Honda TRX450R Owner's Manual

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This manual should be considered a permanent part of the ATV and should remain with the ATV when it is resold.

This Owner’s Manual covers the

TRX450R (kickstarter)

TRX450ER (electric starter) models. You may find descriptions of and equipment and features that are not on your particular model. All illustrations are based on the TRX450ER model.

This publication includes the latest production information available before printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.

The vehicle pictured on the front cover may not match your vehicle.

Honda Motor Co., Ltd. 2007

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2008

Honda TRX450ER (electric starter)

Honda TRX450R (kickstarter)

SPORTRAX 450R

OWNER’S MANUAL

FOR OFF-ROAD USE ONLY

This vehicle is designed and manufactured for off-road use only.

USA only:

It conforms to US EPA Noise Emission regulations, but does not conform to Federal Motor Vehicle Safety Standards or US EPA On

Highway Exhaust Emission regulations, and operation on public streets, roads, or highways is illegal. The vehicle is equipped with a USDA qualified spark arrester. Obey local laws and regulations.

It conforms to US EPA, California, and Environment Canada exhaust emission regulations for ATVs.

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Introduction

Congratulations on choosing your Honda ATV.

When you own a Honda, you’re part of a worldwide family of satisfied customers − people who appreciate Honda’s reputation for building quality into every product.

Your Honda was designed as a recreational ATV for off-road use by one rider only.

Before riding, take time to get acquainted with your ATV and how it works. To protect your investment, we urge you to take responsibility for keeping your ATV well maintained. Scheduled service is a must, of course. But it’s just as important to observe the break-in guidelines, and perform all pre-ride and other periodic checks detailed in this manual.

We also recommend that you read this owner’s manual before you ride.

It’s full of facts, instructions, safety information, and helpful tips. To make it easy to use, the manual contains a detailed list of topics at the beginning of each section, and both an in-depth table of contents and an index at the back of the book.

As you read this manual, you will find information that is preceded by a symbol. This information is intended to help you avoid damage to your Honda, other property, or the environment.

Read the Warranties Booklet (page 217 ) thoroughly so you understand the coverages that protect your new Honda and are aware of your rights and responsibilities.

Whenever you ride, tread lightly. By staying on established trails and riding only in approved areas, you help protect the environment and keep off-road riding areas open for the future.

Introduction

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Introduction

If you have any questions, or if you ever need special service or repairs, remember that your Honda dealer knows your ATV best and is dedicated to your complete satisfaction.

Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information.

You may also want to visit our website at www.honda.com.

Happy riding!

California Proposition 65 Warning

WARNING: This product contains or emits chemicals known to the

State of California to cause cancer and birth defects or other reproductive harm.

Introduction

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A Few Words About Safety

Your safety, and the safety of others, is very important. And operating this ATV safely is an important responsibility.

To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.

This information alerts you to potential hazards that could hurt you or others.

Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining an ATV. You must use your own good judgment.

You will find important safety information in a variety of forms, including:

Safety Labels –– on the ATV.

Safety Messages –– preceded by a safety alert symbol and one of three signal words: DANGER, WARNING, or CAUTION .


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These signal words mean:

You WILL be KILLED or

SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

Safety Headings –– such as Important Safety Reminders or Important

Safety Precautions.

Safety Section –– such as ATV Safety.

Instructions –– how to use this ATV correctly and safely.

This entire manual is filled with important safety information –– please read it carefully.


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Contents

These pages give an overview of the contents of your owner’s manual.

The first page of each section lists the topics covered in that section.

ATV Safety .......................................................................................

.

Important safety information you should know, plus a look at the safety-related labels on your ATV.

1

Indicators & Controls ......................................................................

.

The location and function of indicators and controls on your ATV and operating instructions for various controls and features.

9

Before Riding ....................................................................................

.

27

The importance of wearing a helmet and other protective gear, how to make sure you and your ATV are ready to ride, and important information about loading.

Basic Operation & Riding ...............................................................

.

How to start and stop the engine, shift gears, and brake. Also, riding precautions.

41

Contents

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Contents

Servicing Your Honda .....................................................................

.

Why your ATV needs regular maintenance, what you need to know before servicing your Honda, an owner maintenance schedule, and instructions for specific maintenance and adjustment items.

73

Tips ....................................................................................................

.

169

How to store and transport your ATV and how to be an environmentally-responsible rider.

Taking Care of the Unexpected ......................................................

.

179

What to do if you have a flat tire, your engine won’t start, etc.

Technical Information .....................................................................

.

197

ID numbers, technical specifications, and other technical facts.

Consumer Information ....................................................................

.

213

Information on warranties, emission controls, how to get Honda service manuals.

Table of Contents .............................................................................

.

222

Sequential listing of topics in this owner’s manual.

Index ..................................................................................................

.

228

Quick Reference

Handy facts about fuel, engine oil, tire sizes, and air pressures.

Contents

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ATV Safety

This section presents some of the most important information and recommendations to help you ride your ATV safely. Please take a few moments to read these pages. This section also includes information about the location of safety labels on your ATV.

Important Safety Information ................................................................

. 2

Safety Labels ..........................................................................................

. 5

ATV Safety

1

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Important Safety Information

Your ATV can provide many years of service and pleasure − if you take responsibility for your own safety and understand the challenges you can meet while riding.

There is much that you can do to protect yourself when you ride. You’ll find many helpful recommendations throughout this manual. The following are a few that we consider most important.

Follow the Age Recommendation

The minimum recommended age for this ATV model is 16. Children under age 16 should never operate this vehicle.

Always Wear a Helmet

It’s a proven fact: helmets significantly reduce the number and severity of head injuries. So always wear an approved motorcycle helmet. We also recommend that you wear eye protection, sturdy boots, gloves, and other protective gear (page 28 ).

Never Carry a Passenger

Your ATV is designed for one person only. There are no handholds, footrests, or seat for a second person − so never carry a passenger. A passenger could interfere with your ability to move around to maintain your balance and control of the ATV.

2

ATV Safety

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Ride Off-Road Only

Your ATV is designed and manufactured for off-road use only. The tires are not made for pavement, and the ATV does not have turn signals and other features required for use on public roads. If you need to cross a paved or public road, get off and walk your ATV across.

Take Time to Learn & Practice

Even if you have ridden other ATVs, take time to become familiar with how this ATV works and handles. Practice in a safe area until you build your skills and get accustomed to the ATV’s size and weight.

Because many accidents involve inexperienced or untrained riders, we urge all riders to take a training course approved by the ATV Safety

Institute (ASI). See page 30 .

Contact an authorized ATV dealer or call 1-800-887-2887 (USA only) to find out about the training courses nearest you.

Be Alert for Off-Road Hazards

The terrain can present a variety of challenges when you ride off-road.

Continually ‘‘read’’ the terrain for unexpected turns, drop-offs, rocks, ruts, and other hazards. Always keep your speed low enough to allow time to see and react to hazards.

ATV Safety

3

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Ride within Your Limits

Pushing limits is another major cause of ATV accidents. Never ride beyond your personal abilities or faster than conditions warrant.

Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good judgments and ride safely.

Don’t Drink and Ride

Alcohol and riding don’t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don’t drink and ride, and don’t let your friends drink and ride either.

Keep Your Honda in Safe Condition

It’s important to keep your ATV properly maintained and in safe riding condition. Having a breakdown can be difficult, especially if you are stranded off-road far from your base. To help avoid problems, inspect your ATV before every ride and perform all recommended maintenance.

4

ATV Safety

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Safety Labels

Your ATV 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 permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your Honda dealer for replacements.

ATV Safety

5

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Safety Labels

USA only

6

ATV Safety

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Safety Labels

ATV Safety

7

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Safety Labels

8

ATV Safety

(For Canada)

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Indicators & Controls

This section shows the location of all indicators and controls you would normally use before or while riding your ATV.

The items listed on this page are described in this section. Instructions for other components are presented in other sections of this manual where they will be most useful.

Operation Component Locations .........................................................

. 10

Indicators ..............................................................................................

. 13

High Coolant Temperature Indicator ...............................................

. 13

Neutral Indicator (TRX450ER only) ................................................

. 14

Controls & Features .............................................................................

. 15

Fuel Valve ........................................................................................

. 15

Choke Knob .....................................................................................

. 16

Hot Start Lever (TRX450R only) .....................................................

. 17

Ignition Switch .................................................................................

. 18

Start Button (TRX450ER only) ........................................................

. 19

Kickstarter (TRX450R only) ............................................................

. 20

Engine Stop Switch ..........................................................................

. 21

Headlight Switch ..............................................................................

. 22

Headlight Dimmer Switch ................................................................

. 22

Throttle Lever ..................................................................................

. 23

Clutch Lever/Parking Brake Lever ..................................................

. 23

Front Brake Lever ............................................................................

. 24

Rear Brake Pedal ..............................................................................

. 24

Parking Brake ...................................................................................

. 25

Flag Pole Bracket .............................................................................

. 26


9

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Operation Component Locations parking brake lock lever parking brake pin headlight dimmer switch headlight switch ignition switch engine stop switch clutch lever/ parking brake lever front brake lever

TRX450R only hot start lever

10

Indicators & Controls throttle lever start button

(TRX450ER only)

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Operation Component Locations

TRX450R only kickstarter rear brake pedal


11

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Operation Component Locations seat lock lever flag pole bracket fuel valve choke knob shift lever

12


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Indicators

High Coolant Temperature Indicator

CENTER OF HANDLEBAR

TRX450ER

(1) (1)

TRX450R

(1) high coolant temperature indicator

Lights when the engine coolant temperature is high enough to adversely affect the service life of the engine.

riding, immediately bring the vehicle to a stop, turn the engine off and let it cool. See page 189 .

Lamp Check

(TRX450ER)

The high coolant temperature indicator comes on for a few seconds and then goes off when you turn the ignition switch to ON ( ).

(TRX450R)

The engine is started when you operate the kickstarter, you can see the indicator comes on at the same time. If the engine is running, the indicator will goes off after a few seconds. If the engine is stopping, the indicator will goes off at the same time.

If the indicator does not come on when it should, have your Honda dealer check for a burned-out bulb or other problems.


13

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Indicators

Neutral Indicator

(TRX450ER only)

CENTER OF HANDLEBAR

(1)

(1) neutral indicator and the ignition switch is ON ( ).

If the indicator does not come on when it should, have your Honda dealer check for a burned-out bulb or other problems.

14


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Controls & Features

Fuel Valve

LEFT SIDE

ON

(1)

OFF RES

(1) fuel valve

The three-way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor.

ON − normal position for riding.

OFF − for parking, storing, or transportation.

RES − for extra fuel to get to a gas supply for refueling.

Reserve Fuel

Remember to check that the fuel valve is in the ON position each time you refuel. If the fuel valve is left in the RES position, you may run out of fuel with no reserve.

For complete information about fueling your ATV, see page 89 .


15

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Choke Knob

LEFT SIDE

50 .

( A )

( B )

(1) choke knob

(1)

(A) fully ON

(B) fully OFF

16


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Hot Start Lever (TRX450R only)

LEFT HANDLEBAR

(1) hot start lever

(1)

The hot start lever (1) may be used when starting a warm engine. See page 53 .


17

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Ignition Switch

(page 47 ). Insert the key and turn it to the right for the ON ( ) position.

Key Position

ON ( )

OFF ( )

CENTER OF HANDLEBAR

Function

Electrical circuits on.

No electrical circuits function.

ON

OFF

(1)

(1) ignition switch ON

OFF

18


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Start Button (TRX450ER only)

LEFT HANDLEBAR

START

(1)

(1) start button starts the engine. See Starting Procedure, page 50 .

When the start button is pushed, the starter motor will crank the engine.

The starter motor will operate even if the engine stop switch is in the

OFF ( ) position when the start button is pushed.


19

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Kickstarter (TRX450R only)

RIGHT SIDE

(1) kickstarter

(1) kickstarter out from its stored position and depress it through its entire stroke. See Starting Procedure, page 51 .

20


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Engine Stop Switch

LEFT HANDLEBAR


(1) engine stop switch RUN

OFF

(1)

To operate, slide the switch to the OFF ( ) position. The switch must be in the RUN ( ) position to start the engine, and it should normally remain in the RUN ( ) position even when the engine is OFF.

(TRX450ER only)

If your ATV is stopped with the ignition switch ON ( ) and the engine stop switch OFF ( ), the battery will discharge. Turn the ignition switch OFF ( ) to prevent battery discharge.


21

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Headlight Switch

LEFT HANDLEBAR

(1)

(2)

(1) headlight switch

(2) headlight dimmer switch

OFF

ON

HI

LO

The headlight switch ( ) is used to turn the headlight ON ( ) or OFF

( ). To operate, turn the switch to ON ( ) or OFF ( ).

Headlight Dimmer Switch

and low beams of the headlight. To operate, turn the switch to HI ( ) for high beam, LO ( ) for low beam.

22


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Throttle Lever

RIGHT HANDLEBAR


(A)

(A) to open the throttle

(1)

(1) throttle lever

The throttle controls engine rpm (speed). To increase engine rpm, press pressure on the throttle lever. The throttle will automatically return to the closed position (engine idle) when you remove your thumb.

Clutch Lever/Parking Brake Lever

The clutch lever/parking brake lever is used to disengage the clutch whenever you shift gears. To operate, pull the clutch lever/parking brake lever in all the way before shifting, then slowly release it after shifting.

See Clutch System, page 116 .


23

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Front Brake Lever

The front brake lever is used to slow or stop your ATV. To operate, pull the lever. For information on braking techniques, see page 58 .

Rear Brake Pedal

The rear brake pedal is used to slow or stop your ATV. To operate, depress the pedal. For information on braking techniques, see page 58 .

24


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Parking Brake

LEFT HANDLEBAR

(2)

(3)

(1)

( A )

(1) lock lever

(2) parking brake pin

(3) clutch lever/parking brake lever

(A) to lock down and hold the parking brake pin, squeeze the clutch lever/parking brake lever and then lock it with the lock lever. See Parking page 72 .

To release the parking brake, squeeze the clutch lever/parking brake lever.


25

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Flag Pole Bracket

RIGHT REAR

(1)

(1) flag pole bracket

Flag poles are optional equipment available from your Honda dealer. To the flag pole kit.

Flag poles are required in some riding areas. Check local regulations before riding.

26


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Before Riding

Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, what items you should check on your

ATV, and adjustments to make for your comfort, convenience, or safety.

This section also includes important information about loading.

Are You Ready to Ride?

......................................................................

. 28

Protective Apparel ............................................................................

. 28

Rider Training ..................................................................................

. 30

Age Recommendation ......................................................................

. 31

No Passengers ..................................................................................

. 31

No Alcohol or Drugs ........................................................................

. 32

Is Your ATV Ready to Ride?

...............................................................

. 33

Pre-ride Inspection ...........................................................................

. 33

Load Limits & Guidelines ....................................................................

. 36

Loading ............................................................................................

. 36

Load Limits ......................................................................................

. 37

Loading Guidelines ..........................................................................

. 38

Accessories & Modifications ...............................................................

. 39

Accessories .......................................................................................

. 39

Modifications ...................................................................................

. 40

Before Riding

27

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Are You Ready to Ride?

Before you ride your ATV for the first time, we urge you to:

Read this owner’s manual and the labels on your ATV carefully.

Make sure you understand all the safety messages.

Know how to operate all the controls.

Before each ride, be sure:

You feel well and are in good physical and mental condition.

You are wearing an approved motorcycle helmet (with chin strap tightened securely), eye protection, and other protective clothing.

You don’t have any alcohol or drugs in your system.

Protective Apparel

For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket whenever you ride.

Although complete protection is not possible, wearing proper gear can reduce the chance of injury when you ride.

Following are suggestions to help you choose the proper gear.

Helmets and Eye Protection

Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely.

28

Before Riding

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An open-face helmet offers some protection, but a full-face helmet offers more. Regardless of the style, look for a DOT (Department of

Transportation) sticker on any helmet you buy (USA only). Always wear a face shield or goggles to protect your eyes and help your vision.

Operating this ATV without wearing an approved motorcycle helmet, eye protection, and protective clothing could increase your chances of severe injury or death in the event of an accident.

Always wear an approved motorcycle helmet that fits properly and wear eye protection

(goggles or face shield), gloves, boots, long-sleeved shirt or jacket and long pants.

Additional Riding Gear

In addition to a helmet and eye protection, we also recommend:

Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs.

Off-road motorcycle gloves to help protect your hands.

Riding pants with knee and hip pads, a riding jersey with padded elbows, and a chest/shoulder protector.

Before Riding

29

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Rider Training

Developing your riding skills is an on-going process. Even if you have ridden other ATVs, take time to become familiar with how this ATV works and handles. Practice riding the ATV in a safe area to build your skills. Do not ride in rough terrain until you get accustomed to the

ATV’s controls, and feel comfortable with its size and weight.

We urge all riders to take a certified course approved by the ATV Safety

Institute (ASI). For information about the ASI training course nearest you, call the national toll-free number; (800) 887-2887 (USA only).

Other riding tips can be found in the Tips & Practice Guide f or the ATV

Rider booklet that came with your ATV (USA only).

Operating this ATV without proper instruction could increase your risk of an accident which could lead to serious injury or death.

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 the owner’s manual.

30

Before Riding

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Age Recommendation

The minimum recommended age for this ATV model is 16. For safety, never let children under 16 years old operate this vehicle.

A child using an ATV that is not recommended for their age could lose vehicle control while riding, resulting in severe injury or death.

A child under 16 should never operate an ATV with engine size greater than 90cc.

No Passengers

This ATV is designed as an operator-only vehicle. The long seat is designed to allow the rider to change body position, not for carrying a passenger. Never let a passenger ride on the seat.

Carrying a passenger on this ATV greatly reduces your ability to balance and control this

ATV and could cause a crash and you or your passenger could be injured or killed.

Never carry a passenger on this ATV.

Before Riding

31

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No Alcohol or Drugs

Alcohol, drugs and ATVs don’t mix. Even a small amount of alcohol can impair your ability to operate an ATV safely. Likewise, drugs − even if prescribed by a physician − can be dangerous while operating an

ATV. Consult your doctor to be sure it is safe to operate a vehicle after taking medication.

Operating this ATV after consuming alcohol or drugs can seriously affect your judgement, cause you to react more slowly, affect your balance and perception, and result in serious injury or death.

Never consume alcohol or drugs before or while operating this ATV.

32

Before Riding

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Is Your ATV Ready to Ride?

Before each ride, it’s important to inspect your ATV and make sure any problem you find is corrected. A pre-ride inspection is a must, not only for safety, but because having a breakdown, or even a flat tire, can be a major inconvenience.

If your ATV has overturned or been involved in a collision, do not ride the vehicle until it has been inspected by your Honda dealer. There may be damage or other problems you cannot see.

Improperly maintaining this ATV or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed.

Always perform a pre-ride inspection before every ride and correct any problems.

Pre-ride Inspection

Check the following items before you get on the ATV:

Engine Oil Check the level and add oil if needed (page

Check for leaks.

95 ).

Transmission

Oil

Radiator

Coolant

Check the level and add oil if needed (page

Check for leaks.

101 ).

Check the coolant level and add coolant if needed

(page 105 ).

Check for leaks.

Before Riding

33

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Fuel

Tires

Drive Chain

Nuts & Bolts

Underbody &

Exhaust System

Leaks, Loose Parts

Cable

Lights

Check the level and add fuel (page 90 ) if needed. Also make sure the fuel fill cap is securely fastened.

Check for leaks.

Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damage or excessive wear (page 143 ).

Check the condition and slack. Adjust and lubricate if needed. Also check the chain slider and chain roller for wear and replace if needed

(page 151 ).

Check the wheels to see that the axle nuts are tightened. Use a wrench to make sure all accessible nuts, bolts, and fasteners are tight.

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.

Walk around your ATV and look for anything that appears unusual, such as a leak or loose cable.

Check the cable housings for wear. Check the fittings for looseness. Replace or tighten as needed.

