN 7 ~ Fig. 4-27 (2) Adjuster (1) Brake lever (3) Lock nut 122 To check rear brake shoe wear: When the brake is applied, an arrow (3) attached to the brake arm (2) moves toward a reference mark (4) on the brake panel (see Fig. 4-28). 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. = 4) Fig. 4-28 (2) Brake arm (1) Brake lever adjusting nut (3) Arrow (4) Reference mark Other Checks: Check the condition of the brake cables. If there are kinks or signs of wear that could cause sticking or failure, have the cables replaced by an authorized Honda dealer. Make sure the brake arm, spring, and fasteners are in good condition. 123 DRAINING WATER FROM BRAKES Make sure the engine is off and the parking brake is set. Then remove the inspection hole plug (Fig. 4-29) from the front brakes, and the drain bolt (Fig. 4-30) 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. 4-29 (1) Front brake inspection hole plug Fig. 4-30 (1) Rear brake drain bolt 124 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. 4-31) 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 to 47 ft-lb (65 N-m, 6.5 kg-m). Be sure the tapered side of the wheel nuts face the wheel rim (2). AWARNING 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. 125 NOTE: if a torque wrench was not used for installation, see your authorized Honda dealer before operating the vehicle to verify proper assembly. 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 air pressure gauge sup- plied with the vehicle. For normal use, the tires should be inflated to the pressure recommended in Fig. 4-32. 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. 126 * 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. Front Rear TIRE SIZE АТ 23х8-1 1 ж * | AT 24x9-11 xx TIRE BRAND A/T 504 Ohtsu | A/T 502 Ohtsu RECOMMENDED | 4.4 psi (30 kPa, | 2.9 psi (20 kPa, PRESSURE 0.30 kg/cm?) 0.20 kg/cm?) NO MAX. 5.0 psi (34 kPa, | 3.3 psi (23 kPa, CARGO | PRESSURE 0.34 kg/cm?) 0.23 kg/cm?) MIN. 3.8 psi (26 kPa, | 2.5 psi (17 kPa, PRESSURE 0.26 kg/cm?) 0.17 kg/cm?) WITH RECOMMENDED | 4.4 psi (30 kPa, | 3.6 psi (25 kPa, CARGO | PRESSURE 0.30 kg/cm?) 0.25 kg/cm?) Fig. 4-32 Tire specifications AWARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in this Owner's Manual for this vehicle. Always maintain proper tire pressure as described in this Owner's Manual. 127 Tire Tread Condition To check the condition of a tire tread, measure the groove depth (1) in the center of the tire, or check the wear indicator (2) as shown in Fig. 4-33. The minimum tread depth is 0.16 in (4 mm). When the tread depth is less than recommended, the tire should be replaced. Replace Fig. 4-33 (2) Wear indicator (1) Groove depth (3) Wear indicator location mark 128 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. 129 SEAT REMOVAL To remove the seat (Fig. 4-34), pull up the seat lock lever (1) at the left side of the seat, then slide the seat backwards and lift it up. To reinstall the seat, slide the front prong (3) into the recess (4) and press the seat down until it locks. Fig. 4-34 (2) Seat (1) Seat lock lever (3) Front prong (4) Recess 130 ENGINE GUARD AND SKID PLATES The engine guard and skid plates (Fig. 4-35) protect the front frame/lower arm, engine crankcase and the rear brake. Check the guard and plates for cracks, damage or looseness at intervals shown in the Maintenance Schedule. Have the engine guard and skid plates replaced if they are cracked or damaged. If the plate bolts are loose, tighten them securely. Fig. 4-35 (1) Engine guard (2) Skid plates 131 SPARK ARRESTER The exhaust system must be periodically purged of accumulated carbon. To purge the system: 1. Select a well-ventilated area and make sure the exhaust pipe is cool. 2. Remove the bolts (Fig. 4-36), gasket (2) and spark arrester lid (3). 