Honda 2007 TRX420FM, TRX420FM Owner's Manual

2007
Honda TRX420TM/FM
FOURTRAX RANCHER 420/4×4
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 and California exhaust emission regulations for
ATVs.
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 209 ) 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
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
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.
A Few Words About Safety
A Few Words About Safety
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.
A Few Words About Safety
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
Instruments & Controls ....................................................................
The location and function of indicators and controls on your ATV
and operating instructions for various controls and features.
9
Before Riding..................................................................................... 29
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 ................................................................ 45
How to start and stop the engine, shift gears, and brake. Also, riding
precautions.
Contents
Contents
Servicing Your Honda ...................................................................... 77
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.
Tips ..................................................................................................... 161
How to store and transport your ATV and how to be an
environmentally-responsible rider.
Taking Care of the Unexpected ....................................................... 171
What to do if you have a flat tire, your engine won’t start, etc.
Technical Information ...................................................................... 191
ID numbers, technical specifications, and other technical facts.
Consumer Information ..................................................................... 205
Information on warranties, emission controls, how to get Honda
service manuals.
Table of Contents .............................................................................. 214
Sequential listing of topics in this owner’s manual.
Index ................................................................................................... 220
Quick Reference
Handy facts about fuel, engine oil, tire sizes, and air pressures.
Contents
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
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 30 ).
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
Important Safety Information
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 32 .
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
Important Safety Information
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
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
Safety Labels
USA only
6
ATV Safety
Safety Labels
ATV Safety
7
Safety Labels
(TRX420FM only)
8
ATV Safety
Instruments & 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 & Gauge ................................................................................13
Fuel Gauge .........................................................................................16
Controls & Features ...............................................................................17
Fuel Valve ..........................................................................................17
Ignition Switch ...................................................................................18
2WD/4WD Select Lever (TRX420FM only) .................................... 19
Start Button ........................................................................................20
Engine Stop Switch ............................................................................20
Headlight Switch ................................................................................21
Headlight Dimmer Switch ..................................................................21
Throttle Lever ....................................................................................22
Reverse Selector Knob .......................................................................23
Front Brake Lever ..............................................................................24
Rear Brake Lever ...............................................................................24
Rear Brake Pedal ................................................................................24
Parking Brake .....................................................................................25
Flag Pole Bracket ...............................................................................26
Trailer Hitch .......................................................................................27
Instruments & Controls
9
Operation Component Locations
parking brake lock lever
rear brake lever/
parking brake lever
reverse selector knob
headlight switch
front brake lever
throttle lever
headlight dimmer
switch
engine stop
switch
ignition switch
start button
2WD/4WD select lever (TRX420FM only)
10
Instruments & Controls
Operation Component Locations
rear cargo rack
seat latch
rear brake pedal
front cargo rack
fuel valve
Instruments & Controls
11
Operation Component Locations
flag pole bracket
trailer hitch
shift lever
12
Instruments & Controls
Indicators & Gauge
The indicators and gauge on your ATV keep you informed, alert you to
possible problems, and make your riding safer and more enjoyable.
Refer to the indicators frequently. Their functions are described on the
following pages.
(1)
(2)
(5)
(3)
(4)
(1) neutral indicator
(2) high coolant temperature indicator
(3) PGM-FI indicator
(4) 4WD indicator (TRX420FM only)
(5) reverse indicator
Instruments & Controls
13
Indicators & Gauge
Lamp Check
The high coolant temperature indicator and PGM-FI indicator come on
for a few seconds and then go off when you turn the ignition switch ON
( ).
The indicators are identified in the table on page 15 with the words:
Lamp Check.
When applicable, the reverse or neutral indicators come on when you
turn the ignition switch ON ( ) and remain on until you shift out of
reverse or neutral.
TRX420FM only:
When applicable, the 4WD indicator comes on when you turn the
ignition switch ON ( ) and remains on until you shift out of 4WD
mode.
If one of these indicators does not come on when it should, have your
Honda dealer check for burned-out bulbs or other problems.
14
Instruments & Controls
Indicators & Gauge
1
Neutral indicator
2
High coolant
temperature
indicator
3
PGM-FI indicator
4
4WD indicator
(TRX420FM only)
Reverse indicator
5
Lights when the transmission is in
neutral. Lamp Check.
Lights when coolant temperature is
high enough to adversely affect the
service life of the engine.
If the high coolant temperature
indicator comes on while you are
riding, immediately bring the vehicle
to a stop, turn the engine off and let
it cool. See page 180. Lamp Check.