Make sure the headlight, brakelight and taillight are working properly.

34

Before Riding

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Check these items after you get on the ATV:

Throttle Check the freeplay and adjust if needed. Press the throttle to make sure it moves smoothly without sticking, and snaps shut automatically when it is released, in all steering positions

(page 114 ).

Brakes Squeeze the front brake lever and step on the rear brake pedal to check that the controls operate normally. Make sure there is no brake fluid leakeage (page 134 ).

Check for smooth operation and adjust if needed (page 116 ).

Clutch Lever/

Parking Brake

Lever

Headlight and

Headlight Dimmer

Switch

Check for proper function (page 22 ).

Engine Stop Switch Check for proper function (page 21 ).

Steering Check that the wheels turn properly as you steer the handlebar. Move the handlebar right and left and check that there is no excessive backlash.

Remember, be sure to take care of any problem you find, or have your

Honda dealer correct it before you ride.

Before Riding

35

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Load Limits & Guidelines

Your Honda was designed as a rider-only ATV. It was not designed to carry a passenger or cargo. A passenger or cargo could interfere with your ability to move around to maintain your balance and control of the

ATV.

In addition, exceeding the weight limits or carrying an unbalanced load can seriously affect your ATV’s handling, braking and stability. Adding accessories or making modifications that change this ATV’s design and performance can also make it unsafe. Also, the weight of any accessories will reduce the maximum load the ATV can carry.

More specific information on load limits, accessories, and modifications follows.

Loading

How much weight you put on your ATV, and how you load it, are important to your safety. If you decide to carry cargo, you should be aware of the following information.

Overloading, improper loading, or carrying a passenger can cause a crash and you can be seriously hurt or killed.

Follow all load limits and other loading guidelines in this manual.

36

Before Riding

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Load Limits

Following are the load limits for your ATV:

There is a limit to how much weight can be carried on your ATV.

The following load limit applies to standard equipment only. Modifying your ATV, using non-standard equipment, or riding on terrain that is not flat and smooth could further reduce these limits.

maximum weight capacity 243 lbs (110 kg)

(includes the weight of the rider, all cargo, and accessories.)

The weight of added accessories will reduce the maximum cargo weight you can carry.

Before Riding

37

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Loading Guidelines

As discussed on page 36 , we recommend that you do not carry any cargo on this ATV. However, if you decide to carry cargo, ride at reduced speeds and follow these common-sense guidelines.

Carrying cargo or pulling a trailer will affect how your ATV handles and greatly reduce its ability in accelerating, braking and making turns and other maneuvers.

Be sure to observe the weight limit and follow these guidelines:

Check that the tires are properly inflated.

Never ride with a passenger. The ATV is not designed to carry a passenger.

Do not tow another vehicle.

Make sure all cargo is secured before riding.

Never exceed the maximum weight limit.

Allow extra room for starting, stopping and turning whenever you carry cargo or pull a trailer.

Avoid riding on steep slopes when carrying cargo or pulling a trailer.

Never cross a slope when towing a trailer.

38

Before Riding

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Accessories & Modifications

Modifying your ATV or using non-Honda accessories can make your

ATV unsafe.

Before you consider making any modifications or adding an accessory, be sure to read the following information.

Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed.

Follow all instructions in this owner’s manual regarding accessories and modifications.

Accessories

We strongly recommend that you use only Honda Genuine Accessories that have been specifically designed and tested for your ATV. Because

Honda cannot test all other accessories, you must be personally responsible for proper selection, installation, and use of non-Honda accessories.

Check with your Honda dealer for assistance and always follow these guidelines:

Make sure the accessory does not obscure any lights, reduce ground clearance, limit suspension travel or steering travel, or interfere with operating any controls.

Make sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls.

(cont’d)

Before Riding

39

07/04/04 11:16:41 31HP1640_049

Accessories & Modifications

(TRX450ER)

Do not add any electrical equipment that will exceed the vehicle’s electrical system capacity (page of lights or engine power (page

204

191

). A blown fuse can cause a loss

).

Modifications

We strongly advise you not to remove any original equipment or modify your ATV in any way that would change its design or operation. Such changes could seriously impair your ATV’s handling, stability, and braking, making it unsafe to ride.

We also advise you not to make any modifications or remove any equipment (such as the USDA qualified spark arrester or emission control system components) that would make your ATV illegal in your area.

Removing or modifying your lights, exhaust system, emission control system, or other equipment can also make your ATV illegal.

40

Before Riding

07/04/04 11:16:47 31HP1640_050

Basic Operation & Riding

This section gives basic riding instructions, including how to start and stop your engine, how to use the throttle and brakes, and what to do when you’re through riding.

To protect your new engine and enjoy optimum performance and service life, refer to Break-in Guidelines (page 205 ).

For information about carburetor adjustment for riding at high altitude, see page 206 .

Safe Riding Precautions .......................................................................

. 42

Off-Road Use Only ..........................................................................

. 42

Keep Hands and Feet on Controls ....................................................

. 43

Control Speed ...................................................................................

. 44

Use Care on Unfamiliar or Rough Terrain .......................................

. 45

Do Not Perform Stunts .....................................................................

. 46

Starting & Stopping the Engine ...........................................................

. 47

Preparation .......................................................................................

. 48

Starting Procedure ............................................................................

. 50

Flooded Engine ................................................................................

. 54

How to Stop the Engine ...................................................................

. 55

Shifting Gears ......................................................................................

. 56

Braking .................................................................................................

. 58

Riding Your ATV ................................................................................

. 60

Making Turns ...................................................................................

. 60

Skidding or Sliding ..........................................................................

. 62

Riding Up Hills ................................................................................

. 63

Riding Down Hills ...........................................................................

. 67

Crossing or Turning on Hills or Slopes ............................................

. 68

Riding Over Obstacles .....................................................................

. 70

Riding Through Water .....................................................................

. 71

Parking .................................................................................................

. 72


41

07/04/04 11:16:53 31HP1640_051

Safe Riding Precautions

Before riding your ATV for the first time, please review the ATV Saf ety section beginning on page 1, and the Bef ore Riding section beginning on page 27 .

Even if you have ridden other ATVs, take time to become familiar with how this ATV works and handles. Practice in a safe area until you build your skills and get accustomed to the ATV’s size and weight.

Off-Road Use Only

Your ATV and its tires are designed and manufactured for off-road use only, not for pavement. Riding on pavement can affect handling and control. You should not ride your ATV on pavement.

Operating this ATV on paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.

Never operate the ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

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.

42


07/04/04 11:16:59 31HP1640_052


You should never ride your ATV 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. In many states it is illegal to operate ATVs on public streets, roads and highways.

Operating this ATV on public streets, roads or highways could cause you to collide with another vehicle.

Never operate this ATV on any public street, road or highway, even a dirt or gravel one.

Keep Hands and Feet on Controls

Always keep both hands on the handlebars and both feet on the footpegs when riding your ATV. This is important to maintain your balance and to control the vehicle. Removing even one hand from the handlebars or one foot from the footpegs can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV.

Removing hands from handlebars or feet from footpegs during operation can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.

Always keep both hands on the handlebars and both feet on the footpegs of your ATV during operation.


43

07/04/04 11:17:03 31HP1640_053


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.

Operating this ATV at excessive speeds increases your chances of losing control of the

ATV, which can result in an accident.

Always go at a speed that is proper for your vehicle, the terrain, visibility and other operating conditions, and your experience.

44


07/04/04 11:17:07 31HP1640_054


Use Care on Unfamiliar or Rough 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 like hidden rocks, bumps, or holes in time to react.)

Failure to use extra care when operating this

ATV on unfamiliar terrain could result in the ATV overturning or going out of control.

Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the

ATV.


45

07/04/04 11:17:12 31HP1640_055


Never ride past the limit of visibility. Maintain a safe distance between your ATV and other off-road vehicles. Always exercise caution, and use extra care on rough, slippery and loose terrain.

Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction or vehicle control, which could result in an accident, including an overturn.

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.

Do Not Perform Stunts

You should always operate your ATV in a safe and reasonable manner.

When riding, always keep all four wheels on the ground.

Attempting wheelies, jumps, and other stunts increases the chance of an accident, including an overturn.

Never attempt stunts, such as wheelies or jumps. Don’t try to show off.

46


07/04/04 11:17:17 31HP1640_056

Starting & Stopping the Engine

Always follow the proper starting procedure described below.

For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your ATV’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

(TRX450ER only)

Your ATV is equipped with a gear position starter cut-off system. The engine cannot be started if the transmission is in gear − unless the clutch lever is pulled in.


47

07/04/04 11:17:26 31HP1640_057


Preparation

(TRX450ER)

(1)

(3)

(2)

(1) fuel valve

(2) ignition switch

(3) neutral indicator

(4) engine stop switch

1.

Before starting, select a level surface and lock the parking brake

(page 25 ).

2.

1 ).

Confirm the following:

The engine stop switch ( ) is set to RUN ( ).

The high coolant temperature indicator should go off a few seconds after the ignition switch to ON ( ).

(4)

48


07/04/04 11:17:36 31HP1640_058

(TRX450R)


(1)

(2)

(4)

(3)

(1) fuel valve

(2) ignition switch

(3) handlebar

(4) engine stop switch

1.

Before starting, select a level surface and lock the parking brake

(page 25 ).

2.

1 ).

3.

Confirm the following:

The transmission is in neutral (the tires roll freely).

The engine stop switch ( ) is set to RUN ( ).

The high coolant temperature indicator should go off a few seconds after the engine starts.


49

07/04/04 11:17:45 31HP1640_059


Starting Procedure

The carburetor is equipped with an accelerator pump. Do not open the throttle when starting the engine. This will flood the engine with excess fuel, resulting in hard starting.

Opening the throttle, even slightly, while starting the engine, may cause engine kick-back and engine damage.

To restart a warm engine, follow the procedure for ‘‘High Air

Temperature.’’

(TRX450ER only)

The starter motor will operate when the transmission is in neutral or pull in the clutch lever.

Normal Air Temperature 10° − 35°C (50° − 95°F)

(TRX450ER)

LEFT SIDE LEFT HANDLEBAR

( A )

( B )

(1) choke knob

(2) start button

1.

the engine is cold.

50


(1)

(A) fully ON

(B) fully OFF

(2)

07/04/04 11:17:57 31HP1640_060


2.

Pressing the electric start button for more than 5 seconds at a time may cause the starter to overheat and damage the starter. Release the start button for approximately 10 seconds before pressing it again.

3.

Immediately after the engine starts, operate the choke knob to keep fast idle.

4.

About a half minute after the engine starts, push the choke knob right

5.

If idling is unstable, open the throttle slightly.

Normal Air Temperature 10° − 35°C (50° − 95°F)

(TRX450R)

LEFT SIDE RIGHT SIDE

( A )

( B )

(1) choke knob

(2) kickstarter

(1)

(2)

(A) fully ON

(B) fully OFF

1.

the engine is cold.

2.

kickstarter return to the top of its stroke. With the throttle closed, operate the kickstarter.

3.

Immediately after the engine starts, operate the choke knob to keep fast idle.

4.

About a half minute after the engine starts, push the choke knob right

5.

If idling is unstable, open the throttle slightly.


51

07/04/04 11:18:07 31HP1640_061


High Air Temperature 35°C (95°F) or above

(TRX450ER)

1.

Do not use the choke.

2.

With the throttle closed, press the start button.

(TRX450R)

1.

Do not use the choke.

2.

Lightly depress the kickstarter until resistance is felt. Then let kickstarter return to the top of its stroke. With the throttle closed, operate the kickstarter. Kick from the top of the stroke through to the bottom with a rapid, continuous motion. Allowing the kickstarter to snap back freely against the pedal stop can damage the engine case.

Low Air Temperature 10°C (50°F) or below

(TRX450ER & TRX450R)

1.

Follow steps 1 − 2 under ‘‘Normal Air Temperature.’’

2.

When engine speed begins to pick up, operate the choke knob to keep fast idle.

3.

Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is fully OFF.

When air temperature is below − 15°C (5°F), push the throttle lever eight times to discharge fuel from the accelerator pump into the intake port.

Extended use of the choke may impair piston and cylinder wall lubrication and shorten the lif e of the engine.

52


07/04/04 11:18:19 31HP1640_062


Warm Engine Starting:

(TRX450R only)

LEFT HANDLEBAR

(1)

(1) hot start lever

1.

Turn the fuel valve ON.

2.

Shift the transmission into neutral.

3.

throttle.)

4.

As soon as the engine starts, release the hot start lever.

Starting the engine after a stall during riding or after a fall:

(TRX450R only)

1.


2.

Push the hot start lever and kick-start the engine (Do not open the throttle).

3.


Starting the engine excessively charged with fuel by throttle blipping or other reasons:

(TRX450R only)

1.


2.

With the throttle fully opened, repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine.

3.

Push the hot start lever and kick-start the engine. (Do not open the throttle.)

4.



53

07/04/04 11:18:30 31HP1640_063


Flooded Engine

If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine:

(TRX450ER)

1.

Move the engine stop switch to OFF ( ).

2.

Push the choke knob right all the way to fully OFF.

3.

Open the throttle fully.

4.

Press the start button for 5 seconds.

5.

Wait 10 seconds, then turn the engine stop switch to RUN ( ).

6.

Repeat the ‘‘Normal Air Temperature’’ use the choke.

starting procedure, but don’t

(TRX450R)

1.

Push the choke knob right all the way to fully OFF.

2.

With the throttle fully opened, repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine.

3.

Push the hot start lever and kick-start the engine. (Do not open the throttle.)

4.


If the engine still won’t start, refer to If Your Engine Quits or Won’t

Start, page , .

54


07/04/04 11:18:38 31HP1640_064


How to Stop the Engine

Normal Engine Stop

(TRX450ER)

To stop the engine, make sure the transmission is in neutral by checking that the neutral indicator lights, and turn the ignition switch OFF ( ).

If your ATV is stopped with the engine stop switch OFF ( ) and the ignition switch ON ( ), the battery will discharge.

(TRX450R)

To stop the engine, make sure the transmission is in neutral, and turn the ignition switch OFF ( ).

The engine stop switch should normally remain in the RUN ( ) position even when the engine is OFF.

Emergency Engine Stop

To stop the engine in an emergency, use the engine stop switch. To operate, slide the switch to the OFF ( ) position.


55

07/04/04 11:18:44 31HP1640_065

Shifting Gears

GEAR SHIFTING SEQUENCE

The shift lever is located near the left footpeg. One full stroke of the shift lever shifts the transmission to the next higher or lower gear in the shifting sequence. The shift lever automatically returns to the horizontal position when released.

Your ATV has five forward gears (1, 2, 3, 4 and 5). To shift the transmission, pull in the clutch lever, then operate the shift lever as follows.

To upshift to a higher gear, put the toe of your boot under the shift lever and raise it one full stroke. To downshift, step on the shift lever and depress it one full stroke.

After starting the engine and letting it warm up, follow these procedures:

1.

With the transmission in neutral, depress and hold down the rear brake pedal. Release the parking brake (page 25 ).

56


07/04/04 11:18:54 31HP1640_066

Shifting Gears

2.

With the throttle closed while the engine is idling, pull in the clutch lever and depress the shift lever to shift into 1st gear.

3.

Release the rear brake pedal, gradually release the clutch lever, and increase engine speed by gradually opening the throttle.

4.

When the speed increases, close the throttle, pull in the clutch lever, shift to 2nd gear by raising the shift lever, and gradually release the clutch lever while gradually opening the throttle.

5.

Repeat this sequence to progressively upshift to 3rd, 4th and 5th (top) gear.

6.

To downshift, reverse this sequence. Remember to close the throttle each time you shift to the next lower gear.

Learning when to shift gears comes with experience. Keep the following tips in mind:

As a general rule, shift while moving in a straight line.

Close the throttle and pull the clutch lever in completely before shifting. Improper shifting may damage the engine, transmission, and drive train.

Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high. Learn the relationship between engine sound and the normal shifting points.

Downshift to a lower gear before you feel the engine laboring

(lugging) at low rpm.

Avoid downshifting to help slow your ATV when engine rpm is high.

Downshifting when engine speed is near its allowable maximum may over-rev the engine and cause possible damage.

To prevent transmission damage, do not coast or tow the ATV for long distances with the engine off.

Recommended Shift Points

Ride in the highest gear that lets the engine run and accelerate smoothly.

This will give you good fuel economy and effective emissions control.


57

07/04/04 11:19:01 31HP1640_067

Braking

Your ATV is equipped with disc braking systems which are hydraulically activated. Depressing the brake pedal applies the rear disc brake. Operating the brake lever applies the two front disc brakes.

As a general rule, the front braking system provides about 70 percent of total stopping power.

For full braking effectiveness, use both the pedal and lever simultaneously. Using both braking systems will stop your ATV faster with greater stability.

To slow or stop, apply the brake lever and brake pedal smoothly, while downshifting to match your speed.

Gradually increase braking as you feel the brakes slowing your speed.

The increase in engine compression from downshifting will help slow your ATV.

For maximum braking, close the throttle and firmly apply the brake lever and pedal controls.

Applying the brakes too hard may cause the wheels to lock and slide, reducing control of your ATV. If this happens, release the brake controls, steer straight ahead until you regain control, then reapply the brakes more gently.

When possible, reduce your speed or complete braking before entering a turn. Avoid braking or closing the throttle quickly while turning. Either action may cause one or more wheels to slip and reduce your control of your ATV.

58


07/04/04 11:19:07 31HP1640_068

Braking

Your ability to brake in a turn and to brake hard in an emergency situation are important riding skills.

When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduce their effectiveness.

To prevent stalling the engine, pull the clutch lever/parking brake lever in before coming to a complete stop.

Riding with your foot resting on the brake pedal or your hand on the brake lever may overheat the brakes, reducing effectiveness.

For information on how to apply the brakes in various riding situations, see the following section, Riding Your ATV .


59

07/04/04 11:19:11 31HP1640_069

Riding Your ATV

Making Turns

Learn how to turn your ATV properly. Practice the techniques outlined in this section on level ground and at low speeds until you are confident in making turns.

Turning improperly can make the ATV go out of control, causing a collision or overturn.

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.

60


07/04/04 11:19:17 31HP1640_070

Riding Your ATV

Lean your body to the inside of a turn and forward.

To make a turn on level ground: Steer the handlebar and lean your body toward the inside of the turn. Leaning helps balance the vehicle, and it feels more comfortable. Leaning into a turn is an important technique to master in riding an ATV.

To make a sharp turn at low speed: It helps to shift your body slightly forward on the seat, and lean inside, as you steer the handlebar. Shifting weight forward allows the rear wheels to turn easier, and it also improves front-wheel steering.

To make a turn from a full stop: Apply the throttle gradually when you turn and start up at the same time. Remember to shift your body forward to make sharp low-speed turns and whenever you turn while accelerating from a full stop.


61

07/04/04 11:19:21 31HP1640_071

Riding Your ATV

Skidding or Sliding

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.

Skidding or sliding improperly may cause you to lose control of this ATV. You may also regain traction unexpectedly, which may cause the

ATV to overturn.

Learn to safely control skidding by practicing at low speeds and on level, smooth terrain.

If your ATV skids sideways during a turn, steer in the direction of the skid. Avoid hard braking or accelerating until you have regained directional control.

62


07/04/04 11:19:27 31HP1640_072

Riding Your ATV

Riding Up Hills

The ATV’s ability to safely climb hills largely depends on the rider’s skill and judgment. Begin by practicing on smooth, gentle slopes. As you gain experience, you’ll learn the hazards and your own limitations.

You may then proceed to ride on more difficult terrain. However, you must be able to decide which hills or hazards might cause the ATV to overturn. Avoid excessively steep hills.

Operating on excessively steep hills can cause the vehicle to overturn more easily than operating on level surfaces or small hills.

Never operate the ATV on hills too steep for the

ATV or for your abilities.

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.