3. Start the engine and momentarily rev it up several times. 4. Stop the engine and allow the exhaust pipe to cool. 5. Reinstall the removed parts and tighten the bolts securely. TT — —> = Fig. 4-36 (2) Gasket (1) Bolts (3) Spark arrester lid 132 AWARNING 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. 133 DRIVESHAFT BOOTS Check the rubber driveshaft boots (1) for damage or leaking grease. If necessary, have your authorized Honda dealer replace them. Fig. 4-37 (1) Driveshaft boots 134 While reading this manual, remember: ANDES Indicates a strong possibility that serious injury or death may result if instructions are not followed. 135 TRANSPORTING YOUR FOURTRAX When you transport your FOURTRAX, we recommend that you carry the vehicle in its normal operating position (on all four wheels) and follow these procedures: 1. Set the parking brake and place the transmission in gear. 2. Turn the fuel cap lever and fuel valve OFF. 3. Secure the vehicle properly. Suitable “tie downs"' are available from your Honda dealer. Ordinary rope is not recommended because it can stretch under load. If it is necessary to incline your FOURTRAX upright on the rear end: . Follow steps 1 and 2 above. . Place the carburetor drain tube in a suitable container. . Turn the drain screw counterclockwise and drain the fuel from the carburetor. . After draining the carburetor, turn the drain screw clockwise until it is tight. | 5. Pour the drained fuel into the fuel tank. 6. Tilt the vehicle and secure properly. + WN = Do not tow your FOURTRAX behind a car or other vehicle. 136 AWARNING 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. AWARNING 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. 137 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. 138 AWARNING 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 tank cap is closed properly and securely. If any fuel is spilled; make sure the area is dry before starting the engine. AWARNING 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. 139 3. Spray the inside of the fuel tank with an aerosol rust-inhibiting oil. Reinstall the fuel cap. 4. 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 before pressing the starter button.) 5. Remove the battery and store it in an area protect from freezing temperatures and direct sunlight and out of the reach of children. Slow charge the battery once a month. AWARNING POTENTIAL HAZARD Allowing open flames or sparks near the battery. WHAT CAN HAPPEN Gases may explode and possibly cause injury. HOW TO AVOID THE HAZARD Do not allow open flames or sparks near the battery. 6. Wash and dry the FOURTRAX, and wax all painted surfaces. 7. Inflate the tires to their recommended pressures. 8. Place the FOURTRAX on blocks to raise all four tires off the ground. 140 SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height 75.2 in (1,910 mm) 43.7 in (1,110 mm) 42.7 in (1,085 mm) Wheelbase 48.6 in (1,235 mm) WEIGHT Dry Weight 520 Ibs (236 kg) CAPACITIES Engine oil 2.6 US gt (2.5 ) Fuel tank 3.3 US gal (12.5 ?) Fuel reserve 0.7 US gal (2.5 ?) ENGINE Bore and stroke 2.9 x 2.6 ın Compression ratio Displacement Spark plug gap Valve clearance (74.0 x 65.5 mm) 9.0:1 17.2 cu-in (281.7 cc) 0.031 —0.035 in (0.8—0.9 mm) 0.006 in (0.15 mm) CHASSIS AND SUSPENSION Caster angle Trail length Tire size, Front Rear 2 deg 0.39 in (10 mm) AT 23 x 8-11 Xx x AT 24 x 9-11 x POWER TRANSMISSION Primary reduction Final reduction Front: Rear: Gear ratio, SL 1st 2nd 3rd 4th Reverse gear ratio 2.407 5.554 5.684 4.083 2.389 1.609 1.179 0.848 5.397 141 WIRING DIAGRAM OLAS ош + 8 ЗЫ + SRN ве Вой НН HARM 109010 Nüda In) HEN WW [NOILdD ) 704 | (A MEAL. 142 WARRANTY SERVICE Your satisfaction and goodwill are important to American Honda and to your Honda dealer. All Honda warranty details are explain- ed 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 manage- ment. 