Lights when there is any abnormality
in the PGM-FI (Programmed Fuel
Injection) system. Should also light
for a few seconds and then go off
when the ignition switch is turned
ON ( ). If the indicator comes on
at any other time, reduce speed and
take your vehicle to a Honda dealer
as soon as possible. Lamp Check.
Lights when the drive mode is in the
4WD mode. Lamp Check.
Lights when the transmission is in
reverse. Lamp Check.
Instruments & Controls
15
Indicators & Gauge
Fuel Gauge
The fuel gauge ( 1 ) shows the approximate fuel supply available. At F
(Full), the fuel tank capacity including reserve is:
3.62 US gal (13.7 )
When the gauge needle ( 2 ) enters the red band ( 3 ), fuel will be low and
you should refill the tank as soon as possible. The amount of fuel left in
the tank when the needle enters the red band is approximately:
0.74 US gal (2.8 )
(1)
(3)
(2)
(1) fuel gauge
(2) gauge needle
16
Instruments & Controls
(3) red band
Controls & Features
Fuel Valve
RIGHT SIDE
ON
OFF
RES
(1)
(1) fuel valve
The manual fuel valve ( 1 ) is located on the right side under the fuel
tank.
The three-way fuel valve is used to control the flow of fuel from the
fuel tank to the fuel pump unit.
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 94 .
Instruments & Controls
17
Controls & Features
Ignition Switch
The ignition switch ( 1 ) is used for starting and stopping the engine
(page 52 ). Insert the key and turn it to the right for the ON ( )
position.
Key Position
ON ( )
OFF ( )
Function
Electrical circuits on.
No electrical circuits function.
CENTER OF HANDLEBAR
ON
(1)
OFF
(1) ignition switch
18
Instruments & Controls
ON
OFF
Controls & Features
2WD/4WD Select Lever (TRX420FM only)
Your ATV is equipped with a 2WD/4WD select lever ( 1 ), which
permits a choice between the ‘‘2WD’’ and ‘‘4WD’’ drive modes. Select
a drive mode that’s suitable for your riding.
Keep both hands on the handlebar while machine is in motion and come
to a complete stop before using the 2WD/4WD select lever.
The 2WD/4WD select lever is located on the left side of the fuel tank.
To select the drive mode, shift the 2WD/4WD select lever to the desired
position.
To check your present drive mode, look at the 4WD indicator ( 2 ).
2WD mode : the 4WD indicator goes off.
4WD mode : the 4WD indicator goes on.
(1)
4WD MODE
2WD MODE
2WD MODE 4WD MODE
(1) 2WD/4WD select lever
(2)
(2) 4WD indicator
Instruments & Controls
19
Controls & Features
Start Button
LEFT HANDLEBAR
(2)
(1)
(1) start button
(2) engine stop switch
START
OFF
RUN
The start button ( 1 ) is used for starting the engine. Pushing the button in
starts the engine. See Starting Procedure, page 53 .
When the start button is pushed, the starter motor will crank the engine.
The starter motor will not operate if the engine stop switch is in the OFF
( ) position when the start button is pushed.
Engine Stop Switch
The engine stop switch ( 2 ) is used to stop the engine in an emergency.
To operate, slide the switch to either 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.
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.
20
Instruments & Controls
Controls & Features
Headlight Switch
LEFT HANDLEBAR
(1)
(2)
(1) headlight switch
(2) headlight dimmer switch
ON
OFF
HI
LO
The headlight switch ( 1 ) is used to turn the headlight ON ( ) or OFF
( ). To operate, turn the switch to ON ( ) or OFF ( ).
Headlight Dimmer Switch
The headlight dimmer switch ( 2 ) is used to change between the high
and low beams of the headlight. To operate, turn the switch to HI ( )
for high beam, LO ( ) for low beam.
Instruments & Controls
21
Controls & Features
Throttle Lever
RIGHT HANDLEBAR
(A)
(1)
(1) throttle lever
(A) to open the throttle
The throttle controls engine rpm (speed). To increase engine rpm, press
the throttle lever ( 1 ) with your thumb. To reduce engine rpm, release
pressure on the throttle lever. The throttle will automatically return to the
closed position (engine idle) when you remove your thumb.
22
Instruments & Controls
Controls & Features
Reverse Selector Knob
The reverse selector knob ( 1 ), located on the rear brake lever/parking
brake lever ( 2 ), is used to shift into reverse. To operate, with your ATV
stopped and the transmission in neutral (make sure the neutral indicator
lights), push in the knob, squeeze the rear brake lever/parking brake
lever, then depress the shift lever. See Riding in Reverse, page 59 .
LEFT HANDLEBAR
(1)
(2)
(1) reverse selector knob
(2) rear brake lever/parking brake lever
Instruments & Controls
23
Controls & Features
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 61 .