Climbing hills improperly could cause loss of control or cause the ATV to overturn.

Always follow proper procedures for climbing hills as described in this owner’s manual.


63

07/04/04 11:19:34 31HP1640_073

Riding Your ATV

Shift weight forward when climbing hills.

Always check the terrain carefully before you start up any hill.

Never climb hills with excessively slippery or loose surfaces.

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.

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.

64


07/04/04 11:19:42 31HP1640_074

Riding Your ATV

Stalling the ATV and/or Rolling Backwards:

If you incorrectly estimate climbing capability or terrain conditions, the

ATV may not have enough power or traction to continue uphill. If this happens, the ATV can stall and/or roll backwards.

Stalling, rolling backwards or improperly dismounting while climbing a hill could result in the ATV overturning.

Always follow proper procedures for climbing a hill as described in this owner’s manual.

What to do if the ATV stalls or rolls backwards when climbing a hill:

If you are about to lose all forward speed:

1.

Using the front and rear brakes together, bring the ATV to a stop with the vehicle pointed straight uphill.

2.

Get off the ATV while you continue holding the brakes.

3.

Shift into neutral, set the parking brake and turn the engine off.

4.

Then assess the situation.

If the ATV starts rolling backwards before you begin braking:

1.

Keep your weight uphill.

2.

Carefully apply the front brakes first, then carefully apply the rear brake. Do not apply either brake abruptly if you are rolling backwards, or the vehicle may overturn.

If the ATV continues sliding backwards:

After you’ve applied the brakes, get off and away from the vehicle.


65

07/04/04 11:19:50 31HP1640_075

Riding Your ATV

What to do after the ATV has stalled or rolled backwards:

If the hill is too steep or too slippery, or if you have any doubt whether you can safely walk the ATV back down the hill, leave the vehicle where it is and get help. If possible, block the wheels so the vehicle doesn’t roll backwards.

If the hill is not too steep and you have good footing, you may be able to walk the ATV back down the hill. Make sure your intended path is clear in case you lose control of the ATV.

Be sure your legs are clear of the wheels.

Body position for backing down a hill.

1.

Stand with your body facing downhill, beside the vehicle so you can reach the front brake lever with your left hand.

2.

Be sure your legs are clear of the wheels.

Check your footing.

3.

Slowly and carefully back the ATV down the hill using the front brake lever to control speed.

4.

If you lose control of the ATV, for your safety, get away from the vehicle.

66


07/04/04 11:19:56 31HP1640_076

Riding Your ATV

Riding Down Hills

It’s usually advisable to descend hills with the ATV pointed straight downhill. Avoid angles that would cause the vehicle to lean sharply to one side.

Going down a hill improperly could cause loss of control or cause the ATV to overturn.

Always follow proper procedures for going down hills as described in this owner’s manual.

On downhills, shift your weight back.

As you approach a downhill, stop and survey the terrain below. Never ride past the limit of your visibility. Never go down a hill at high speed.


67

07/04/04 11:20:02 31HP1640_077

Riding Your ATV

When you’ve selected a safe downhill path, shift into a lower gear, shift your weight back with your arms extended and braced against the handlebar, then go down slowly with the throttle closed.

Use mainly the rear brake to control speed. Avoid using either the front brake or rear brake hard or abruptly when riding down hills.

Remember, braking effectiveness is reduced on any hill with a loose surface.

Crossing or Turning on Hills or Slopes

Riding on hills or slopes is different from riding on level terrain. Be careful when riding on any hill. Make sure that you practice on gentle, smooth slopes before attempting to ride on steeper or more difficult terrain.

Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn.

Always follow proper procedures for crossing or turning on slopes as described in this owner’s manual. Avoid crossing steep hills if possible.

68


07/04/04 11:20:09 31HP1640_078

Riding Your ATV

Crossing Hills or 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.

Shift weight uphill when crossing slopes.

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.


69

07/04/04 11:20:13 31HP1640_079

Riding Your ATV

Riding Over Obstacles

Before operating in a new area, check for 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.

Improperly operating over obstacles could cause loss of control or a collision and could cause the ATV to overturn.

When you go over obstacles, always follow proper procedures as described in this owner’s manual.

70


07/04/04 11:20:22 31HP1640_080

Riding Your ATV

Riding Through Water

Your ATV is designed to travel through water up to approximately

10 inches (254 mm) deep. Before crossing a stream, make sure the water is not too deep or flowing too fast.

The ATV tires have some ability to float.

Operating this ATV through deep or fast-flowing water may cause a loss of traction and loss of control, which could lead to an accident.

Never operate this ATV in fast-flowing water or in water deeper than that specified in this owner’s manual.

1.

Choose a path where both banks have gradual slopes.

2.

Proceed through the water at a slow, steady speed.

3.

Watch out for submerged obstacles and slippery rocks.

4.

Avoid getting the spark plug or air cleaner wet, as this would cause the engine to stop.

5.

After leaving the water, always test both the front and rear brakes.

Riding through water can make the brakes less effective than normal, and may reduce stopping ability.

If necessary, apply the brakes repeatedly until they dry out and operate normally.


71

07/04/04 11:20:32 31HP1640_081

Parking

1.

Look for level parking area. Make sure the ground surface is firm.

2.

After bringing your ATV to a stop, hold the brakes while you shift into neutral.

3.

Set the parking brake.

4.

Turn the ignition switch OFF ( ).

5.

If you’re finished riding for the day, turn the fuel valve OFF.

If it is necessary to start the engine when your ATV is stopped on a grade in gear, rock the vehicle back and forth to allow shifting the transmission into neutral.

Parking on a Steep Incline or a Loose or Slippery Surface

If you must park your ATV on a steep incline or loose or slippery surface, use the following procedure:

1.

While holding the brakes, set the parking brake.

2.

Turn the ignition switch OFF ( ) and release the brakes.

3.

If the ATV begins to move, either while sitting on it or after you dismount, find a better parking location.

4.

If rocks or other objects are available, you can block the wheels as shown for additional security.

72


07/04/04 11:20:40 31HP1640_082

Servicing Your Honda

To help keep your ATV in good shape, this section includes a

Maintenance Schedule for required service and step-by-step instructions for specific maintenance tasks. You’ll also find important safety precautions, information on fuels and oils, and tips for keeping your

Honda looking good.

(TRX450ER only)

For information about replacing the fuse, see page 191 .

For information about the exhaust emission and noise requirements of the U.S. Environmental Protection Agency (EPA), the California Air

Resources Board (CARB), and Environment Canada (EC), see page

207 .

USA Only

Maintenance, replacement or repair of the emission control devices and systems may be performed by any ATV repair establishment or individual using parts that are ‘‘certified’’ to EPA standards.

Bef ore You Service Your Honda

The Importance of Maintenance ..........................................................

. 75

Maintenance Safety ..............................................................................

. 76

Important Safety Precautions ...........................................................

. 77

Maintenance Schedule .........................................................................

. 78

Maintenance Record .............................................................................

. 82

Service Preparations

Maintenance Component Locations .....................................................

. 83

Tool Kit ................................................................................................

. 86

Owner’s Manual Storage ......................................................................

. 87

Seat Removal .......................................................................................

. 88

(cont’d)


73

07/04/04 11:20:48 31HP1640_083


Service Procedures

Fluids & Filters

Fuel ......................................................................................................

. 89

Engine Oil & Filter ...............................................................................

. 92

Transmission Oil ..................................................................................

. 99

Coolant ...............................................................................................

. 104

Air Cleaner .........................................................................................

. 110

Engine

Throttle ...............................................................................................

. 114

Clutch System ....................................................................................

. 116

Engine Idle Speed ..............................................................................

. 120

Spark Plug ..........................................................................................

. 121

Valves .................................................................................................

. 124

Spark Arrester ....................................................................................

. 125

Chassis

Suspension .........................................................................................

. 127

Brakes .................................................................................................

. 133

Tires ...................................................................................................

. 143

Engine Guard & Skid Plates ...............................................................

. 150

Drive Chain ........................................................................................

. 151

Electrical

Battery (TRX450ER only) .................................................................

. 158

Appearance Care ................................................................................

. 163

74


07/04/04 11:20:54 31HP1640_084

The Importance of Maintenance

A well-maintained ATV is essential for safe, economical, and troublefree riding. It will also help reduce air pollution. Careful pre-ride inspections and good maintenance are especially important because your

ATV is designed to be ridden over rough off-road terrain.

To help you properly care for your ATV, this section of the manual provides a Maintenance Schedule. The service intervals in this schedule are based on average riding conditions.

More frequent service is needed if you subject your ATV to severe use or ride in unusually wet or dusty areas.

Improperly maintaining this ATV or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed.

Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.

Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair.

If your ATV overturns or is involved in a crash, be sure your Honda dealer inspects all major parts, even if you are able to make some repairs.


75

07/04/04 11:21:00 31HP1640_085

Maintenance Safety

This section includes instructions on how to perform some important maintenance tasks. If you have basic mechanical skills, you can perform many of these tasks with the tools provided with your ATV.

Other tasks that are more difficult and require special tools are best performed by professionals. Removing the wheels should normally be handled only by a Honda technician or other qualified mechanic.

Instructions are included in this manual only to assist in emergency service.

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.

Always follow the procedures and precautions in this owner’s manual.

76


07/04/04 11:21:05 31HP1640_086

Maintenance Safety

Important Safety Precautions

Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards:

Carbon monoxide poisoning from engine exhaust.

Be sure there is adequate ventilation whenever you operate the engine.

Burns from hot ATV parts.

Let the engine and exhaust system cool before touching.

Injury from moving parts.

Do not run the engine unless instructed to do so.

Read the instructions before you begin, and make sure you have the tools and skills required.

To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only non-flammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts.

Remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new Honda Genuine Parts or other equivalents for repair and replacement. If you have the tools and skills required for additional maintenance jobs, you can purchase an official Honda

Service Manual (page 214 ).


77

07/04/04 11:21:10 31HP1640_087

Maintenance Schedule

The required Maintenance Schedule that follows specifies how often you should have your ATV serviced, and what things need attention. It is essential to have your ATV serviced as scheduled to maintain safe, dependable performance and proper emission control.

The service intervals in this Maintenance Schedule are based on average riding conditions. Some items will need more frequent service if you ride in unusually wet or dusty areas or at full throttle. Consult your

Honda dealer for recommendations applicable to your individual needs and use.

Some items in the Maintenance Schedule can be performed with basic mechanical skills and hand tools. Procedures for these items are provided in this manual. Other items involve more extensive procedures and may require special training, tools, and equipment. We recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools and equipment.

Procedures for such items in this schedule are provided in an official

Honda Service Manual available for purchase (page 214 ).

If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only Honda Genuine Parts or their equivalents for repair or replacement to ensure the best quality and reliability.

78


07/04/04 11:21:18 31HP1640_088


Perform the pre-ride inspection (page 33 ) and owner maintenance on this section at each scheduled maintenance period.

Each item on the maintenance schedule requires some mechanical knowledge. Certain items (particularly those marked ＊ and ＊＊ ) may require more technical information and tools. Consult your Honda dealer.

＊

＊＊

Should be serviced by your Honda dealer, unless you have the proper tools and service data and are mechanically qualified. Refer to the official Honda Service Manual (page 214 ).

In the interest of safety, we recommend these items be serviced only by your Honda dealer.

Summary of Maintenance Schedule Notes & Procedures:

NOTES:

1.

Service more frequently when riding in dusty areas, sand or snow.

2.

Service more frequently after riding in very wet or muddy conditions.

3.

Replace every 2 years. Replacement requires mechanical skill.


79

07/04/04 11:21:27 31HP1640_089


Maintenance Procedures:

I: inspect and clean, adjust, lubricate, or replace, if necessary

C: clean

A: adjust

L: lubricate

R: replace

ITEMS

FUEL LINE

THROTTLE OPERATION

AIR CLEANER

SPARK PLUG

VALVE CLEARANCE/

DECOMPRESSOR

SYSTEM

ENGINE OIL

FREQUENCY

WHICHEVER

COMES

FIRST

NOTE mi km

HOURS

INITIAL

MAINT.

100

150

20

NOTE 1

I

REGULAR

MAINT. INTERVAL

600

1000

100

C

I

1200

2000

200

I

I

I

I

C

ENGINE OIL FILTER

TRANSMISSION OIL

ENGINE IDLE SPEED

RADIATOR COOLANT

COOLING SYSTEM

NOTE 3

NOTE 2

INITIAL=

100 mi (150 km),

20 operating hours or 1 month: R

REGULAR=

Every 600 mi (1,000 km),

100 operating hours or

12 months: R

R R

R

I

I

I

I

I

I

R

R

I

Refer to page

−

114

110

121

124

92

96

99

120

104

105


80


07/04/04 11:21:35 31HP1640_090


ITEMS

FREQUENCY

DRIVE CHAIN

DRIVE CHAIN SLIDER

BRAKE FLUID

BRAKE PADS WEAR

BRAKELIGHT SWITCH

BRAKE SYSTEM

SKID PLATES, ENGINE

GUARD

CLUTCH SYSTEM

SUSPENSION

SPARK ARRESTER

NUTS, BOLTS,

FASTENERS

WHEELS/TIRES

TIE-ROD AND JOINT

BOOTS

STEERING SHAFT

HOLDER BEARINGS

STEERING SYSTEM

WHICHEVER

COMES

FIRST

NOTE

NOTE 1,2 mi km

HOURS

NOTE 3

NOTE 1,2

INITIAL

MAINT.

100

150

20

I,L

I

I

REGULAR

MAINT. INTERVAL

600

1000

100

1200

2000

200

I,L EVERY 300 mi (500 km) or 50 operating hours

I

I

I

I

I I

I

I

I

I

I

Refer to page

151

153

133

137

140

133

150

I

I

I

I

I

I

C

I

I

C

I

I

I

I

I

I

I

116

127

125

−

−

−

−

−


In the interest of safety, we recommend these items be serviced only by your Honda dealer.


81

07/04/04 11:21:41 31HP1640_091

Maintenance Record

Keeping an accurate maintenance record will help ensure that your ATV is properly maintained. Retain detailed receipts to verify the maintenance was performed. If the ATV is sold, these receipts should be transferred with the ATV to the new owner. Make sure whoever performs the maintenance completes this record. All scheduled maintenance, including the 100 mile (150 km) or 20 hours initial maintenance, is considered a normal owner operating cost and will be charged for by your dealer. Use the space under Notes to record anything you want to remind yourself about or mention to your dealer.

Miles (km) or hours

100 (150) or

20

600 (1,000) or

100

1,200 (2,000) or

200

1,800 (3,000) or

300

2,400 (4,000) or

400

3,000 (5,000) or

500

3,600 (6,000) or

600

4,200 (7,000) or

700

4,800 (8,000) or

800

Date Performed By: Notes

82


07/04/04 11:21:45 31HP1640_092

Maintenance Component Locations clutch lever/ parking brake lever front brake fluid reservoir front brake lever

TRX450R only hot start lever fuel fill cap throttle lever


83

07/04/04 11:21:50 31HP1640_093

Maintenance Component Locations air cleaner rear brake fluid reservoir transmission oil filler cap throttle stop screw

(engine idle speed) coolant reserve tank front suspension compression damping adjuster front suspension rebound damping adjuster rear brakelight switch rear brake pedal front suspension rebound damping adjuster front brake caliper

84


07/04/04 11:21:55 31HP1640_094

Maintenance Component Locations rear suspension compression damping adjuster spark plug choke knob storage compartment tool kit air pressure gauge owner’s manual engine oil filler cap spark arrester engine oil filter engine oil drain bolt drive chain rear brake caliper battery main fuse

(TRX450ER only) transmission oil drain bolt rear suspension rebound damping adjuster


85

07/04/04 11:22:01 31HP1640_095

Tool Kit tool kit securely.

To access the tool kit, remove the seat (see page 88 ), and then remove the rubber band.

An optional, larger tool kit may be available. Check with your Honda dealer’s parts department.

UNDER SEAT

(1)

(2)

(3)

(1) tool kit

(2) storage compartment

(3) rubber band

86


07/04/04 11:22:07 31HP1640_096

Owner’s Manual Storage

Your ATV provides storage for the owner’s manual so you’ll have it

To access the owner’s manual, remove the seat (see page 88 ), then

Make sure the owner’s manual and tool kit are fastened securely with the rubber band.

Be careful not to flood this area when washing your ATV.

REAR

(1)

(4)

(3)

(2)

(1) owner’s manual

(2) storage compartment

(3) rubber band

(4) plastic cover


87

07/04/04 11:22:17 31HP1640_097

Seat Removal

Refer to Saf ety Precautions on page 77 .

The seat must be removed for the air cleaner maintenance, and access to the tool kit and owner’s manual.

(3) (2) (5)

(1)

(4)

(1) seat lock lever

(2) seat

(3) studs

Removal

1.

2.

2

3.

Slide the seat back and up.

Installation

1.

the studs into the grommets.

2.

Press down on the seat until it locks.

88


(6)

(4) grommets

(5) front prongs

(6) hooks

07/04/04 11:22:26 31HP1640_098

Fuel


Fuel Recommendation

type pump octane number premium unleaded

91 (or higher)

We recommend that you use premium unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components.

Your engine is designed to use any premium gasoline that has a pump octane number of 91 or higher. Gasoline pumps at service stations normally display the pump octane number. For information on the use of oxygenated fuels, see page 211 .

Use of lower octane gasoline can cause persistent ‘‘pinging’’ or ‘‘spark knock’’ (a loud rapping noise) which, if severe, can lead to engine damage. Light pinging experienced while operating under a heavy load, such as climbing a hill, is no cause for concern.

If pinging or spark knock occurs at a steady engine speed under normal load, change brands of gasoline. If pinging or spark knock persists, consult your Honda dealer.

Never use stale or contaminated gasoline or an oil/gasoline mixture.

Avoid getting dirt, dust, or water in the fuel tank.


89

07/04/04 11:22:34 31HP1640_099

Fuel

Fuel Capacity

Fuel tank capacity, including reserve:

2.72 US gal (10.3 )

Reserve capacity:

0.79 US gal (3.0 )

The tank should be refilled as soon as possible after switching to reserve, and the fuel valve should be returned to the ON position after refueling to avoid running out of fuel with no reserve.

Refueling Procedure


(3)

(4)

(2)

(1)

(1) fuel fill cap

(2) breather tube

90


(3) handlebar cover hole

(4) filler neck

07/04/04 11:22:42 31HP1640_100

Fuel

1.

2.

3.

Avoid over filling the tank. There should be no fuel in the filler neck.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

Stop the engine and keep heat, sparks and flame away.

Handle fuel only outdoors.

Wipe up spills immediately.

4.

After refueling, turn the fuel fill cap clockwise.

5.

Insert the breather tube into the handlebar cover hole.

6.

If the fuel valve was set to RES, turn the fuel valve ON.

If you replace the fuel fill cap, use only a Honda Genuine replacement part.


91

07/04/04 11:22:46 31HP1640_101

Engine Oil & Filter

Engine oil quality is a major factor that affects both the performance and the service life of the engine.

Using the proper oil (page 93 ) and filter, and regularly checking, adding, and changing oil will help extend your engine’s life. Even the best oil wears out. Changing oil helps get rid of dirt and deposits in the engine. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the engine and transmission.

Change the engine oil as specified in the maintenance schedule on page

80 . When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule.

92


07/04/04 11:22:58 31HP1640_102


Engine Oil Recommendation

API classification viscosity (weight)

JASO T 903 standard suggested oil ＊

SG or higher except oils labeled as energy conserving on the circular API service label

SAE 10W-30

MA

Pro Honda GN4 4-stroke oil (USA &

Canada), or Honda 4-stroke oil

(Canada only), or an equivalent motorcycle oil.

＊ Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label.

Your ATV does not need oil additives. Use the recommended oil.

Do not use API SH or higher oils displaying a circular API ‘‘energy conserving’’ service label on the container. They may affect lubrication.

NOT RECOMMENDED OK

Do not use non-detergent, vegetable, or castor based racing oils.