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. 143 * 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 420, Gardena, CA 90247-0805. Telephone: (213) 532-9811. We will need the following information in order to assist you: . Your name, address, and telephone number. . The model humber and serial number of your FOURTRAX. . Date of purchase. . Dealer's name and address. . The nature of your problem. сл + © Ю — 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. Both American Honda and your Honda dealer want to assist you in every way possible to assure your complete satisfaction. 144 SERIAL NUMBERS The frame, engine and key numbers (Fig. 5-1) will be needed when you order replacement parts. Record the numbers here for your reference. The frame serial number (2) is stamped on the front of the frame. The engine serial number (3) is stamped on the right crankcase. KEY NO. FRAME NO. ENGINE NO. Fig. 5-1 (1) Key number (2) Frame number (3) Engine number 145 INDEX A ACCesSsories ...........eeeeenevevorcorrrrcavacoracecacovarereracereecca 32, 42 Age recommendation .................….....essecesece cer e nec a nc 34 Air cleaner Case drain tube caresse rca ns een nana nas e ne» 95 Filter iit re eee a 92 Air pressure gauge ...........e...eeec..eeersvcenacorvrarenecareaamean. 31 Apparel, recommended ..................eeeerrrecenercecacerrrece 44 B Battery ..............—.__errecocorcoorecoreerere once aaarenaceeae ae. 110 Brakes Brake cables o.oo nono ee neceae 123 Brake fluid ..............ec.eeeerreescrvevervenerocaacarececenecercere 118 Front brakes Adjustment ............e..._rreeseverrevereneerecocaoreanoreooaea 115 Brake lever ............_reeonmeccscconreconreenecooneccorececeermo e 25 Brake lever free play ..................eeerceesrecarcorzireoa.. 115 Brake shoes ...............eeceerresceveccorrarereocerecen eco 115 Parking brake .............e..ereee_rrrerecesceveacccarcarecanecea e 25 Rear brake Brake lever ...............eneocccccorzc0en00iore na nanas ae ee san nn 25 Brake lever free play ..…..…..…..........ssesesena nanas ana cena e 122 Brake pedal .….….….…..…..........rrsrrrerrnaararan canne rennes canne 25 Brake pedal free play ................ssecesssanaa nana nan0 120 Break-in procedures .................cereserdccacccrarececeracecece e H C Carburetor Air-fuel mixture adjustment ...............eeee_eeeenerceconereos 96 High altitude adjustment .......................eessverircevec... 98 Idle speed adjustment ..................e.... EEE ER RER RER REEL 0 96 Cargo carrying Loading and operational guidelines ..…......…..…..…......….……………… 40 Weight limits oii cece eens 39 Choke Cab eee ieee, 96 LEVEr TT 15, 96 Climbing hills o.oo nene 65 Clutch adjustment cocoons 108 146 Crossing slopes ............eeecerecnarerrcocccnoaconnerecene eco ENG 74 Customer Service ..............ecerrencccurrveriecreornecor ee A 143 D Decompressor lever ............e...e...eesrraceroreonveceneenen eee. 18 Dimmer switch ..................eerrrerercervoceanerceraconece ene. 20 Dipstick ............eeonrrccrrconcoronccirenaro rene acera ee nen once De 28, 99 Direct current (DC) power ReceptaCleE ETT 32 Special plug .............ee.eereericerecoracararcenier ee ne nce ee 32 Driveshaft boots ...............eeeecerreresrecrnrrooconececeraoc eo ee 134 E Engine Break-in procedures ................rreeecerrrvcconvonercennecece.. H Filooded engine ..................eerrrerencceerrocconveneonenco a e. 58 Engine guard and skid plates ................e....ee.eexrvecanaro 131 Starting the engine ...............———e_.