Rear Brake Lever
The rear brake lever is used to slow or stop your ATV. To operate, pull
the lever. For information on braking techniques, see page 61 .
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 61 .
24
Instruments & Controls
Controls & Features
Parking Brake
LEFT HANDLEBAR
(1)
(A)
(2)
(1) lock lever
(2) rear brake lever/parking brake lever
(A) to lock
The lock lever ( 1 ) on the rear brake lever/parking brake lever ( 2 )
allows it to be used as a parking brake. To operate, first squeeze the rear
brake lever/parking brake lever using your left hand and then lock it
with the lock lever using your right hand. See Parking page 75 .
The brakelights are activated by applying the parking brake. When using
the parking brake, be sure to turn the ignition switch OFF ( ) to avoid
discharging the battery.
Instruments & Controls
25
Controls & Features
Flag Pole Bracket
RIGHT REAR
(1)
(1) flag pole bracket
Flag poles are optional equipment available from your Honda dealer. To
mount a pole in the bracket ( 1 ), follow the instructions that come with
the flag pole kit.
Flag poles are required in some riding areas. Check local regulations
before riding.
26
Instruments & Controls
Controls & Features
Trailer Hitch
REAR
(2)
(1)
(1) trailer hitch
(2) ball
The trailer hitch ( 1 ) is located on the rear axle housing. To use the hitch,
you’ll need a proper size ball ( 2 ) as specified by the trailer
manufacturer.
To attach the ball and properly hook up a trailer, follow the trailer
manufacturer’s instructions. For load limits and operational guidelines,
see page 40 .
Instruments & Controls
27
28
Instruments & Controls
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? ........................................................................30
Protective Apparel..............................................................................30
Rider Training ....................................................................................32
Age Recommendation ........................................................................33
No Passengers ....................................................................................33
No Alcohol or Drugs ..........................................................................34
Is Your ATV Ready to Ride? .................................................................35
Pre-ride Inspection .............................................................................35
Load Limits & Guidelines ......................................................................39
Loading ..............................................................................................39
Load Limits ........................................................................................40
Loading Guidelines ............................................................................41
Accessories & Modifications .................................................................42
Accessories.........................................................................................42
Modifications .....................................................................................43
Before Riding
29
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.
30
Before Riding
Are You Ready to Ride?
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 in 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
31
Are You Ready to Ride?
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.
32
Before Riding
Are You Ready to Ride?
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 or on the front or rear
cargo racks.
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
33
Are You Ready to Ride?
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.
34
Before Riding
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
100 ).
Check for leaks.
Radiator
Coolant
Check the coolant level and add coolant if
needed (page 111 ).
Check for leaks.
Before Riding
35
Is Your ATV Ready to Ride?
Fuel
Check the level and add fuel (page 95 ) if
needed. Also make sure the fuel fill cap is
securely fastened.
Check for leaks.
Tires
Use a gauge to check the air pressure. Adjust if
needed. Also look for signs of damage or
excessive wear (page 145 ).
Driveshaf t Boots
(TRX420FM only)
Check for damage (page 150 ).
Propeller Shaf t Boots
& Yoke Joint Boot
Check for damage (page 151 ).
Nuts & Bolts
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.
Underbody &
Exhaust System
Check for, and remove, any dirt, vegetation or
other debris that could be a fire hazard or
interfere with the proper operation of the
vehicle.
Air Cleaner Housing
Drain Tube
Check for deposits in the drain tube. If
necessary, clean the tube (page 121 ) and check
the air cleaner housing.
Leaks, Loose Parts
Walk around your ATV and look for anything
that appears unusual, such as a leak or loose
cable.
36
Before Riding
Is Your ATV Ready to Ride?
Cable
Check the cable housings for wear. Check the
fittings for looseness. Replace or tighten as
needed.
Lights
Make sure the headlight, brakelight and
taillight are working properly.
If you are carrying cargo, also check the following:
Loading Limits
Make sure you do not exceed the load limits
(page 40 ).
Cargo
Check that all cargo is secure.
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 122 ).
Brakes
Squeeze the front and rear brake levers and
step on the rear brake pedal to check that the
controls operate normally. Check for proper
freeplay (pages 135 , 137 ). Make sure there is
no brake fluid leakage.
Reverse Assist Lever
Check the freeplay and adjust if needed (page
125 ). Make sure the lever operates smoothly
without sticking.
Before Riding
37
Is Your ATV Ready to Ride?
Headlight and
Headlight Dimmer
Switch
Check for proper function (page 21 ).
Engine Stop
Switch
Check for proper function (page 20 ).
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.