93

07/04/04 11:23:04 31HP1640_103


Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range.

JASO T 903 standard

The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines.

There are two classes: MA and MB.

Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification.

(1)

(2)

(1) code number of the sales company of the oil

(2) oil classification

94


07/04/04 11:23:14 31HP1640_104


Checking & Adding Engine Oil


Check the engine oil level each day before operating your ATV and add if needed.

Bef ore riding your ATV, check the engine oil level.

1.

Park your ATV on a firm, level surface.

2.

Start the engine in a well-ventilated area and let it idle for 3 − 5 minutes. Stop the engine and wait 2 − 3 minutes.

3.

of the crankcase cover.

4.

the crankcase and add the specified oil into the filler cap hole, up to the upper level mark in the inspection window. Do not overfill.

5.

Reinstall the engine oil filler cap. Check for oil leaks.

Running the engine with an improper oil level can cause serious engine damage.

LEFT SIDE

(4) (1)

(3)

(1) upper level mark (H)

(2) lower level mark (L)

(2)

(3) inspection window

(4) engine oil filler cap


95

07/04/04 11:23:24 31HP1640_105


Changing Engine Oil & Filter


Your ATV’s oil filter has very specific performance requirements. Use a new Honda Genuine oil filter specified for your model or a filter of equal quality.

Using the wrong oil f ilter may result in leaks or premature engine damage.

This procedure requires mechanical skill and professional tools such as a torque wrench, as well as a means for disposing of the drained fluid

(page 178 ). If you do not have the skills or the tools, see your Honda dealer.

Drain the Engine Oil:

1.


2.

With the ATV on level ground, remove the engine oil filler cap from the left side of the crankcase cover.

3.

Place an oil drain pan under the crankcase and remove the engine oil

UNDER ENGINE

(2)

(1)

(1) engine oil drain plug

96


(2) sealing washer

07/04/04 11:23:32 31HP1640_106


Install a New Engine Oil Filter:

1.

2.

manner (page 178 ).

then install a new oil filter. Use only the Honda Genuine oil filter or a filter of equivalent quality specified for your model. Using the wrong

Honda filter or a non-Honda filter which is not of equivalent quality may cause engine damage.

3.

on the filter body, near the seal.

Improper installation of the oil f ilter can cause serious engine damage.

LEFT SIDE (5) (3)

(7)

(2)

(1) oil filter cover

(2) bolts

(3) oil filter

(4) O-ring

(6) (4) (1)

(5) spring

(6) rubber seal

(7) OUTSIDE mark

(cont’d)


97

07/04/04 11:23:43 31HP1640_107


4.

Reinstall the oil filter cover, making sure the bolts are tightened to the specified torque:

9 lbf·ft (12 N·m , 1.2 kgf·m)

5.

Pour the drained oil into a suitable container and dispose of it in an approved manner (page 178 ).

Improper disposal of drained f luids is harmf ul to the environment.

Add Engine Oil:

1.

Check that the drain plug sealing washer is in good condition. If necessary, replace the sealing washer.

2.

Reinstall the engine oil drain plug and tighten it to the specified torque:

18 lbf·ft (25 N·m , 2.5 kgf·m)

3.

Fill the crankcase with the recommended grade oil approximately:

0.73 US qt (0.69 )

4.

Reinstall the engine oil filler cap.

5.

Start the engine and let it idle for 3 − 5 minutes.

6.

Stop the engine, wait 2 − 3 minutes and check the engine oil level.

Make sure the engine oil level is at the upper level mark in the inspection window with the ATV upright on firm, level ground. If necessary, add more oil but do not overfill.

7.

Check that there are no oil leaks.

If a torque wrench is not used for installation, see your Honda dealer as soon as possible to verify proper assembly.

98


07/04/04 11:23:56 31HP1640_108

Transmission Oil

Transmission Oil Recommendation

API classification viscosity (weight)

JASO T 903 standard suggested oil ＊

SG or higher except oils labeled as energy conserving on the circular API service label

SAE 10W-30

MA

Pro Honda HP Trans Oil, Pro Honda

GN4 4-stroke oil or an equivalent.

＊ Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label.

Your ATV does not need oil additives. Use the recommended oil.

Do not use oils with graphite or molybdenum additives. They may adversely affect clutch operation.

Do not use API SH or higher oils displaying a circular API ‘‘energy conserving’’ service label on the container. They may affect lubrication and clutch performance.

NOT RECOMMENDED OK

Do not use non-detergent, vegetable, or castor based racing oils.


99

07/04/04 11:24:02 31HP1640_109


Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range.

JASO T 903 standard

The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines.

There are two classes: MA and MB.

Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification.

(1)

(2)

(1) code number of the sales company of the oil

(2) oil classification

100


07/04/04 11:24:11 31HP1640_110


Checking & Adding Transmission Oil


Check the transmission oil level each day before operating your ATV and add if needed.

1.


2.

Start the engine in a well-ventilated area and let it idle for 3 − 5 minutes. Stop the engine and wait 2 − 3 minutes to allow the oil to properly distribute itself in the clutch and transmission.

3.

from the right crankcase cover.

A small amount of oil should flow out of the oil check bolt hole. If no oil flows out of the oil check bolt hole, add transmission oil slowly through the transmission oil filler hole until oil starts to flow out of the oil check bolt hole. Install the oil check bolt and transmission oil filler cap.

4.

After inspecting the transmission oil level or adding oil, tighten the oil check bolt and tighten it to the specified torque:

9 lbf·ft (12 N·m , 1.2 kgf·m)

5.

Install the transmission oil filler cap.

Running the engine with an improper oil level can cause serious engine damage.

RIGHT SIDE

(1)

(2)

(1) transmission oil filler cap (2) oil check bolt


101

07/04/04 11:24:20 31HP1640_111


Changing Transmission Oil


Drain the Transmission Oil:

1.


2.

With the ATV on level ground, remove the transmission oil filler cap from the right crankcase cover.

3.

Place an oil drain pan under the crankcase and remove the

4.

Pour the drained oil into a suitable container and dispose of it in an approved manner (page 178 ).


LEFT SIDE CRANKCASE

(2)

(1) transmission oil drain plug

(1)

(2) sealing washer

102


07/04/04 11:24:28 31HP1640_112


Add Transmission Oil:

5.

Check that the transmission oil drain plug sealing washer is in good condition. If necessary, replace the sealing washer.

6.

Reinstall the transmission oil drain plug and tighten it to the specified torque:

16 lbf·ft (22 N·m , 2.2 kgf·m)

7.

Fill the crankcase with the recommended grade oil approximately:

0.72 US qt (0.68 )

8.

Reinstall the transmission oil filler cap.

9.

Start the engine and let it idle for 3 − 5 minutes. Stop the engine, wait

2 − 3 minutes to allow the oil to properly distribute itself in the clutch and transmission. Check the transmission oil level by following the steps in Checking & Adding Transmission Oil (see page 101 ).

10.

Check that there are no oil leaks.



103

07/04/04 11:24:35 31HP1640_113

Coolant

Your ATV’s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head.

Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion.

Coolant Recommendation

Use Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. Check the antifreeze container label.

Use only distilled water as a part of the coolant solution. Water that is high in mineral content or salt may be harmful to the aluminum engine.

Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage.

The factory provides a 50/50 solution of antifreeze and water in this

ATV. This coolant solution is recommended for most operating temperatures and provides good corrosion protection.

Decreasing the concentration of antifreeze to less than 40% will not provide proper corrosion protection.

104


07/04/04 11:24:43 31HP1640_114

Coolant

Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance. Higher concentrations of antifreeze (up to 60%) should only be used to provide additional protection against freezing. Check the cooling system frequently during freezing weather.

Checking & Adding Coolant


Check the engine coolant level each day before operating your ATV and add if needed.

RIGHT FRONT

(2)

(3)

(1)

(1) reserve tank

(2) UPPER level mark

(3) LOWER level mark

1.

Make sure the vehicle is on level ground.

2.

With the engine at normal operating temperature, check the coolant

2

If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your Honda dealer for repair.

(cont’d)


105

07/04/04 11:24:48 31HP1640_115

Coolant

3.

Always add coolant to the reserve tank. Do not attempt to add coolant by removing the radiator cap.

4.

Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark.

FRONT

(4)

(5)

(4) steering cover (5) reserve tank cap

5.

After adding coolant, install the reserve tank cap and steering cover.

106


07/04/04 11:24:54 31HP1640_116

Coolant

Coolant Replacement


Coolant should be replaced by your Honda dealer, unless you have the proper tools and service data and are mechanically qualified. Refer to the official Honda Service Manual (page 214 ).

Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you.

Always let the engine and radiator cool down before removing the radiator cap.

To properly dispose of drained coolant, refer to You & the Environment, page 178 .



107

07/04/04 11:25:03 31HP1640_117

Coolant

Radiator Core


Check the air passages for clogging or damage. Remove insects, mud, or any obstruction with low water pressure. Have the radiator checked by your Honda dealer if the air flow is restricted over more than 20% of the radiator surface.

Clean the radiator core after riding the ATV in mud.

To clean the radiator core and radiator grill:

1.

Remove the steering cover (page 106 ).

2.

2 3

3.

The right and left shrouds can be removed in the same manner.

(2)

(4)

(1)

(1) shroud

(2) bolts A

(3) bolt B

108


(5)

(4) clip

(5) grommets

(3)

07/04/04 11:25:10 31HP1640_118

Coolant

4.

5.

High pressure water (or air) can damage the radiator core.

LEFT SIDE

(7)

(6)

(6) radiator grill (7) radiator core

6.

Install the radiator grill, right and left shrouds and steering cover in the reverse order of removal.


109

07/04/04 11:25:16 31HP1640_119

Air Cleaner


Proper air cleaner maintenance is very important for off-road vehicles.

A dirty, water-soaked, worn-out, or defective air cleaner will allow dirt, dust, mud, and other impurities to pass into the engine.

Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions.

Your ATV’s air cleaner has very specific performance requirements.

Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality.

Using the wrong air cleaner may result in premature engine damage.

Proper air cleaner maintenance can prevent premature engine wear or damage, expensive repairs, low engine power, poor gas mileage, and spark plug fouling.

Improper or lack of proper air cleaner maintenance can cause poor perf ormance and premature engine wear.

110


07/04/04 11:25:23 31HP1640_120

Cleaning

UNDER SEAT

(1)

Air Cleaner

(2)

(1)

(1) retainer clips

1.

Remove the seat (page 88 ).

2.

3.

(2) air cleaner housing cover

(cont’d)


111

07/04/04 11:25:32 31HP1640_121

Air Cleaner

4.

5.

from the air cleaner housing.

6.

7.

Remove the air cleaner ( ) from the air cleaner body ( 9 ).

8.

Gently wash the air cleaner in clean, non-flammable (high flash point) solvent such as kerosene − not gasoline. After cleaning, gently squeeze out the remaining solvent. Avoid twisting or wringing the air cleaner. This can tear the foam.

9.

Inspect for tears or cracks in the foam or seams of the air cleaner.

Replace the air cleaner if it is damaged.

10.

Allow the air cleaner to dry thoroughly before applying oil. A wet air cleaner will not fully absorb the oil.

11.

Pour clean Pro Honda Foam Filter Oil or an equivalent (Canada:

Honda Foam Filter Oil or an equivalent) over the entire surface of the air cleaner. Use both hands to evenly spread the oil into the air cleaner.

Gently squeeze out any excess oil. (To keep your hands dry, place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner.)

UNDER SEAT (7) (8) (3)

(6)

(4)

(3) screw A

(4) stay

(5) screw B

(6) air cleaner assembly

112


(5)

(7) clamp

(8) air cleaner

(9) air cleaner body

(9)

07/04/04 11:25:38 31HP1640_122

Air Cleaner

12.

13.

Install the air cleaner on the air cleaner body.

Apply a thin coat of grease to the sealing surface of the air cleaner

14.

15.

16.

17.

assembly.

Install the clamp.

Insert the air cleaner assembly into the air cleaner housing.

Fasten the screw B.

Install the stay and fasten the screw A.

18.

Install the air cleaner housing cover and latch the retainer clips.


113

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Throttle

Throttle Freeplay


RIGHT HANDLEBAR

( B )

(4)

(2) (3)

(1) throttle lever

(2) rubber sleeve

(3) throttle cable adjuster

( A )

3/16 − 3/8 in

(5 − 10 mm)

(1)

(4) lock nut

(A) decrease freeplay

(B) increase freeplay

Inspection

Freeplay:

3/16 − 3/8 in (5 − 10 mm)

Adjustment

1.

2.

3.

Turn the adjuster to obtain the correct freeplay.

4.

Tighten the lock nut and reinstall the sleeve.

5.

After adjustment, check for smooth operation of the throttle lever from fully closed to fully open in all steering positions.

6.

Make sure the engine starts. If the engine does not start or engine stall, see your Honda dealer.

114


07/04/04 11:25:55 31HP1640_124

Throttle

Throttle Inspection


1.

Check that the throttle assembly is positioned properly and the securing bolts are tight.

2.

Check for smooth operation of the throttle lever from fully open to fully closed in all steering positions. If there is a problem, see your

Honda dealer.

3.

Inspect the condition of the throttle cables from the throttle lever down to the carburetor. If the cable is kinked or chafed, have it replaced.

4.

Check the cables for tension or stress in all steering positions.

5.

Lubricate the cables with a commercially-available cable lubricant to prevent premature wear and corrosion.


115

07/04/04 11:26:02 31HP1640_125

Clutch System

Clutch Adjustment


LEFT HANDLEBAR

(1)

3/8 − 13/16 in

(10 − 20 mm)


Clutch adjustment may be required if the ATV stalls when shifting into gear, if it tends to creep, or if the clutch slips, causing acceleration to lag behind engine speed.

Inspection

Check freeplay.

Freeplay:

3/8 − 13/16 in (10 − 20 mm)

If necessary, adjust to the specified range.

Improper freeplay adjustment can cause premature clutch wear.

116


07/04/04 11:26:12 31HP1640_126

Clutch System

Upper Adjustment

Minor adjustments are generally made with the upper clutch cable adjuster.

LEFT HANDLEBAR

(2)

( ( ) )

( ( ) )

(4)

(2) dust cover

(3) upper lock nut

(4) upper clutch cable adjuster

(

(

(3)

＋

−

) increase freeplay

) decrease freeplay

1.

2.

3.

freeplay.

4.

Tighten the lock nut and check the freeplay again.

5.

Pull on the dust cover.

If proper adjustment cannot be obtained or the clutch does not work correctly, the cable or clutch friction discs may be worn. See your

Honda dealer.


117

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Clutch System

Lower Adjustment

The lower clutch cable adjuster is used if the upper clutch cable adjuster is threaded out near its limit − or the correct freeplay cannot be obtained.

LEFT SIDE (5)

( ( ) )

( ( ) )

(5) lower adjusting nut

(6) lower lock nut

(6)

( ＋ ) increase freeplay

( − ) decrease freeplay

1.

2.

normal position.

3.

the lower end of the cable.

4.

Turn the lower adjusting nut to obtain the specified freeplay.

5.

Hold the lower adjusting nut and tighten the lower lock nut. Check the adjustment.

118


07/04/04 11:26:26 31HP1640_128

Clutch System

6.

Start the engine, pull the clutch lever/parking brake lever in, and shift into gear. Make sure the engine does not stall and the ATV does not creep. Gradually release the clutch lever/parking brake lever and open the throttle. Your ATV should move smoothly and accelerate gradually.

Check the clutch lever/parking brake lever and clutch cable for loose connections or other damage. If the clutch cable is worn or kinked, have it replaced by your Honda dealer.

Other Inspections & Lubrication

Check that the clutch lever/parking brake lever assembly is positioned properly and the securing bolts are tight.

Check the clutch cable for kinks or signs of wear. If necessary, have it replaced.

Lubricate the clutch cable with a commercially-available cable lubricant to prevent premature wear and corrosion.


119

07/04/04 11:26:35 31HP1640_129

Engine Idle Speed

The best way to assure proper carburetion is to see your Honda dealer for regularly scheduled servicing, including carburetor adjustment.

Remember, idle speed adjustment is not a ‘‘cure-all’’ for other problems in your engine’s fuel-delivery system. Adjusting the idle will not compensate for a fault elsewhere.

The engine must be at normal operating temperature for accurate idle speed adjustment.

For information about high altitude carburetor adjustment, see page 206 .

Idle Speed Adjustment


RIGHT SIDE

( A )

( B )

(1)

(1) throttle stop screw (A) increase

(B) decrease

1.

If the engine is cold, start it and warm it up with ten minutes of stopand-go riding. Stop the engine.

2.


3.

Connect a tachometer to the engine.

4.

Shift into neutral. Start the engine.

5.

Idle speed (in neutral):

1,700 ± 100 rpm

120


07/04/04 11:26:44 31HP1640_130

Spark Plug

Spark Plug Recommendation

standard spark plug for extended high speed riding

IFR7L11 (NGK)

VK22PRZ11 (DENSO)

IFR8H11 (NGK)

VK24PRZ11 (DENSO) or or

Use only the recommended type of spark plug in the recommended heat range.

Using spark plug with an improper heat range can cause engine damage.

This ATV uses spark plug that have an iridium coated center electrode.

Be sure to observe the following when servicing the spark plug.

Do not clean the spark plug. If an electrode is contaminated with accumulated objects or dirt, replace the spark plug with a new one.

To check the spark plug gap, use only a ‘‘wire-type feeler gauge.’’ To prevent damaging the iridium coating of the center electrode, never use a ‘‘leaf-type feeler gauge.’’

Do not adjust the spark plug gap. If the gap is out of specification, replace the spark plug with a new one.


121

07/04/04 11:26:53 31HP1640_131

Spark Plug

Spark Plug Inspection & Replacement


1.

Clean any dirt from around the spark plug base.

2.

spark plug wire when disconnecting the cap.

3.

Using a spark plug wrench provided in the tool kit, remove the spark plug.

4.

Inspect the electrode and center porcelain for deposits, corrosion, or carbon fouling. If the corrosion or deposits are heavy, replace the plug.

5.

Make sure that a 1.2 mm wire-type feeler gauge cannot be inserted between the spark plug gap ( 2 ). If the gauge fits in the gap, replace the plug with a new one.

RIGHT SIDE

(2)

(1) spark plug cap

(1)

(2) spark plug gap

122


07/04/04 11:27:00 31HP1640_132

Spark Plug

6.

With the plug washer attached, thread the spark plug in by hand to prevent cross-threading.

7.

Tighten the spark plug:

If the old plug is good:

1/8 turn after it seats.

If installing a new plug, tighten it twice to prevent loosening: a) First, tighten the plug:

NGK:

DENSO:

3/4


turn after it seats.

b) Then loosen the plug.

c) Next, tighten the plug again:


An improperly tightened spark plug can damage the engine. If a plug is too loose, a piston may be damaged. If a plug is too tight, the threads may be damaged.

8.

Reinstall the spark plug cap. Take care to avoid pinching any cables or wires.


123

07/04/04 11:27:06 31HP1640_133

Valves

Valve Inspection


Valve clearance should be: intake: exhaust:

0.006 in (0.16 mm)

0.011 in (0.28 mm)

Excessive clearance will cause noise. Insufficient clearance will cause loss of power and possibly damage the valves.

For those who are mechanically proficient and have the proper tools, instructions on adjusting valve clearances are given in the official

Honda Service Manual. All others should have valves adjusted by your

Honda dealer.

124


07/04/04 11:27:14 31HP1640_134

Spark Arrester


The spark arrester must be serviced every 100 operating hours to maintain its efficiency.

Regular servicing prevents carbon build up (which can diminish engine performance) and also complies with USDA regulations for regular maintenance to assure proper function. The spark arrester prevents random sparks from the combustion process in your engine from reaching the environment.

1.

Allow the engine and muffler to cool.

2.