—..erer.eovrecovoccoren ee. 57 Engine oil Changing Oil .................e...eeereerecer recen ar aaron reee 101 Checking oil level and adding oil ..................ee....e..e.... 99 Oil filler cap/dipstick ..............eeeeeecerrrrariorenaear eee. 28 Oil filter .................eeeeceooreocccecoceienoroneororenenenecen nee. 101 Qil temperature warning lamp... 20 Recommendations ................e..eeerírrreocenencecca eee 100 Engine stop switch .......... PES 14 Exhaust system Cleaning ..........eeeoerrenoreccccrorcanceneateracarene re tener 37 PUrging eee receDD. 132 F Final gear case Oil .................eeercroeceacerorreocercenee eee. 104 Flag pole bracket ..................mmmm.eccrarrcedaronenr enn ene ne 30 Flooded engine ..............e....eccccrcerconenececer retar arena. 58 Fuel Fuel recommendations ..................reeeerrrserceriroenecee.. 86 Fuel strainer screen ...........ee..orrrcercenrecconecoreroccnDe 88 Fuel tank cap ............e......eeservecccocarecceroreaioce none. 26, 84 Fuel tank cap vent lever .............eeerrecoriicoorcaneoe ee. 26 Fuel tank capacity ............ee_eeoocceccenercccaroreneconecevA.. 84 Fuel valve ...............ecommernadecccereceereraatcanercconerocmene.. 26 High altitude fuel mixture adjustment ............c.....e..... 98 Refueling ................eeem.ererrereenerccareocecaoeceneroneanen ace. 84 Reserve fuel supply een nen R RAR RR RER REGEL 27 Fuses Location ee rr aes 113 Replacement coir ere 113 G Gasoline (see Fuel) Gearshift pedal een encon 23 Gearshifting PPP 23, 59 Gear case Oil .............cee.resnrriranecaccocereneereverecer eee. 104 H Headlight switches ..................e.ee.e.e0errrenreorecee ene 20 Helmet holder ................e...e.ee.ercvcccacorreneooncane ercer 29 High altitude carburetor adjustment .....................eos.e..... 98 Hills Riding across Slopes ......................eesexmrrenereencenene 74 Riding down hills ...............e..e..e.e.erecsvrenenieneremecneene 72 Riding up hills ...............eee.eeeesccrscererecerencan eee DA 65 Stopping on hills ...............ee-..eeereecsrrooreneorerene nece 67 Turning on slopes ...............ewrrrreesreevcenereoaoonecen cen. 75 | Idle speed adjustment .....................eesreecconcocooecer en 96 Ignition SWITCH oie 13 indicator lamps Neutral indicator lamp ...............—.—.ecereseereccccrerrarecere.. 22 Reverse indicator lamp ....................reeecesveccececceeeere 22 Inspection, pre-ride .............e..ermercenvccconenianer nene eee 36 K Kick starter ...............eeeeerer.mrencurriocrenrecocaarerrrcscano ea 17 L Loading Loading guidelines and procedures ........................... 40 Weight limits ............e.—.er--esreccreoroerrorneconeere cane 39 Lubrication (see Engine oil and Gear case oil) 148 M Maintenance Precautions ...........e.eemnreresriccieorereearerenocan eran icaneoA. 80 Schedule ..…..............recreerrrre rar nana na ana aa e seen rence area 79 Modifications .............e...eeeesssrcarrreccanreceeconeroro re acen ee. 44 N Neutral indicator lamp .............eecesrrmmrcerertccrenceeo ene 22 O Obstacles, riding Over ...........eeerrrrrececarroceonecrroor ear eee. 76 Oil (see Engine oil and Gear case oil) Oil filler cap/dipstick .................eeee2eeceererverooccnneen 28 Oil filter, changing ............e.eceerreserecrcrrraverooe cane e ee. 101 Owner's manual compartment ................ee_eeemm2rreenecee.. 31 P Parking ..............cece res e ee eee ee rene rene ee ren nan rene nee nee c en cn cc 78 Parts location .............ee.eceeecsnorveovecucacoraresvacaorremecene.. 10 Parking brake ...........ee.ererrrernecccccrecorreeertn cen ec a ceca 25 Passenger carrying ..............eeee.eexeerecorrcrirrenecce ner ire. 46 Pavement, no riding on ............eee=.eerrrerrercecccanreracrenene. 48 PInging ...........e...w.en2esverercrrercer rare e nro eee. 86 Power supply, 12 V DC coir eee 32 Pre-ride inspection ...............eeecenrrerororerctecear ee eno ne. 36 R Reverse Gear, shifting into ...................