REAR (4)

(3)

(1)

(1) bolts

(2) muffler tail cover

(3) spark arrester

(5)

(2)

(4) gasket

(5) muffler

(cont’d)


125

07/04/04 11:27:19 31HP1640_135

Spark Arrester

3.

Use a brush to remove carbon deposits from the spark arrester screen

The spark arrester must be free of breaks and holes. Replace, if necessary. Check the gasket. Replace, if necessary.

(6)

(6) spark arrester screen

4.

Install the gasket to the muffler, the spark arrester, and the muffler tail cover and tighten the bolts securely.

126


07/04/04 11:27:24 31HP1640_136

Suspension

Your front and rear suspension systems use springs and hydraulic damping devices that suspend your weight and most of the weight of your ATV.

The oil damper systems hydraulically control the natural compression and rebound of the suspension springs so that traction and comfort are maintained as the wheels ride over road surfaces.

The way you ride your ATV and the type of ride you want to experience can also influence your suspension needs.

You may adjust the rebound and compression damping of the front and rear suspension systems.


127

07/04/04 11:27:28 31HP1640_137

Suspension

Suspension Adjustment

The suspension can be adjusted for rider weight and riding conditions by changing the rebound and compression damping.

The shock absorber assemblies include a damper unit that contains high pressure nitrogen gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. The instructions found in this owner’s manual are limited to adjustments of the shock assemblies.

128


07/04/04 11:27:38 31HP1640_138

Suspension

Front Suspension Damping


Rebound Damping

RIGHT FRONT

(1)

(2)

(1) rebound damping adjuster

(3)

(2) punch mark

(3) reference punch mark

To adjust to the standard position:

1.

longer turn (lightly seats). This is the full hard setting.

2.

Turn the adjuster counterclockwise approximately 1 turns so that

3.

Make sure that both shock absorbers are adjusted to the same position.

To Reduce Rebound Damping (SOFT):

For a light load and smooth road conditions, turn the adjuster counterclockwise toward SOFT (S).

To Increase Rebound Damping (HARD):

For a firmer ride and rough road conditions, turn the adjuster clockwise toward HARD (H).


129

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Suspension

Compression Damping

LEFT FRONT

(1) (3)

(1) compression damping adjuster

(2) punch mark

(2)



1.

2.


Turn the adjuster counterclockwise approximately 1 7/8 turns so that

3.

Make sure that both shock absorbers are adjusted to the same position.

To Reduce Compression Damping (SOFT):


To Increase Compression Damping (HARD):


130


07/04/04 11:27:58 31HP1640_140

Suspension

Rear Suspension Damping


Rebound Damping

LEFT REAR

(2)

(3)

(1) rebound damping adjuster

(2) punch mark

(1)



1.

2.


Turn the adjuster counterclockwise approximately 1 6/8 turns so that

To Reduce Rebound Damping (SOFT):


To Increase Rebound Damping (HARD):



131

07/04/04 11:28:06 31HP1640_141

Suspension

Compression Damping

LEFT SIDE

(1)

(3)

(2)

(1) compression damping adjuster

(2) punch mark



1.

2.


Turn the adjuster counterclockwise 26 clicks so that the punch

This is the standard position.

To Reduce Compression Damping (SOFT):


To Increase Compression Damping (HARD):


132


07/04/04 11:28:13 31HP1640_142

Brakes

The hydraulic disc braking systems on your ATV dissipate the heat generated by the friction of the brake pads on the brake discs as the wheels are slowed.

As the brake pads wear, the brake fluid level will drop. A leak in the system will also cause the level to drop.

There are no adjustments to perform, but fluid level and pad wear must be inspected periodically. The system must be inspected frequently to ensure there are no fluid leaks.

If the brake lever or brake pedal freeplay does not feel within the normal range while riding, check the brake pads for wear (page 137 ).

Worn pads should be replaced. If the pads are not worn beyond the recommended limit, there is probably air in the brake system. See your

Honda dealer to have the air bled from the system.

Brake Fluid Recommendation

brake fluid Honda DOT 4 Brake Fluid

The recommended brake fluid is Honda DOT 4 Brake Fluid, or any brake fluid of equal quality and performance. Use fresh brake fluid from a sealed container. Be sure to read the label before opening the sealed container. An opened container may be contaminated or may have absorbed moisture from the air.


133

07/04/04 11:28:21 31HP1640_143

Brakes

Fluid Level Inspection


If your inspection indicates a low fluid level, have your Honda dealer add the recommended fluid.

Do not add or replace brake fluid, except in an emergency. If you do add fluid, have your Honda dealer check the system as soon as possible.

Brake f luid can damage plastic and painted surf aces. Handle with care.

Wipe up spills immediately. Avoid contact with skin or eyes. In case of contact, wash thoroughly and call a doctor immediately if it contacts your eyes.

Front Brake Fluid Level

RIGHT HANDLEBAR

(2)

(1) LOWER level mark

134


(1)

(2) inspection window

07/04/04 11:28:28 31HP1640_144

Brakes

With the ATV in an upright position, check the fluid level.

below the LOWER level mark, check the brake pads for wear

(page 137 ).

Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks.

Rear Brake Fluid Level

RIGHT SIDE

(3)

(4)

(3) UPPER level mark (4) LOWER level mark

With the ATV in an upright position, check the fluid level.

level is at or below the LOWER level mark, check the brake pads for wear (page 137 ).

Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks.


135

07/04/04 11:28:33 31HP1640_145

Brakes

Other Inspections

Make sure there are no fluid leaks.

Check for deterioration or cracks in the hoses and fittings. If the hoses are worn or cracked, have them replaced by your Honda dealer.

136


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Brakes

Brake Pad Wear


Brake pad wear will depend upon the severity of usage and riding conditions. The pads will wear faster in wet or muddy conditions.

Inspect the pads visually during all regular service intervals to determine the pad wear.

RIGHT FRONT

(Left side similar)

(2)

REAR

(2)

(1)

(1) wear indicator (2) edge of reference mark

(1)

Honda dealer for this replacement.

Always inspect each pad of the right and left front brake calipers.


137

07/04/04 11:28:49 31HP1640_147

Brakes

Front Brake Lever Adjuster


The distance between the tip of the front brake lever and the grip can be adjusted.

RIGHT HANDLEBAR

(1)

(A)

(2)

(3)

(1) brake lever cover

(2) lock nut

(3) adjust bolt

1.

2.

3.

Apply the brake, release it, then spin the wheel and check that it rotates freely. Repeat this procedure several times.

4.

Fasten the lock nut.

138


07/04/04 11:28:58 31HP1640_148

Brakes

Right Side Mudguard Removal


The right side mudguard must be removed to adjust the rear brakelight switch.

RIGHT SIDE

(2) (5) (3)

(4)

(1) clip

(2) nut

(4)

(3) screw A

(4) screws B

Removal

1.

2.

Installation

Install the right side mudguard in the reverse order of removal.

(1)

(5) right side mudguard


139

07/04/04 11:29:04 31HP1640_149

Brakes

Brakelight Switch Adjustment


Rear Brake Only: behind the engine from time to time. The brakelight should turn on at

0.6 in (15 mm) of pedal stroke. Remove the right side mudguard (see page 139

RIGHT SIDE

( B )

( A )

(1) brakelight switch

(1) (2)

(2) adjusting nut

140


07/04/04 11:29:15 31HP1640_150

Brakes

Parking Brake Adjustment


Parking brake adjustment may be required if the parking brake does not hold properly.

LEFT HANDLEBAR

(1) (3) (2)

REAR

(5)

(6)

(1) dust cover

(2) lock nut

(3) adjuster

(4)

(4) lock nut

(5) parking brake arm

(6) adjusting bolt

4.

5.

Adjustment

1.

Temporarily adjust the clutch lever/parking brake lever freeplay to more than 1 3/16 in (30 mm) (page 116 ).

2.

3.

(cont’d)


141

07/04/04 11:29:24 31HP1640_151

Brakes

6.

Measure the distance the clutch lever/parking brake lever has moved; the distance should be:

1 − 1 3/16 in (25 − 30 mm)

7.

If necessary, adjust the clutch lever/parking brake lever freeplay

(page 116 ).

LEFT HANDLEBAR

(7)

(8)

1 − 1 3/16 in

(25 − 30 mm)

(7) parking brake pin


Check the clutch lever/parking brake lever and parking brake cable for loose connections or other damages. If the parking brake cable is worn or kinked, have it replaced by your Honda dealer.

Other Inspections & Lubrication

Check that the clutch lever/parking brake lever assembly is positioned properly and the securing bolts are tight.

Check the parking brake cable for kinks or signs of wear. If necessary, have it replaced.

Lubricate the parking brake cable with a commercially-available cable lubricant to prevent premature wear and corrosion.

142


07/04/04 11:29:28 31HP1640_152

Tires

To safely operate your ATV, your tires must be the proper type and size, in good condition with adequate tread, and correctly inflated.

Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed.

Follow all instructions in this owner’s manual regarding tire inflation and maintenance.

This ATV 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.

The following pages give detailed information on how and when to check your air pressure, how to inspect your tires for wear and damage, and our recommendations for tire repair and replacement.


143

07/04/04 11:29:33 31HP1640_153

Tires

Air Pressure


Properly inflated tires provide the best combination of handling, tread life, and riding comfort. Generally, underinflated tires wear unevenly, adversely affect handling, and are more likely to fail from being overheated. Overinflated tires make your ATV ride harshly, are more prone to damage from surface hazards, and wear unevenly.

Make sure the air valve caps are secure. If necessary, install new caps.

144


07/04/04 11:29:39 31HP1640_154

Tires

Always check air pressure when your tires are ‘‘cold.’’ If you check air pressure when your tires are ‘‘warm’’ − even if your ATV has only been ridden for a few miles − the readings will be higher. If you let air out of warm tires to match the recommended cold tire pressures, the tires will be underinflated. Be sure to check tire pressure at the riding site, since changes in altitude can affect air pressure.

The recommended ‘‘cold’’ tire pressures are:

RECOMMENDED

PRESSURE

FRONT REAR

4.0 psi (27.5 kPa ,

0.275 kgf/cm )

4.7 psi (32.5 kPa ,

0.325 kgf/cm )


145

07/04/04 11:29:47 31HP1640_155

Tires

A manually operated tire pump should be used rather than the high pressure system found in service stations. This will minimize the possibility of tire damage from overinflation. If you use a high pressure system at a service station, add air in small amounts and check the pressure increase frequently to prevent possible tire damage from overinflation.

Operating this ATV with improper tires, or with uneven tire pressure may cause loss of control, and you could be seriously injured or killed.

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.

Inspection


Whenever you check the tire pressures, you should also look for:

Bumps or bulges in the side of the tire or the tread. Replace any tire that has a bump or bulge.

Cuts, slits, or cracks in the tires. Replace the tire if you can see fabric or cord.

Nails or other foreign objects embedded in the side of the tire or tread.

Excessive tread wear.

146


07/04/04 11:29:56 31HP1640_156

Tires

Also, if you hit a pothole or other hard object while riding, stop as soon as you safely can and carefully inspect the tires for damage.

Tread Wear

FRONT

Replace

NEW

REAR

(3)

(1) groove depth

(2) wear indicator

(2) (1)

3/16 in

(4 mm)

NEW

Replace

3/16 in

(4 mm)

(1)

(3) wear indicator location mark

For best performance, you should replace a tire before the tread depth at the center reaches the following limits: front rear

3/16 in (4 mm)

3/16 in (4 mm)


147

07/04/04 11:30:02 31HP1640_157

Tires

Tire Repair


A tire that is repaired, either temporarily or permanently, will have lower speed and performance limits than a new or undamaged tire.

A temporary repair can sometimes be made in an emergency situation.

However, since a temporary repair may not hold, you must ride very slowly and have the tire replaced or permanently repaired as soon as possible. (For more information on temporary repairs, see If You Have a

Flat Tire, page 186 .)

A permanent repair, such as an internal plug patch, can be made if a tire has only a small puncture in the tread area. However you may not be able to safely carry as much weight. If you choose to have a tire repaired, be sure the repair work is performed by a professional.

If you have a tire professionally repaired at a non-Honda facility, we recommend that you have the work checked by your Honda dealer.

148


07/04/04 11:30:12 31HP1640_158

Tires

Tire Replacement


The tires that came on your ATV were designed to match the performance capabilities of your ATV and provide the best combination of handling, braking, and comfort.

It is best to replace all four tires, however if that is not possible, you must replace the tires in pairs (front or rear) with tires of the same size and type as the originals. Never replace just one tire.

Installing improper tires on your ATV can affect handling and stability. This can cause a crash in which you can be seriously hurt or killed.

Always use the size and type of tires recommended in this owner’s manual.

The recommended tires for your ATV are: front rear

AT21

AT20

×

×

7R10

10R9

★★

★★

DUNLOP KT331H

DUNLOP KT355H

When you replace a tire, remember:

Have the tire replaced by your Honda dealer if possible.

If you have a tire professionally replaced at a non-Honda facility, we recommend that you have the work checked by your Honda dealer.


149

07/04/04 11:30:19 31HP1640_159

Engine Guard & Skid Plates


(1)

(1) engine guard

(2)

(2) skid plates 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 guard and plate bolts are loose, tighten them securely.

150


07/04/04 11:30:27 31HP1640_160

Drive Chain

An endless (riveted master link) chain connects the front and rear wheel sprockets. The O-ring chain uses rubber rings between the side plates of the pin and roller links to seal in the manufacturer-installed lubricating grease and keep out moisture and dirt.

The service life of the chain depends on proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain or sprockets.

The drive chain should be checked, adjusted, and lubricated as part of the pre-ride inspection (page 33 ).

Under severe usage, or when the ATV is ridden in unusually dusty or muddy areas, more frequent maintenance will be necessary.

Before servicing your drive chain, turn the engine OFF and check that your transmission is in neutral.

It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule.

Inspection


1.

Chain slack should be checked by measuring the amount of chain slack midway between the sprockets. The amount of slack should be:

1 − 1 3/8 in (25 − 35 mm)

(cont’d)


151

07/04/04 11:30:34 31HP1640_161

Drive Chain

LEFT SIDE

(1)

1 −

(25

1 3/8 in

− 35 mm)

(1) drive chain

2.

Check drive chain slack at several points along the chain. The slack should remain constant. If it isn’t, some links may be kinked and binding. Lubricating the chain will often eliminate binding and kinking.

Excessive chain slack may allow the drive chain to damage the engine cases.

3.

Inspect the drive chain for: damaged rollers loose pins dry or rusted links kinked or binding links excessive wear damaged or missing O-rings

Replace the drive chain (page 157 ) if it has damaged rollers, loose pins, or kinks that cannot be freed. Lubricate the drive chain (page 156 ) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed.

152


07/04/04 11:30:42 31HP1640_162

Drive Chain

4.

tenance Schedule.

The chain slider must be replaced if it is worn to the wear limit line

LEFT SIDE (2)

(1)

(2) wear limit line (1) drive chain slider

5.

With the upper or lower section of drive chain tight between the sprockets measure the distance between a span of 21 pins from pin center to pin center. If the distance exceeds the service limit, the chain is worn out and should be replaced.

Service limit:

12.56 in (319.1 mm)

Measure a span of 21 pins

(cont’d)


153

07/04/04 11:30:49 31HP1640_163

Drive Chain

6.

The chain roller must be replaced if it is worn to 1/16 in (1.5 mm).

For replacement, see your Honda dealer.

LEFT SIDE

1/16 in

(1.5 mm)

(1) chain roller

(1)

7.

Inspect the front and rear sprocket teeth for excessive wear or damage.

If necessary, have your Honda dealer replace a worn sprocket.

Damaged Sprocket

Teeth

REPLACE

Worn Sprocket

Teeth

REPLACE

Normal Sprocket Teeth

GOOD

Use of a new chain with worn sprockets will cause rapid chain wear.

154


07/04/04 11:30:56 31HP1640_164

Drive Chain

Adjustment


1.

2.

3.

Retighten the rear axle holder fixing bolts.

Rear axle holder fixing bolts torque:

15 lbf·ft (21 N·m , 2.1 kgf·m)


REAR

( B )

(1)

(2)

( A )

(3)

(1) Allen wrench

(2) fixing bolts

(3) adjuster


155

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Drive Chain

Lubrication


Lubricate every 30 days of riding or sooner if chain appears dry.

Lubricate only with SAE 80 or 90 gear oil. Commercial chain lubricants may contain solvents which could damage the rubber O-rings.

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Drive Chain

Removal, Cleaning & Replacement


Your ATV has an endless (riveted master link) type chain. It should only be removed or replaced by your Honda dealer.

The O-rings can be damaged by steam cleaning, high pressure washers, and certain solvents.

1.

Clean the side surfaces of the chain with a dry cloth. Use a high flashpoint solvent such as kerosene − not gasoline.

Do not brush the rubber O-rings.

Brushing will damage them. Use of a solvent may also damage the

O-rings.

2.

Inspect the drive chain for possible wear or damage.

Replace the drive chain if it has damaged rollers, loose fitting links, damaged O-rings, or otherwise appears unserviceable.

Replacement Chain:

DID520V or RK520 SMOZ10S


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Battery (TRX450ER only)

Your ATV has a maintenance-free type battery. You do not have to check the battery electrolyte level or add distilled water as you would with a conventional-type battery.

Your battery is a maintenance-f ree type and can be permanently damaged if the cap strip is removed.

Electrical accessories use current from the battery –– even when the ignition is OFF. Limited operation also allows the battery to discharge.

If you have electrical accessories on your ATV –– or do not ride frequently –– we recommend that you charge the battery frequently (see

Battery Charging, page 162 ).

If you do not expect to ride your ATV for at least two weeks, we recommend you remove the battery –– or at least disconnect the battery cables (negative cable first).

If you plan to store your ATV, see Battery Storage, page 159 .

If your battery seems weak and/or is leaking electrolyte (causing slow starting or other electrical problems), see your Honda dealer.

WARNING: Battery posts, terminals and related accessories contain lead and lead compounds.

Wash your hands after handling.

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07/04/04 11:31:23 31HP1640_168


Battery Storage


If you plan to store your ATV, we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life.

If you do not remove the battery, we recommend disconnecting the battery cables (negative cable first).

You will get the best storage results from removing the battery and slow

(trickle) charging it every 30 days (see Battery Charging, page 162 ).

Before you remove the battery, be sure to read all the information that follows, as well as the information on the battery label.

The battery gives off explosive hydrogen gas during normal operation.

A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you.

Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance.


159

07/04/04 11:31:30 31HP1640_169


The battery is located in a compartment under the left rear fender.

LEFT SIDE

(1)

(2)

(1) battery cover (2) screws

Removal

1.

Make sure the ignition switch is OFF ( ).

2.

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07/04/04 11:31:40 31HP1640_170

LEFT SIDE

(4)


(5) (7)

(3)

(6)

(3) battery holder

(4) mount bolts

(5) negative ( − ) terminal lead

(6) battery

(7) positive ( ＋ ) terminal lead

3.

4.

Disconnect the negative ( − 5 first, then disconnect the positive ( ＋ 7

5.

Remove the battery.

6

6.

Charge the battery (see following section), unless you have been riding regularly.

7.

Store your battery in an easy-to-reach location off the floor, in an area protected from freezing temperature and direct sunlight.

8.

Clean the battery box after removing the battery for storage. Dry the battery box and, if paint is missing, re-paint the area.

9.

Slow charge the battery (see following section) once every 30 days.

Installation

1.

Reinstall in the reverse order of removal.

Be sure to connect the positive ( ＋ ) terminal first, then the negative

( − ) terminal.

2.

Check all bolts and other fasteners are secure.


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Battery Charging


(1)

(1) ‘‘trickle’’ charger

Be sure to read the information that came with your battery charger and follow the instructions on the battery. Improper charging may damage the battery.

units can be left connected for long periods without risking damage to the battery. However, do not intentionally leave the charger connected longer than the time period recommended in the charger’s instructions.

Avoid using an automotive-type battery charger. An automotive charger can overheat an ATV battery and cause premature damage.

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07/04/04 11:31:56 31HP1640_172

Appearance Care

Frequent cleaning and polishing will keep your Honda looking newer longer.

Frequent cleaning also identifies you as an owner who values his ATV.

A clean ATV is also easier to inspect and service.

General Recommendations


To clean your ATV, you may use:

− water

− a mild, neutral detergent and water

− a mild spray and wipe cleaner/polisher

− a mild spray and rinse cleaner/degreaser and water

Avoid products that contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic on your ATV.

If your ATV is still warm from recent operation, give the engine and exhaust system time to cool off.

Park in a shady area. Washing your ATV in bright sunlight may cause the finish to fade because water droplets intensify the sun’s brightness.

Spotting is also more likely because surface water can dry before you have time to wipe it off.

Clean your ATV regularly to protect surface finishes.

We recommend the use of a garden hose to wash your ATV. High pressure washers (like those at coin-operated car washers) can damage certain parts of your ATV.

High pressure water (or air) can damage certain parts of your ATV.

After cleaning, inspect for damage, wear, and leaks (fuel, oil, coolant and brake fluid).


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Appearance Care

Washing Your ATV with a Mild Detergent


1.

Rinse your ATV thoroughly with cool water to remove loose dirt.

2.

Fill a bucket with cool water. Mix in a mild, neutral detergent, such as dish washing liquid or a product made especially for washing motorcycles or automobiles.

3.

Wash your ATV with a sponge or soft towel. As you wash, check for heavy grime. If necessary, use a mild cleaner/degreaser to remove the grime.

4.

After washing, rinse your ATV thoroughly with plenty of clean water to remove any residue. Detergent residue can corrode alloy parts.

5.

Dry your ATV with a chamois or a soft towel. Leaving water on the surface to air dry can cause dulling and water spots. As you dry, inspect for chips and scratches.

6.

Start the engine and let it idle for several minutes. The engine heat will help dry moist areas.

7.

As a precaution, ride your ATV at a slow speed and apply the brakes several times. This will help dry the brakes and restore normal braking performance.

If the inside of the headlight lens appears clouded immediately after washing, it should clear after a few minutes of riding.

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Appearance Care

Spray Cleaning Your ATV


Avoid using spray cleaner products on the tires or suspension components.

Suggestions for using spray cleaner(s) follow:

ATV condition

Dust and fingerprint smudges.

Light road grimes.

Heavy grime. Oil leaks.

Brake dust.

Dull, corroded chrome or aluminum.

Recommended Cleaning

Apply a spray cleaner/polish and wipe paint, chrome, glass, and clear plastic.

Spray any difficult-to-reach or very dirty areas with a spray cleaner/ degreaser.

Rinse and dry.

Apply a spray cleaner/polish and wipe with a non-abrasive cloth.

Use a spray cleaner/degreaser. If necessary, rub with a sponge.

Rinse and dry.

Apply a spray cleaner/polish and wipe with a non-abrasive cloth.

Apply a high quality chrome/ aluminum polish and wipe with a non-abrasive cloth.


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Appearance Care

Aluminum Wheel Maintenance


Aluminum may corrode from contact with dirt, mud, or road salt. Clean the wheels after riding through any of these substances. Use a wet sponge and mild detergent. Avoid stiff brushes, steel wool, or cleaners containing abrasives or chemical compounds.

After washing, rinse with plenty of water and dry with a clean cloth.

Then apply a mild, commercially-available spray cleaner/polish or wax.

For stained or dull-looking wheels, use a quality chrome/aluminum polish to restore the finish.

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Appearance Care

Finishing Touches


After washing your ATV, consider using a commercially-available spray cleaner/polish or quality liquid or paste wax to finish the job. Use only a non-abrasive polish or wax made specifically for motorcycles or automobiles. Apply the polish or wax according to the instructions on the container.

If a surface on your ATV is chipped or scratched, your Honda dealer has touch-up paint to match your ATV’s color. Be sure to use your

ATV’s color code (page 199 ) when you buy touch-up paint.

If the frame has a chip that exposes the metal, first apply primer (to prevent corrosion) and then apply the touch-up paint. Several thin layers of touch-up paint are better than one thick coat.


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168


07/04/04 11:32:31 31HP1640_178

Tips

Here’s helpful advice on how to prepare for an off-road adventure, how to transport and store your Honda, and how to be an environmentally responsible ATV owner.

Preparing for a Ride ...........................................................................

. 170

What to Take to the Riding Area ...................................................

. 170

What to Take on the Trail ..............................................................

. 171

Transporting Your Honda ..................................................................

. 172

Storing Your Honda ...........................................................................

. 174

Preparation for Storage ..................................................................

. 175

Removal from Storage ...................................................................

. 177

You & the Environment .....................................................................

. 178

Tips

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07/04/04 11:32:40 31HP1640_179

Preparing for a Ride

A safe and enjoyable ride begins with good planning and preparation.

Always ride with at least one other person in case you have trouble, and let someone know where you’re going and when you expect to return.

Before riding in an unfamiliar area, find out in advance if you need special permits, get maps so you can study the terrain, and talk to other riders who know the area. The Forest Service and the Bureau of Land

Management (USA only), the Ministry of Natural Resources (Canada only), riding clubs, and off-road magazines are good sources of information.

What to Take to the Riding Area

Along with your ATV and riding gear, you should take along some tools and supplies in case you have a problem. For some of the difficulties you might encounter, see Taking Care of the Unexpected, on page 179 .

which begins

We recommend that you always take water, food, a first aid kit, and your owner’s manual. Other items you should consider loading on your truck or trailer include: a tool kit tire repair supplies and tools, and tires extra parts, control levers, cables, and spark plugs wire, duct tape, and rope extra gasoline

For safety, all refueling should be done at a gas station on the way to the riding area or at your base camp.

170

Tips

07/04/04 11:32:44 31HP1640_180

Preparing for a Ride

What to Take on the Trail

What you take with you during a ride depends on the kind of terrain, how long you expect to ride, how far you might go from your base camp or help, and how experienced you or your companions are in making repairs.

If you decide to take some tools, spare parts, or other supplies on the trail, be sure you can carry them safely and know how to use them. Also, be sure to follow the loading guidelines and weight limit (page 37 ).

Tips

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07/04/04 11:32:50 31HP1640_181

Transporting Your Honda

Do not tow your ATV behind a car or other vehicle.

When you transport your ATV, we recommend that you carry the vehicle in its normal operating position (on all four wheels). Do not incline the vehicle upright on its rear end. This can damage the vehicle, and leaking gasoline could be a hazard.

Follow these procedures:

1.

Set the parking brake and place the transmission in gear.

2.

Turn the fuel valve OFF.

172

Tips

07/04/04 11:32:58 31HP1640_182

Transporting Your Honda

3.

Secure the vehicle with ‘‘tie-down straps’’ in the areas shown.

Suitable ‘‘tie-down straps’’ are available from your Honda dealer.

Ordinary rope is not recommended because it can stretch under load.

Using ‘‘tie-down straps’’ in any other areas can damage your ATV.

4.

Rock the vehicle back and forth to make sure the ‘‘tie-down straps’’ are tight and the vehicle is secure.

(1)

(3)

(4)

(1) front carry pipe

(2) right footpeg

(2)

(3) left footpeg

(4) rear carry pipe or rear axle shaft

Tips

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07/04/04 11:33:02 31HP1640_183

Storing Your Honda

If you won’t be riding for an extended period, such as during the winter, thoroughly inspect your ATV and correct any problem before storing it.

That way, needed repairs won’t be forgotten and it will be easier to get your ATV running again.

For more information about storage, refer to the Honda Motorcycle

Winter Storage Guide, available from your Honda dealer (USA only).

We suggest you perform the following procedures to keep your ATV in top condition. These storage procedures will reduce the deterioration that can occur during storage.

174

Tips

07/04/04 11:33:13 31HP1640_184


Preparation for Storage


This procedure requires a means for draining and disposing of drained fuel (page 178 ).

1.

Change the engine oil and filter (page 96 ).

2.

Change the transmission oil (page 102 ).

3.

Make sure the cooling system is filled with a 50/50% antifreeze solution (page 105 ).

4.

Fill the fuel tank. Make sure the fuel fill cap is properly installed.

5.

Check that the fuel valve is OFF.

6.

Drain the carburetor into an approved gasoline container and dispose of it in an approved manner (page 178 ).

If storage will last longer than one month, carburetor draining is important to assure proper performance after storage.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

Stop the engine and keep heat, sparks and flame away.

Handle fuel only outdoors.

Wipe up spills immediately.

7.

To prevent rusting in the cylinder, perform the following:

Remove the spark plug cap from the spark plug.

Remove the spark plug.

Do not connect the spark plug to the spark plug cap.

(cont’d)

Tips

175

07/04/04 11:33:21 31HP1640_185


Pour a tablespoon (15 − 20 cc) of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth.

(TRX450ER)

With the engine stop switch in the OFF ( ) position, press the start button several times to crank the engine and distribute the oil.

(TRX450R)

With the engine stop switch in the OFF ( ) position, depress the kickstarter several times to crank the engine and distribute the oil.

8.

Reinstall the spark plug and spark plug cap.

(TRX450ER only)

Remove the battery and charge it fully. Store it in an area protected from freezing temperatures and direct sunlight. Slow charge the battery (page 162 ) once a month.

The battery gives off explosive hydrogen gas during normal operation.

A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you.

Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance.

9.

Wash and dry your ATV. Wax all painted surfaces.

10.

Lubricate the drive chain (page 156 ).

176

Tips

07/04/04 11:33:32 31HP1640_186


11.

12.

Inflate the tires to their recommended pressures (page 144 ).

Store your ATV in an unheated area, free of dampness, away from sunlight, with a minimum of daily temperature variation.

Place your ATV on blocks to lift all tires off the floor.

13.

14.

Cover your ATV with a porous material. Avoid using plastic or similar non-breathing, coated materials that restrict air flow and allow heat and moisture to accumulate.

Removal from Storage


1.

Uncover and clean your ATV.

2.

If your ATV has been stored for more than four months − change the engine oil (page 96 ) and transmission oil (page 102 ).

Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark.

3.

If your ATV has been stored for more than two months − ask your

Honda dealer to drain and replace the fuel.

4.

Lubricate the drive chain (page 156 ).

5.

(TRX450ER only)

Charge the battery (page 162 ) as required. Install the battery.

6.

Perform a pre-ride inspection (page 33 ), then test-ride your ATV at low speeds.

Tips

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You & the Environment

Owning and riding an ATV can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport of off-road riding.

Following are tips on how you can be an environmentally-responsible

ATV owner.

Tread Lightly.

Stay on existing roads and trails, avoid surfaces that are easily damaged, and ride only in areas approved for off-road vehicles.

Keep the Noise Down.

Loud vehicles can be offensive. Ride as quietly as possible, don’t remove your spark arrester, and don’t modify the muffler or any other part of your air intake and exhaust systems. Such modifications not only increase noise, they also reduce engine performance and may be illegal.

Choose Sensible Cleaners.

Use a biodegradable detergent when you wash your ATV. Avoid aerosol spray cleaners that contain chlorofluorocarbons (CFCs) which damage the atmosphere’s protective ozone layer. Don’t throw cleaning solvents away; see the following guidelines for proper disposal.

Recycle Wastes.

It’s illegal and thoughtless to put used engine oil in the trash, down a drain, or on the ground. Used oil, gasoline, and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water, lakes, rivers, and oceans. Before changing your oil, make sure you have the proper containers. Put oil and other toxic wastes in separate sealed containers and take them to a recycling center. Call your local or state office of public works or environmental services to find a recycling center in your area, and to get instructions on how to dispose of non-recyclable wastes.

178

Tips

07/04/04 11:33:43 31HP1640_188

Taking Care of the Unexpected

With all the challenges you can encounter off-road, there’s a chance that sometime something may go wrong. This section gives practical advice to help you deal with a wide range of problems. Take time to read this section before you ride. Also review the tips in Preparing f or a Ride

(page 170 ).

General Guidelines .............................................................................

. 180

If Your Engine Quits or Won’t Start ..................................................

. 182

If You Have a Flat Tire .....................................................................

. 186

If the High Coolant Temperature Indicator Lights .............................

. 189

If a Fuse Blows (TRX450ER only) ...................................................

. 191

If You Crash .......................................................................................

. 193

If You Lose Your Key .......................................................................

. 194

If the Battery Is Low (or Dead) (TRX450ER only) ...........................

. 195

If a Component Fails ..........................................................................

. 196


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General Guidelines

Keeping your ATV well-maintained is the best way to reduce the possibility of having a problem while riding. However, problems can arise even with well-maintained machines.

Remember to take along your owner’s manual, the tool kit that came with your ATV, and any other items (such as tire repair supplies and additional tools) that might help you solve a problem on your own.

If something goes wrong during a ride, the first thing to do is stop as soon as you safely can. Do not continue riding if you have a flat tire, or you hear an unusual noise, or your ATV just doesn’t feel right. If you continue riding, you could cause more damage and endanger your own safety.

After a stop, take time to assess the situation. Carefully inspect your

ATV to identify the problem, then consider your options before you decide what to do.

If a problem is relatively minor and you have the tools, supplies, and skills to make a permanent repair, you may be able to fix it on the trail and continue riding. Or, you may be able to make a temporary repair that allows you to slowly ride back to your base where you can make a permanent repair or get help.

When a problem is more serious − or you don’t have the tools, supplies, experience, or time to deal with it − you need to choose the safest way to get yourself and your ATV back to base. For example, if you are close enough, you (or you and another person) might be able to push it back.

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07/04/04 11:33:55 31HP1640_190


Should you ever have a problem while riding, please follow these guidelines:

Always put personal safety first.

Take time to assess the situation and your options before deciding what to do.

If the problem is relatively minor and you have the tools, supplies, and skills to make a temporary repair, be sure to have permanent repairs made as soon as possible.

Do not continue riding if you are hurt or your ATV is not in safe riding condition.

Additional recommendations for specific problems follow.


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If Your Engine Quits or Won’t Start

Proper operation and maintenance can prevent starting and engine performance problems. In many cases, the cause of the problem may be a simple operational oversight.

If you have a problem starting the engine − or experience poor engine performance − the following information may help you. If you can’t correct the problem, see your Honda dealer.

(TRX450ER)

If your ATV won’t start, listen as you press the start button. If you don’t hear the starter motor turning, refer to the Starter motor doesn’t operate symptom. If you can hear the starter motor working normally, refer to the Starter motor works, but the engine won’t start symptom.

(TRX450R)

If your ATV won’t start, refer to the Engine doesn’t operate symptom.

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07/04/04 11:34:19 31HP1640_192


SYMPTOM: Starter motor doesn’t operate.

POSSIBLE CAUSE ignition switch OFF

(TRX450ER only)

WHAT TO DO

Turn the ignition switch ON.

Shift into neutral.

transmission not in neutral blown fuse battery lead loose low (or dead) battery

Replace with a new fuse of the same rating (page 191 ).

Tighten the battery lead.

Charge the battery (page 162 ).

faulty starter motor

If charging doesn’t help, see your

Honda dealer.

If all possible causes are negative, the starter motor may be faulty. See your Honda dealer.

SYMPTOM: Starter motor works, but the engine won’t start.

(TRX450ER only)

POSSIBLE CAUSE engine stop switch

WHAT TO DO

Turn the engine stop switch to RUN.

OFF out of fuel flooded engine loose or unconnected spark plug cap not enough throttle

Fill the fuel tank.

See

F looded Engine

(page 54 ).

Install the spark plug cap securely. If the engine still won’t start, see your

Honda dealer.

Check the throttle freeplay freeplay loose battery cables weak battery

(page 114 ).

Tighten the battery terminal bolts.

Charge the battery (page 162 ). If charging doesn’t help, see your

Honda dealer.


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07/04/04 11:34:32 31HP1640_193


SYMPTOM: Engine doesn’t operate.

POSSIBLE CAUSE ignition switch OFF

(TRX450R only)

WHAT TO DO

Turn the ignition switch ON.

Turn the engine stop switch to RUN.

engine stop switch

OFF transmission not in neutral

Shift into neutral.

out of fuel flooded engine loose or unconnected spark plug cap not enough throttle

Fill the fuel tank.

See

F looded Engine

(page 54 ).

Install the spark plug cap securely. If the engine still won’t start, see your

Honda dealer.

Check the throttle freeplay (page freeplay 114 ).

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07/04/04 11:34:47 31HP1640_194


SYMPTOM: Engine starts, but runs poorly.

POSSIBLE CAUSE idles roughly, too fast, stalls

Check engine idle adjustment (page

120

WHAT TO DO

). If the problem persists, see your Honda dealer.

improperly throttle freeplay

Check the throttle freeplay

(page 114 ).

poor engine performance at altitudes above

4,500 feet (1,500 m).

high coolant temperature

Ask your Honda dealer to modify the carburetion with a high altitude jet.

Refer to

High Altitude Car bur etor

Adjustment,

page 206 .

Check the high coolant temperature indicator. Refer to

If the High

Coolant T emper atur e Indicator

Lights,

page 189 .

See your Honda dealer.

runs erratically, misfires blubbers (rich fuel mixture) sooty exhaust (rich fuel mixture) detonates or pings under load



If applicable, switch to the recommended octane gasoline

(page 89 ) or change your brand of gasoline. If the problem persists, see your Honda dealer.

afterfires (backfires) pre-ignition (runs on after ignition switched OFF)




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07/04/04 11:34:54 31HP1640_195

If You Have a Flat Tire

How you handle a flat tire on the trail depends on how serious the tire damage is, and what tools and supplies you have with you.

If you have a slow leak or a minor puncture, 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 your Honda dealer. Any tire that cannot be repaired should be replaced.

Whenever the ATV 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.

If the leak is more serious, or a temporary repair doesn’t hold, the tire must be replaced. The tire will also need to be replaced if it is damaged

(page 149 ). Replacing a tire involves removing and re-installing the wheel (page 187 ).

If you are unable to repair a flat tire on the trail, you will need to send for help. We strongly recommend that you do not try to ride with a flat tire. The ATV will be hard to handle, and if the tire comes off the rim, it may lock up the wheel and cause you to crash.

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Emergency Wheel Removal/Installation


(1)

(1)

(2)

(1) wheel nuts (2) wheel rim

Removal

1.


2.

Raise the front (or rear) wheels off the ground and place a support block under the vehicle.

3.

4.

Remove the wheel.

Avoid getting grease, oil, or dirt on the disc or pad surfaces when removing and installing each wheel. Any contamination can cause poor brake performance or rapid pad wear after reassembly.


187

07/04/04 11:35:08 31HP1640_197


Installation

1.

Position the wheel.

2.

Position the wheel nuts so that the tapered sides face the wheel rim

3.

Tighten the wheel nuts in a crisscross (rather than a circular) pattern to the specified torque:

47 lbf·ft (64 N·m , 6.5 kgf·m)

If a torque wrench was not used for installation, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capability.

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07/04/04 11:35:16 31HP1640_198

If the High Coolant Temperature

Indicator Lights

(TRX450ER)

Normally, the high coolant temperature indicator will only light momentarily when you turn the ignition ON ( ).

(TRX450R)

Normally, the high coolant temperature indicator will only light momentarily when you start and running the engine.

Occasionally, it may flicker at or near idling speed.

High coolant temperature may be caused by restriction of air flow to the radiator (such as mud caked on the radiator), extended idling, an oil leak, a coolant leak, a low oil level, a low coolant level, or extended operation under adverse conditions.

If the indicator comes on while you’re riding, don’t ignore it. Pull safely to a stop. Stop the engine as soon as it’s safe to do so, and let it cool.

Continuing to ride with high coolant temperature or an overheated engine can cause serious engine damage.

A steaming engine indicates a coolant leak. Shut the engine off and wait until the steaming stops. Look for a leak, but don’t touch the engine or radiator system. Let everything cool off first.