—ec =—_rewrrreereacoccorecenmen. 24, 59 Indicator lamp ............eeee.e..e.eeeverrreorecnenereanear reno. 22 Lock cable ................eeorrrecdnsrecccaocarecicooerocarenerceceN 109 Lock lever ..............eerecdnssmmareconesriioooorrrenoreomecaN ee. 109 Riding in reverse .................e...rrrmemeroccaniarecece ee ene 60 Selector knob ...............e_cesrrcorreccacocarccrecccace cena. 24 Rider training Course .............e.rwnrerrírecerernorer cs cn anna anne 1, 36 S Safety messages, special o.oo ae 1 Seat removal and installation ............c.oceiiiiiiiiiiiiiiiiaenn.. 130 Serial numbers ...............e.ees.ecsreciiocaorrereareveceneorerer ecc. 145 Shifting gears ................-eerreeercececencerrecacanonanecnomene De. 23, 59 1419191101 BEE 64 Spark arrester ..…..............rsreccerssnsssa sera nee nana ane as an annees 132 Spark KNOCK oon, 86 Spark plug «one De 106 SpecificationS «0.000000. r er eee. 141 Stalling on a hill ..............eee.eececesrccocioor earn ee e 67 Starter button oot eccrine 16 Starting primer Knob ................ee—.re=ereseemeresereeenere nes 16 Storage compartment .............e....e.errervereeconeeaoreeen e. 31 Storing procedures ................._re-+-rreseercerer rencores 138 T Throttle Cable ...........e....e..d00rccsicococarecacccorrecccrececereacooaeneeos 91 Lever .............eeerrecccccnicaseovartecearecececancaneceearereacaeao 19, 91 Tires inflation and air pressure .................ee.mreercerrorecrrecee.. 126 Repairing ............ee.eesverecescerocirceoreonccaree reee e 129 Specifications .............e..e_erescerrrceeriareece0 eee Ree 127 Tread condition .............eeeoocerrrrreccconerecrorere co. 128 Tool Kit .............e.eeoccccerveorenereoneeorrcane nee rene eean 82 Trailer hitch ...............eeeeererereccererecrace o neon ene 0 30 Trailer towing Operational guidelines ..................e....erecorerecercecerece. 40 Weight limits .................e..rererresrecenareer nora o eee 39 Transporting procedures ..............ee...r.eserceveraaerere nene 136 Turning On level ground .................rrecemrrecereccerioo rene e. 62 Onslopes ............e.e_rremerrerrerecerenaner ion en erre ee. 75 V Valve Clearance RAR eerie reat eae ann 107 W Warning labels .................eeeeorcsrererarereoener ercer ena 7 Warranty Service ............eermreecondcavcacerencororeoriono recen. 143 Water Draining frombrakes ...............ee..e.rsresecoceneaieo mean 124 Riding through .…...............covercccsnaran none seccennacne cero. 77 Weight limits ..............eeesrecesocneroccavorecarenerereecenrercacone. 39 Wheel removal .................rene.esanaarconreccorereoreanenccar e 125 Wiring diagram ............._e_eesrcessreraccerecenereca necio nece 142 150 FN N el Indicates a strong possibility that serious injury or death may result if instructions are not followed. 151 SERVICE MANUALS The Service Manual (Part Number: 61HC403) used by your authorized Honda dealer is available from your dealer's parts department. Also available, but not necessary to service your model: * The Honda Common Service Manual (Part Number: 61CMO000) explains the theory of operation and provides basic service information for various systems common to all Honda motor- cycles, scooters, ATVs and Pilots. 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. 152 10C02

Honda TRX 300 FW Utility Vehicle Owner's Manual 156 Pages

Honda TRX 300 FW Utility Vehicle Owner's Manual

Key Features

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Honda TRX 300 FW Utility Vehicle Owner's Manual 156 Pages

Honda TRX 300 FW Utility Vehicle Owner's Manual

Key Features

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Is the TRX 300 FW a four-wheel drive vehicle?

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