Check for any restriction of air flow through the radiator.

If there’s no obvious problem, leave the engine on so the fan and coolant circulating system can continue working. Monitor the high coolant temperature indicator. The indicator may turn off after a brief stop with no load on the engine.

Check the radiator fan. If the fan is not working, have your Honda dealer check for problems. If the radiator fan is working, visually check the coolant level in the reserve tank, located under the steering cover. It isn’t necessary to touch the radiator system.

(cont’d)


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07/04/04 11:35:22 31HP1640_199

If the High Coolant Temperature

Indicator Lights

If the reserve tank is low or empty, don’t ride without adding coolant

(page 105 ). After adding coolant, turn the engine on and check the high coolant temperature indicator.

If the indicator doesn’t turn off, do not ride. The engine needs repair.

Transport your ATV to a Honda dealer (page 172 ).

If the temperature drops to normal, check the coolant level. If it has gone down, add more coolant.

Check for an oil leak.

Check the oil level. If necessary, add the recommended oil (page 95 ) to the upper level mark. If you must leave your ATV to get oil, secure it as much as possible.

Start the engine, and check that the high coolant temperature indicator goes off.

If the indicator goes off − resume riding. If there is a leak − do not ride the ATV until the leak is repaired by a Honda dealer.

If there’s a mild coolant leak, you can ride for awhile, carefully watching the indicator. Be prepared to stop and add more coolant or water. If the leak is bad, transport your ATV to a Honda dealer (page

172 ).

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07/04/04 11:35:29 31HP1640_200

If a Fuse Blows (TRX450ER only)

All of the electrical circuits on your ATV have a fuse to protect them from damage caused by excess current flow (short circuit or overload).

If something electrical on your ATV stops working, the first thing you

Check the fuse before looking elsewhere for another possible cause of the problem. Replace a blown fuse and check component operation.

(1) blown fuse

The main fuse is located near the battery.

Recommended Fuse main fuse 15 A

(1)


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If a Fuse Blows (TRX450ER only)

Main Fuse Access

INSIDE THE BATTERY COVER

(1)

(2) (3)

(1) main fuse

(2) fuse case cover

(3) spare main fuse

1.

To prevent an accidental short circuit, turn the ignition switch OFF

( ) before checking or replacing the fuse.

2.

To access the main fuse ( ), remove the battery cover (page 160 ).

3.

4.

Pull the main fuse out.

If you do not have a replacement fuse with the proper rating for the circuit, install one with a lower rating.

Replacing a f use with one that has a higher rating greatly increases the chance of damage to the electrical system.

5.

Reinstall the fuse case cover.

6.

Install the battery cover.

If the replacement fuse of the same rating burns out in a short time, there is probably a serious electrical problem on your ATV. Leave the blown fuse in that circuit and have your ATV checked by your Honda dealer.

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If You Crash

Personal safety is your first priority after an accident. If you or anyone else has been injured, take time to assess the severity of the injuries and whether it is safe to continue riding. If you cannot ride safely, send someone for help. Do not ride if you will risk further injury.

If you decide you are capable of riding safely, carefully inspect your

ATV for damage and determine if it is safe to ride. Check the tightness of critical nuts and bolts securing such parts as the handlebar, control levers, brakes, and wheels.

If there is minor damage, or you are unsure about possible damage but decide to try riding the ATV back to your base, ride slowly and cautiously.

Sometimes, crash damage is hidden or not immediately apparent. When you get home, thoroughly check your ATV and correct any problems you find. Also, be sure to have your Honda dealer check the frame and suspension after any serious crash.


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If You Lose Your Key at the rear of the manual. You’ll need this number to have a duplicate key made.

If you lose your key and aren’t carrying a duplicate, either get your spare or have one made. If you don’t know your key number, call the dealer where you purchased your Honda ATV. They may have it listed in their records. If they don’t, transport your ATV to them or the nearest

Honda dealer. The dealer will probably have to remove the ignition switch assembly to find the key number so they can make a key for you.

(1)

(1) key number

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07/04/04 11:35:52 31HP1640_204

If the Battery Is Low (or Dead)

(TRX450ER only)

Jump starting is not recommended, especially if you use an automobile battery. The greater amperage of an automobile battery when the car engine is running can damage your ATV’s electrical system.

Bump starting is also not recommended.

If you can’t charge the battery or it appears unable to hold a charge, contact your Honda dealer.


195

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If a Component Fails

The levers or pedal, control cables, and other components can be damaged as you ride in dense brush or over rocky terrain. Making a trailside repair depends on how serious the damage is and what tools and supplies you have with you.

If any component of the brake system is damaged, you may be able to ride carefully back to your base using the other brake components for slowing or stopping.

If you damage a throttle cable or other critical component, your ATV may be unsafe to ride. Carefully assess the damage and make any repairs that you can. But if there is any doubt, it’s best to be conservative and safe.

196


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Technical Information

This section contains dimensions, capacities, and other technical data, plus information on government requirements and how to break-in your

ATV.

Vehicle Identification .........................................................................

. 198

Specifications .....................................................................................

. 200

Break-in Guidelines ...........................................................................

. 205

High Altitude Carburetor Adjustment ................................................

. 206

Emission Control Systems ..................................................................

. 207

Oxygenated Fuels ...............................................................................

. 211


197

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Vehicle Identification

Serial Numbers

The VIN, engine serial number, and key number may be required when ordering replacement parts. You may record these numbers in the Quick

Reference section at the rear of this manual.

FRONT

(1)

(1) VIN

LEFT SIDE

(2) engine number

(2)

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Vehicle Identification

Color Label & Code

The color code is helpful when ordering replacement parts. You may record the color and code in the Quick Reference section at the rear of this manual.

LEFT FRONT

(1)

(1) color label


199

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Specifications

Dimensions overall length overall width overall height wheelbase ground clearance

Fuel & Lubricants fuel recommendation fuel tank capacity fuel tank reserve engine oil capacity engine oil recommendation

73.3 in (1,862 mm)

46.3 in (1,177 mm)

43.3 in (1,100 mm)

50.2 in (1,275 mm)

4.4 in (111 mm) premium unleaded gasoline, pump octane number of 91 or higher

2.72 US gal (10.3 ) including reserve

0.79 US gal (3.0 ) after disassembly:

0.90 US qt (0.85 ) after draining:

0.69 US qt (0.65 ) after draining & oil filter change:

0.73 US qt (0.69 )

API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label, SAE 10W-30, JASO T

903 standard MA,

Pro Honda GN4 4-stroke oil (USA &

Canada) or Honda 4-stroke oil

(Canada only), or an equivalent motorcycle oil

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Specifications

Fuel & Lubricants (cont’d) transmission oil capacity after disassembly:

0.85 US qt (0.80 ) transmission oil recommendation cooling system recommendation after draining:

0.72 US qt (0.68 )

API Service Classification SG or higher except oils labeled as energy conserving on the circular

API service label, SAE 10W-30,

JASO T 903 standard MA, Pro

Honda HP Trans Oil, Pro Honda

GN4 4-stroke oil, or an equivalent.

Pro Honda HP Coolant or an equivalent high quality ethylene cooling system capacity glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines

1.6 US qt (1.5 )


201

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Specifications

Capacities passenger capacity maximum weight capacity operator only

243 lbs (110 kg) rider, all cargo and accessories

Engine Specifications displacement bore & stroke compression ratio spark plug

(standard) spark plug

(high speed riding) spark plug gap valve clearance

(cold) idle speed

27.4 cu-in (449 cm )

3.78

× 2.44 in (96.0

× 62.1 mm)

12.0 : 1

IFR7L11 (NGK) or VK22PRZ11 (DENSO)

IFR8H11 (NGK) or VK24PRZ11 (DENSO)

0.039

− 0.043 in (1.0

− 1.1 mm) intake: exhaust:

0.006 in (0.16 mm)

0.011 in (0.28 mm)

1,700 ± 100 rpm

Power Transmission primary reduction final reduction gear ratio

1st

2nd

3rd

4th

5th final drive

2.739

2.923

2.230

1.785

1.437

1.181

0.962

chain

DID520V or

RK520 SMOZ10S

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Specifications

Chassis & Suspension caster trail tire size, front tire size, rear tire pressure, front & rear (cold)

5 °

0.9 in (23 mm)

AT21 × 7R10 ★★

DUNLOP KT331H

AT20 × 10R9 ★★

DUNLOP KT355H

Front:

4.0 psi (27.5 kPa , 0.275 kgf/cm )

Rear:

4.7 psi (32.5 kPa , 0.325 kgf/cm )


203

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Specifications

Electrical battery

(TRX450ER only) generator

Lights headlight brake/tail light high coolant temperature indicator neutral indicator

(TRX450ER only)

12 V − 6 Ah

0.214 kW/5,000 rpm

12 V 30/30 W × 2

LED

12 V 3.4 W

12 V 3 W

Fuse main

(TRX450ER only)

15 A

Torque Specification engine oil drain bolt oil filter cover bolts transmission oil drain bolt transmission oil check bolt wheel nuts

18 lbf·ft (25 N·m , 2.5 kgf·m)

9 lbf·ft (12 N·m , 1.2 kgf·m)

16 lbf·ft (22 N·m , 2.2 kgf·m)

9 lbf·ft (12 N·m , 1.2 kgf·m)

47 lbf·ft (64 N·m , 6.5 kgf·m)

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07/04/04 11:37:24 31HP1640_214

Break-in Guidelines

Help assure your ATV’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles

(25 km).

During this period, avoid full-throttle starts, rapid acceleration, and constant rpm operation.


205

07/04/04 11:37:28 31HP1640_215

High Altitude Carburetor Adjustment

At high altitude, the standard carburetor air-fuel mixture will be too rich.

Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting.

Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.

High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above

6,500 feet (2,000 meters), have your servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life.

Even with carburetor modification, engine horsepower will decrease about 3.5% for each 1,000-foot (300-meter) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

When the carburetor has been modif ied f or high altitude operation, the air-f uel mixture will be too lean f or low altitude use. Operation at altitudes below 5,000 f eet (1,500 meters) with a modif ied carburetor may cause the engine to overheat and result in serious engine damage.

For use at low altitudes, have your servicing dealer return the carburetor to original f actory specif ications.

206


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Emission Control Systems

Exhaust Emission Requirements

The U.S. Environmental Protection Agency (EPA), the California Air

Resources Board (CARB), and Environment Canada (EC) require that your ATV comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions provided.

the front of the frame.

FRONT

(1)

(2)

(1) vehicle emission control information label

(2) vehicle emission control information label (Canada only)


207

07/04/04 11:37:39 31HP1640_217


Source of Exhaust Emissions

The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight.

Carbon monoxide does not react in the same way, but it is toxic.

Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.

Exhaust Emission Control System

The exhaust emission control system is composed of appropriate carburetor settings. No adjustments should be made except for an idle speed adjustment with the throttle stop screw or carburetor adjustment for high altitude operation.

The exhaust emission control system is separate from the crankcase emission control system.

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07/04/04 11:37:46 31HP1640_218


Crankcase Emission Control System

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and the carburetor.

Problems That May Affect ATV Exhaust Emissions

If you are aware of any of the following symptoms, have the vehicle inspected and repaired by your Honda ATV dealer.

Symptoms:

1.

Hard starting or stalling after starting

2.

Rough idle

3.

Misfiring or backfiring during acceleration

4.

After-burning (backfiring)

5.

Poor performance (driveability) and poor fuel economy

Federal regulations prohibit removing or disabling a device or element of design that may affect your engine’s emission performance unless your ATV will be used exclusively in competition. If you modify your engine for use in sanctioned competition events, you must deface or destroy the emission control information label.


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Noise Emission Control System

TAMPERING WITH THE NOISE CONTROL SYSTEM IS

PROHIBITED:

State laws prohibit, or Canadian provincial laws may prohibit the inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or the vehicle after such device or element of design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE

TAMPERING ARE THE FOLLOWING ACTS:

1.

Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.

2.

Removal of, or puncturing of any part of the intake system.

3.

Lack of proper maintenance.

4.

Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

Fuel Permeation Emission Control System

This vehicle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency (EPA), the

California Air Resources Board (CARB), and Environment Canada

(EC).

The fuel tank, fuel hoses, and fuel vapor charge hoses used on this vehicle incorporate fuel permeation control technologies.

Tampering with the fuel tank, fuel hoses, or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal regulations.

210


07/04/04 11:37:58 31HP1640_220

Oxygenated Fuels

Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and

Canada use oxygenated fuels to help reduce emissions.

If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.

Before using an oxygenated fuel, try to confirm the fuel’s contents.

Some states/provinces require this information to be posted on the pump.

The following are the EPA-approved percentages of oxygenates:

ETHANOL (ethyl or grain alcohol) 10% by volume

You may use gasoline containing up to 10% ethanol by volume.

Gasoline containing ethanol may be marketed under the name

‘‘Gasohol’’.

MTBE (Methyl Tertiary Butyl Ether) 15% by Volume

You may use gasoline containing up to 15% MTBE by volume.

METHANOL (methyl or wood alcohol) 5% by Volume

You may use gasoline containing methanol containing up to 5% methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system.


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07/04/04 11:38:03 31HP1640_221

Oxygenated Fuels

If you notice any undesirable operating symptoms, try another service station or switch to another brand of gasoline.

Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty.

Oxygenated fuels can damage paint and plastic. Be careful not to spill fuel when filling the fuel tank. Wipe up any spills immediately.

Oxygenated f uels can damage paint and plastic. Damage caused by spilled f uel is not covered by warranty.

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07/04/04 11:38:07 31HP1640_222

Consumer Information

This section contains information on your warranty and how to get an official Honda service manual.

Authorized Manuals ...........................................................................

. 214

Warranty Coverage ............................................................................

. 217

Warranty Service ................................................................................

. 218

Contacting Honda ..............................................................................

. 219

Your Honda Dealer ............................................................................

. 220

The Honda Rider’s Club (USA only) .................................................

. 221


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07/04/04 11:38:14 31HP1640_223

Authorized Manuals

The Service Manual used by your authorized Honda dealer is available from Helm, Inc. (USA only, Canada: See your Honda dealer to order authorized manuals.)

Also available but not necessary to service your model is the Honda

Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles, motor scooters and ATVs.

These Honda manuals are written for the professional technician, but most mechanically-capable owners should find them easy to use if they have the proper tools and observe proper safety standards.

Special Honda tools are necessary for some procedures.

Publication Item No.

61HP104

61CM002

31HP1640

Description

2008 TRX450ER/R Service Manual

Common Service Manual

2008 TRX450ER/R Owner’s Manual

＊ Prices are subject to change without notice and without incurring obligation.

Price Each ＊

$48.00

$48.00

$16.00

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07/04/04 11:38:23 31HP1640_224

Order On-Line: www.helminc.com

Order Toll Free: 1-888-CYCLE93 (1-888-292-5393)

(NOTE: For Credit Card Orders Only)

Monday − Friday 8:00 AM − 6:00 PM EST

OR

By completing this form you can order the materials desired. You can pay by check or money order, or charge to your credit card. Mail to

Helm, Inc. at the address shown on the back of this order form (USA only).

Canada: See your Honda dealer to order authorized manuals.

Publication

Item No.

Item Description Qty.

Price

Each ＊

Total

Price

＊ Prices are subject to change without notice and without incurring obligation.

Orders are mailed within 10 days. Please allow adequate time for delivery.

Sub Total

Purchaser’s Sales Tax

Mich. Add 6 %

Calif. Add 8.25 %

Handling Charge

Grand Total

$5.00


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07/04/04 11:38:36 31HP1640_225

NOTE: Dealers and Companies please provide dealer or company name, and also the name of the person to whose attention the shipment should be sent.

S

H

I

P

T

O

Customer Name

Attention

Street Address

City

Daytime Telephone Number

( )

State

Apartment Number

Zip Code

Check or money order enclosed payable to Helm Inc. U. S. funds only. Do not send cash.

P

A

Y

M

E

N

T

Check here if your billing address is different from the shipping address shown above.

VISA

Account Number

MasterCard Discover

Expiration: Mo. Yr.

−

Customer Signature Date

These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery. On returns, a restocking fee may be applied against the original order.

HELM P. O. BOX 07280, DETROIT, MICHIGAN 48207

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07/04/04 11:38:42 31HP1640_226

Warranty Coverage

Your new Honda is covered by these warranties:

TRX Limited Warranty

Exhaust Emission Warranty

There are responsibilities, restrictions, and exclusions which apply to these warranties. Please read the Warranties Booklet given to you by your Honda dealer at the time of purchase. Be sure to keep your Honda owner’s card with your Warranties Booklet (USA only).

It is important to realize that your warranty applies to defects in material or workmanship of your Honda. Your warranty coverage does not apply to normal wear or deterioration associated with using the ATV.

Your warranty coverage will not be voided if you choose to perform your own maintenance. However, you should have the proper tools and service information and be mechanically qualified. Failures that occur due directly to improper maintenance are not covered.

Almost all of your warranty coverage can be extended through the

Honda Protection Plan (USA only). For more information, see your

Honda dealer.


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07/04/04 11:38:46 31HP1640_227

Warranty Service

Please remember that recommended maintenance interval servicing is not included in your warranty coverage. Additionally, your warranty does not apply to the normal wear of items (such as brakes, tires, etc.).

If you believe you have a problem with your ATV, call the service department of your Honda dealer. Make an appointment for an inspection and diagnosis. Remember, as the owner of the ATV, you will be asked to authorize that inspection. Your dealer will give you the results of the inspection. If the problem is covered under warranty, your dealer will perform the warranty repairs for you.

If you have questions about warranty coverage or the nature of the repair, it is best to talk to the service manager of your Honda dealer.

Sometimes, in spite of the best intentions of all concerned, a misunderstanding may occur. If you aren’t satisfied with your dealer’s handling of the situation, we suggest you discuss your problem with the appropriate member of the dealership’s management team. If the problem has already been reviewed with the Service Manager, Parts

Manager, Sales Manager, etc., contact the Owner of the dealership or their designated representative.

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07/04/04 11:38:53 31HP1640_228

Contacting Honda

Your owner’s manual was written to cover most of the questions you might ask about your Honda. Any questions not answered in the owner’s manual can be answered by your Honda dealer. If your dealer doesn’t have the answer right away, they will get it for you.

If you have a difference of opinion with your dealer, please remember that each dealership is independently owned and operated. That’s why it’s important to work to resolve any differences at the dealership level.

If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address (USA only):

Motorcycle Division, American Honda Motor Co., Inc., P.O. Box 2200,

Torrance, CA 90509-2200, mailstop: 100-4C-7B, telephone: (866) 784-

1870.

Canada: Refer to the Warranties Booklet that was supplied with your vehicle.

Please include the following information in your letter: name, address, and telephone number product model, year, and VIN date of purchase dealer name and address

We will likely ask your Honda dealer to respond, or possibly acknowledge your comments directly.


219

07/04/04 11:38:58 31HP1640_229

Your Honda Dealer

Once you purchase your new Honda, get familiar with the organization of your Honda dealer so you can utilize the full range of services available.

The service department is there to perform regular maintenance and unexpected repairs. It has the latest available service information from

Honda. The service department will also handle warranty inspections and repairs.

The parts department offers Honda Genuine Parts, Pro Honda products,

Honda Genuine Accessories (USA only), and Honda accessories and products (Canada only). The same quality that went into your Honda can be found in Honda Genuine replacement parts. You’ll also find comparable quality in the accessories and products available from the parts department.

The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage (USA only).

Your Honda dealer can inform you about competition and other riding events in your area. You’ll also find that your dealer is a source of information about American Honda’s Rider Education Centers and the

Honda Rider’s Club of America (USA only).

We’re sure you’ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda.

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07/04/04 11:39:01 31HP1640_230

The Honda Rider’s Club (USA only)

You may be eligible for a Honda Rider’s Club of America (HRCA) membership with the purchase of your new Honda. You can log on to the HRCA Clubhouse website for details at www.hrca.honda.com.


221

07/04/04 11:39:05 31HP1640_231

Table of Contents

The following presents the contents of each section of your owner’s manual.

ATV SAFETY ......................................................................................

. 1

Important Safety Information ................................................................

. 2

Safety Labels ..........................................................................................

. 5

INDICATORS & CONTROLS ...........................................................

. 9

Operation Component Locations .........................................................

. 10

Indicators ..............................................................................................

. 13

High Coolant Temperature Indicator ...............................................

. 13

Neutral Indicator (TRX450ER only) ................................................

. 14

Controls & Features .............................................................................

. 15

Fuel Valve ........................................................................................

. 15

Choke Knob .....................................................................................

. 16

Hot Start Lever (TRX450R only) .....................................................

. 17

Ignition Switch .................................................................................

. 18

Start Button (TRX450ER only) ........................................................

. 19

Kickstarter (TRX450R only) ............................................................

. 20

Engine Stop Switch ..........................................................................

. 21

Headlight Switch ..............................................................................

. 22

Headlight Dimmer Switch ................................................................

. 22

Throttle Lever ..................................................................................

. 23

Clutch Lever/Parking Brake Lever ..................................................

. 23

Front Brake Lever ............................................................................

. 24

Rear Brake Pedal ..............................................................................

. 24

Parking Brake ...................................................................................

. 25

Flag Pole Bracket .............................................................................

. 26

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07/04/04 11:39:09 31HP1640_232


BEFORE RIDING .............................................................................

. 27

Are You Ready to Ride?

......................................................................

. 28

Protective Apparel ............................................................................

. 28

Rider Training ..................................................................................

. 30

Age Recommendation ......................................................................

. 31

No Passengers ..................................................................................

. 31

No Alcohol or Drugs ........................................................................

. 32

Is Your ATV Ready to Ride?

...............................................................

. 33

Pre-ride Inspection ...........................................................................

. 33

Load Limits & Guidelines ....................................................................

. 36

Loading ............................................................................................

. 36

Load Limits ......................................................................................

. 37

Loading Guidellines .........................................................................

. 38

Accessories & Modifications ...............................................................

. 39

Accessories .......................................................................................

. 39

Modifications ...................................................................................

. 40


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07/04/04 11:39:12 31HP1640_233


BASIC OPERATION & RIDING ....................................................

. 41

Safe Riding Precautions .......................................................................

. 42

Off-Road Use Only ..........................................................................

. 42

Keep Hands and Feet on Controls ....................................................

. 43

Control Speed ...................................................................................

. 44

Use Care on Unfamiliar or Rough Terrain .......................................

. 45

Do Not Perform Stunts .....................................................................

. 46

Starting & Stopping the Engine ...........................................................

. 47

Preparation .......................................................................................

. 48

Starting Procedure ............................................................................

. 50

Flooded Engine ................................................................................

. 54

How to Stop the Engine ...................................................................

. 55

Shifting Gears ......................................................................................

. 56

Braking .................................................................................................

. 58

Riding Your ATV ................................................................................

. 60

Making Turns ...................................................................................

. 60

Skidding or Sliding ..........................................................................

. 62

Riding Up Hills ................................................................................

. 63

Riding Down Hills ...........................................................................

. 67

Crossing or Turning on Hills or Slopes ............................................

. 68

Riding Over Obstacles .....................................................................

. 70

Riding Through Water .....................................................................

. 71

Parking .................................................................................................

. 72

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07/04/04 11:39:20 31HP1640_234


SERVICING YOUR HONDA ...........................................................

. 73

Bef ore You Service Your Honda

The Importance of Maintenance ..........................................................

. 75

Maintenance Safety ..............................................................................

. 76

Important Safety Precautions ...........................................................

. 77

Maintenance Schedule .........................................................................

. 78

Maintenance Record .............................................................................

. 82

Service Preparations

Maintenance Component Locations .....................................................

. 83

Tool Kit ................................................................................................

. 86

Owner’s Manual Storage ......................................................................

. 87

Seat Removal .......................................................................................

. 88

Service Procedures

Fluids & Filters

Fuel ......................................................................................................

. 89

Engine Oil & Filter ...............................................................................

. 92

Transmission Oil ..................................................................................

. 99

Coolant ...............................................................................................

. 104

Air Cleaner .........................................................................................

. 110

Engine

Throttle ...............................................................................................

. 114

Clutch System ....................................................................................

. 116

Engine Idle Speed ..............................................................................

. 120

Spark Plug ..........................................................................................

. 121

Valves .................................................................................................

. 124

Spark Arrester ....................................................................................

. 125

(cont’d)


225

07/04/04 11:39:26 31HP1640_235


SERVICING YOUR HONDA (cont’d)

Chassis

Suspension .........................................................................................

. 127

Brakes .................................................................................................

. 133

Tires ...................................................................................................

. 143

Engine Guard & Skid Plates ...............................................................

. 150

Drive Chain ........................................................................................

. 151

Electrical

Battery (TRX450ER only) .................................................................

. 158

Appearance Care ................................................................................

. 163

TIPS ...................................................................................................

. 169

Preparing for a Ride ...........................................................................

. 170

What to Take to the Riding Area ...................................................

. 170

What to Take on the Trail ..............................................................

. 171

Transporting Your Honda ..................................................................

. 172

Storing Your Honda ...........................................................................

. 174

Preparation for Storage ..................................................................

. 175

Removal from Storage ...................................................................

. 177

You & the Environment .....................................................................

. 178

TAKING CARE OF THE UNEXPECTED ...................................

. 179

General Guidelines .............................................................................

. 180

If Your Engine Quits or Won’t Start ..................................................

. 182

If You Have a Flat Tire .....................................................................

. 186

If the High Coolant Temperature Indicator Lights .............................

. 189

If a Fuse Blows (TRX450ER only) ....................................................

. 191

If You Crash .......................................................................................

. 193

If You Lose Your Key .......................................................................

. 194

If the Battery Is Low (or Dead) (TRX450ER only) ...........................

. 195

If a Component Fails ..........................................................................

. 196

226


07/04/04 11:39:29 31HP1640_236


TECHNICAL INFORMATION .....................................................

. 197

Vehicle Identification .........................................................................

. 198

Specifications .....................................................................................

. 200

Break-in Guidelines ...........................................................................

. 205

High Altitude Carburetor Adjustment ................................................

. 206

Emission Control Systems ..................................................................

. 207

Oxygenated Fuels ...............................................................................

. 211

CONSUMER INFORMATION ......................................................

. 213

Authorized Manuals ...........................................................................

. 214

Warranty Coverage ............................................................................

. 217

Warranty Service ................................................................................

. 218

Contacting Honda ..............................................................................

. 219

Your Honda Dealer ............................................................................

. 220

The Honda Rider’s Club (USA only) .................................................

. 221

TABLE OF CONTENTS .................................................................

. 222

INDEX ...............................................................................................

. 228

QUICK REFERENCE


227

07/04/04 11:39:34 31HP1640_237

Index

A accessories ............................................................................................

. 39 age recommendation ............................................................................

. 31 air cleaner, filter ................................................................................................

. 110 air pressure, gauge ................................................................................................

. 86 tire ..................................................................................................

. 144

American Honda, contacting ..............................................................

. 219 apparel, protective ................................................................................

. 28 appearance care ..................................................................................

. 163 authorized manuals .............................................................................

. 214

B battery (TRX450ER only) ..................................................................

. 158 brakes, brake pad wear ...............................................................................

. 137 cable ...............................................................................................

. 141 fluid ................................................................................................

. 133 front brake lever ...............................................................................

. 24 front brake lever adjustment ..........................................................

. 138 parking .............................................................................................

. 25 rear brake pedal ................................................................................

. 24 braking .................................................................................................

. 58 break-in guidelines .............................................................................

. 205

228

Index

07/04/04 11:39:38 31HP1640_238

Index

C capacity, fuel ........................................................................................

. 90 care, appearance .................................................................................

. 163 cargo, loading and operational guidelines ...................................................

. 38 choke, knob ..................................................................................................

. 16 climbing hills ........................................................................................

. 63 clutch system ......................................................................................

. 116 color label ...........................................................................................

. 199 compartment, owner’s manual ................................................................................

. 87 tool kit ..............................................................................................

. 86 component fails ..................................................................................

. 196 consumer information ........................................................................

. 213 coolant ................................................................................................

. 104 crash, if you ........................................................................................

. 193 crossing or turning on hills or slopes ....................................................

. 68 customer service .................................................................................

. 219

Index

229

07/04/04 11:39:42 31HP1640_239

Index

D dimmer switch, headlight .....................................................................

. 22

E emission control systems ....................................................................

. 207 engine, flooded .............................................................................................

. 54 guard ..............................................................................................

. 150 idle speed ........................................................................................

. 120 number ...........................................................................................

. 198 oil .....................................................................................................

. 92 pinging .............................................................................................

. 89 starting ..............................................................................................

. 47 stop switch ........................................................................................

. 21 stopping ............................................................................................

. 55 won’t start ......................................................................................

. 182 environment .......................................................................................

. 178 exhaust system, cleaning ............................................................................................

. 34 purging ...........................................................................................

. 125

230

Index

07/04/04 11:39:45 31HP1640_240

Index

F flag pole bracket ...................................................................................

. 26 flat tire ................................................................................................

. 186 flooded engine ......................................................................................

. 54 fuel, fill cap .............................................................................................

. 90 oxygenated .....................................................................................

. 211 recommendation ...............................................................................

. 89 refueling ...........................................................................................

. 90 reserve fuel supply ...........................................................................

. 90 tank capacity ....................................................................................

. 90 valve .................................................................................................

. 15 fuse (TRX450ER only) ......................................................................

. 191

Index

231

07/04/04 11:39:49 31HP1640_241

Index

G gap, spark plug ...........................................................................

. 122, 202 gasohol ...............................................................................................

. 211 gasoline ................................................................................................

. 89 gear shifting .........................................................................................

. 56

H headlight dimmer switch ......................................................................

. 22 headlight switch ...................................................................................

. 22 high altitude carburetor adjustment ....................................................

. 206 hills, crossing or turning on slopes ............................................................

. 68 riding down hills ..............................................................................

. 67 riding up hills ...................................................................................

. 63 stopping on hills ...............................................................................

. 65

Honda, contacting .......................................................................................

. 219

Rider’s Club ...................................................................................

. 221 dealer ..............................................................................................

. 220

Honda service manual ........................................................................

. 214

232

Index

07/04/04 11:39:53 31HP1640_242

Index

I identification, vehicle .........................................................................

. 198 idle speed, engine ...............................................................................

. 120 ignition switch ......................................................................................

. 18 indicators, high coolant temperature indicator ...........................................

. 13, 189 neutral indicator (TRX450ER only) .................................................

. 14 inspection, pre-ride ...............................................................................

. 33

K key, lost ..................................................................................................

. 194 number ...........................................................................................

. 194 kickstarter (TRX450R only) .................................................................

. 20 kit, tool .................................................................................................

. 86

Index

233

07/04/04 11:39:57 31HP1640_243

Index

L labels, safety ...........................................................................................

. 5 limit, weight .........................................................................................

. 37 load limits .............................................................................................

. 37 loading guidelines ................................................................................

. 38 lubrication, engine oil ..........................................................................................

. 92 transmission oil ................................................................................

. 99 drive chain ......................................................................................

. 156

M maintenance, component locations .........................................................................

. 83 importance ........................................................................................

. 75 precautions .......................................................................................

. 77 record ...............................................................................................

. 82 safety ................................................................................................

. 76 schedule ............................................................................................

. 78 manual, service ...................................................................................

. 214 maximum weight limit .........................................................................

. 37 modifications ........................................................................................

. 40

234

Index

07/04/04 11:40:02 31HP1640_244

Index

N neutral indicator (TRX450ER only) .....................................................

. 14 noise emission control system ............................................................

. 210 numbers, serial ...................................................................................

. 198

O obstacles, riding over ...........................................................................

. 70 oil, engine ...............................................................................................

. 92 transmission ......................................................................................

. 99 operating controls .................................................................................

. 15 operation component locations .............................................................

. 10 owner’s manual storage ........................................................................

. 87 oxygenated fuels ................................................................................

. 211

P parking .................................................................................................

. 72 passenger, no carrying ..........................................................................

. 31 pavement, no riding on .........................................................................

. 42 pinging, engine .....................................................................................

. 89 plug, spark ..........................................................................................

. 121 pre-ride inspection ................................................................................

. 33 problems, unexpected .........................................................................

. 179 protective apparel .................................................................................

. 28

Index

235

07/04/04 11:40:06 31HP1640_245

Index

R removal, seat ........................................................................................

. 88 rider training .........................................................................................

. 30

Rider’s Club, Honda ...........................................................................

. 221 riding, basic operations ................................................................................

. 41 clothing .............................................................................................

. 28 precautions .......................................................................................

. 42 preparing for ..................................................................................

. 170 over obstacles ...................................................................................

. 70 safety ..................................................................................................

. 2 safety precautions .............................................................................

. 42 through water ...................................................................................

. 71

236

Index

07/04/04 11:40:09 31HP1640_246

Index

S safety, important precautions .......................................................................

. 77 labels ..................................................................................................

. 5 riding precautions .............................................................................

. 42 schedule, maintenance ..........................................................................

. 78 seat removal .........................................................................................

. 88 serial numbers ....................................................................................

. 198 service, customer .........................................................................................

. 219 manuals ..........................................................................................

. 214 warranty .........................................................................................

. 218 shifting gears ........................................................................................

. 56 skid plates ...........................................................................................

. 150 skidding or sliding ................................................................................

. 62 spark arrester ......................................................................................

. 125 spark knock ..........................................................................................

. 89 spark plug ...........................................................................................

. 121 specifications ......................................................................................

. 200 stalling on a hill ....................................................................................

. 65

(cont’d)

Index

237

07/04/04 11:40:13 31HP1640_247

Index start button (TRX450ER only) .............................................................

. 19 starting, engine ...............................................................................................

. 47 troubleshooting ...............................................................................

. 182 stop switch, engine ...............................................................................

. 21 stopping engine ....................................................................................

. 55 storage,

ATV ...............................................................................................

. 174 owner’s manual ................................................................................

. 87 switch, brakelight .......................................................................................

. 140 headlight ...........................................................................................

. 22 headlight dimmer .............................................................................

. 22 ignition .............................................................................................

. 18

238

Index

07/04/04 11:40:16 31HP1640_248

Index

T throttle, cable .......................................................................................

. 114, 115 lever ..................................................................................

. 23, 114, 115 tires, air pressure .....................................................................................

. 144 flat ..................................................................................................

. 186 replacing .........................................................................................

. 149 repairing .........................................................................................

. 148 specifications ..................................................................................

. 203 tread conditions ......................................................................

. 146, 147 tool kit ..................................................................................................

. 86 training, rider ........................................................................................

. 30 transporting your ATV .......................................................................

. 172 trouble, unexpected ............................................................................

. 179 troubleshooting, starting .....................................................................

. 182 turning, on level ground .................................................................................

. 60 on hills or slopes ...............................................................................

. 68

Index

239

07/04/04 11:40:20 31HP1640_249

Index

V valve, fuel .............................................................................................

. 15 valve clearance ...................................................................................

. 124 vehicle identification no. (VIN) .........................................................

. 198

W warning labels ........................................................................................

. 5 warranty, coverage .........................................................................................

. 217 extended .........................................................................................

. 217 service ............................................................................................

. 218 washing your ATV .............................................................................

. 163 water, riding through ...................................................................................

. 71 weight limit ..........................................................................................

. 37 wheel removal ....................................................................................

. 187

240

Index

07/04/04 11:40:26 31HP1640_250

Quick Reference

The following is a brief, but important collection of information you need to know about your Honda. You’ll also find space to record important notes.

How To Avoid Costly Repairs

The engine of your Honda can be the most expensive component to repair. Proper maintenance, especially the use of the recommended fluids and filters, prevents premature wear and damage.

Frequent causes of costly repairs are:

Engine oil: insufficient quantity, improper oil.

Air cleaner: dirty, leaking because of improper installation (poor seal).

Record important information on the following page:

Quick Reference

07/04/04 11:40:29 31HP1640_251

Quick Reference

Engine No.

VIN

Ignition Key No.

Color Label

Owner’s Name

Address

City/State

Phone

Dealer’s Name

Address

City/State

Phone

Service Mgr.

Quick Reference

07/04/04 11:40:40 31HP1640_252

Scheduled

Maintenance

Pre-ride Inspection

Fuel/Capacity

Engine Oil

Transmission Oil

Maximum Weight

Capacity

Quick Reference

Initial: 100 miles (150 km)

Regular: every 600 miles (1,000 km)

Check the following items each time before you ride (page 33 ): engine oil, transmission oil, radiator coolant, fuel, tires, drive chain, nuts & bolts, underbody

& exhaust system, leaks, loose parts, cables, lights, throttle, brakes, clutch lever/parking brake lever, switches, steering.

premium unleaded gasoline, pump octane number 91 or higher

2.72 US gal (10.3 ) reserve:

0.79 US gal (3.0 )

API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label,

SAE 10W-30, JASO T 903 standard MA,

Pro Honda GN4 4-stroke oil or equivalent

API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label, SAE

10W-30, JASO T 903 standard MA, Pro

Honda HP Trans Oil, Pro Honda GN4

4-stroke oil, or an equivalent.

243 lbs (110 kg) rider, all cargo and accessories

Quick Reference

07/04/04 11:40:50 31HP1640_253

Quick Reference

Tires

Tire Pressure (cold)

Spark Plugs

Coolant

Fuse

(TRX450ER only)

Front: AT21 × 7R10 ★★

DUNLOP KT331H

Rear: AT20 × 10R9 ★★

DUNLOP KT355H standard tire pressure:

Front:

Rear:

4.0 psi (27.5 kPa , 0.275 kgf/cm )

4.7 psi (32.5 kPa , 0.325 kgf/cm ) standard:

IFR7L11 (NGK)

VK22PRZ11 (DENSO) or high speed riding:

IFR8H11 (NGK)

VK24PRZ11 (DENSO) or ethylene glycol antifreeze (silicate-free) for aluminum engines in 50/50 solution with Pro Honda HP Coolant or an equivalent distilled water

15 A

Quick Reference

07/04/04 11:41:01 31HP1640_254

Quick Reference

These symbols are used in Controls & Features section:

SYMBOL COMPONENT choke knob

ON − ignition switch

OFF − ignition switch

START button

RUN − engine stop switch

OFF − engine stop switch

ON − headlight switch

OFF − headlight switch

HI − headlight dimmer switch

LO − headlight dimmer switch

SEE PAGE

16

18

22

22

22

18

19

21

21

22

Quick Reference

07/04/04 11:41:02 31HP1640_255

07/04/04 11:41:04 31HP1640_256

07/04/04 11:41:06 31HP1640_257

Honda TRX450R Owner's Manual 257 Pages

Honda TRX450R Owner's Manual

1

2

3

4

5

6

7

8

9

10

11

12

High Coolant Temperature Indicator

13

Neutral Indicator

14

Fuel Valve

15

Choke Knob

16

Hot Start Lever (TRX450R only)

17

Ignition Switch

18

Start Button (TRX450ER only)

19

Kickstarter (TRX450R only)

20

Engine Stop Switch

21

Headlight Switch

Headlight Dimmer Switch

22

Throttle Lever

Clutch Lever/Parking Brake Lever

23

Front Brake Lever

Rear Brake Pedal

24

Parking Brake

25

Flag Pole Bracket

26

27

Protective Apparel

28

29

Rider Training

30

Age Recommendation

No Passengers

31

No Alcohol or Drugs

32

Pre-ride Inspection

33

34

35

Loading

36

Load Limits

37

Loading Guidelines

38

Accessories

39

Modifications

40

41

Off-Road Use Only

42

Keep Hands and Feet on Controls

43

Control Speed

44

Use Care on Unfamiliar or Rough Terrain

45

Do Not Perform Stunts