38
Before Riding
Load Limits & Guidelines
Your Honda was designed as a rider-only ATV. It was not designed to
carry a passenger. It can carry cargo on the cargo racks, however,
carrying cargo anywhere else or carrying a passenger could interfere
with 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.
Before Riding
39
Load Limits & Guidelines
Load Limits
Following are the load limits for your ATV:
There are limits to how much weight can be carried on your ATV and be
pulled in a trailer.
The following load limits apply 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
(includes the weight of the rider,
all cargo, and accessories.)
485 lbs (220 kg)
front cargo rack weight limit
rear cargo rack weight limit
tow weight limit
(Combined weight of the trailer
and all cargo in the trailer)
tongue weight
(Weight on the trailer tongue)
tongue and rear cargo weight
(Combined weight on the trailer
tongue and on the rear cargo
rack)
= 66 lbs (30 kg)
= 133 lbs (60 kg)
= 850 lbs ｛385 kgf｝
(3776 N)
= 30 lbs ｛14 kgf｝
(137 N) recommended
= 133 lbs (60 kg) maximum
Tongue weight can be measured with an ordinary bathroom scale. Place
the scale under the tongue, using either a tongue jack or other support to
keep the trailer level.
The weight of added accessories will reduce the maximum cargo weight
you can carry.
40
Before Riding
Load Limits & Guidelines
Loading 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 limits and follow these guidelines:
Check that the tires are properly inflated.
Do not place cargo anywhere on the ATV other than on the front and
rear racks. Otherwise, operating stability may be adversely affected.
Never ride with a passenger on the front or rear cargo racks. The
ATV is not designed to carry a passenger.
Use the trailer hitch to tow another vehicle or trailer. Do not tow by
tying a rope or cable to the rear rack.
Load cargo on the rear rack as far forward as possible. Make sure
cargo on the front rack does not interfere with handlebar movement.
Do not allow cargo to extend beyond the edges of either the front or
rear racks.
Make sure all cargo is secured before riding.
Balance cargo weight evenly on both sides.
Never exceed the maximum weight limit.
When towing a trailer, take care to maintain balance and stability.
Distribute cargo between the front and rear of the trailer to obtain the
recommended tongue weight.
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.
Before Riding
41
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 genuine Honda 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.
Do not add any electrical equipment that will exceed the vehicle’s
electrical system capacity (page 197 ). A blown fuse can cause a loss
of lights or engine power (page 182 ).
42
Before Riding
Accessories & Modifications
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.
Before Riding
43
44
Before Riding
Basic Operation & Riding
This section gives basic riding instructions, including how to start and
stop your engine, and how to use the throttle and brakes. It also provides
important information on riding with cargo.
To protect your new engine and enjoy optimum performance and
service life, refer to Break-in Guidelines (page 198 ).
Safe Riding Precautions .........................................................................47
Off-Road Use Only ............................................................................47
Keep Hands and Feet on Controls ......................................................48
Control Speed .....................................................................................49
Use Care on Unfamiliar or Rough Terrain .........................................50
Do Not Perform Stunts.......................................................................51
Starting & Stopping the Engine .............................................................52
Preparation .........................................................................................52
Starting Procedure ..............................................................................53
Flooded Engine ..................................................................................54
Bank Angle Sensor Ignition Cut-off System .....................................54
Stalled Engine ....................................................................................55
How to Stop the Engine .....................................................................56
Shifting Gears ........................................................................................57
Riding in Reverse ...................................................................................59
(cont’d)
Basic Operation & Riding
45
Basic Operation & Riding
Braking ...................................................................................................61
Riding Your ATV ..................................................................................63
Making Turns .....................................................................................63
Skidding or Sliding ............................................................................65
Riding Up Hills ..................................................................................66
Riding Down Hills .............................................................................70
Crossing or Turning on Hills or Slopes ..............................................71
Riding Over Obstacles .......................................................................73
Riding Through Water .......................................................................74
Parking ...................................................................................................75
46
Basic Operation & Riding
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 29 .
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.
Basic Operation & Riding
47
Safe Riding Precautions
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.
48
Basic Operation & Riding
Safe Riding Precautions
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.
Basic Operation & Riding
49
Safe Riding Precautions
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.
50
Basic Operation & Riding
Safe Riding Precautions
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.
Basic Operation & Riding
51
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.
Preparation
(1)
(2)
(3)
(4)
(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. Turn the fuel valve ( 1 ) and ignition switch ( 2 ) to ON ( ).
Confirm the following:
The transmission is in neutral (neutral indicator ( 3 ) ON).
The engine stop switch ( 4 ) is set to RUN ( ).
52
Basic Operation & Riding
Starting & Stopping the Engine
Starting Procedure
This vehicle has a fuel-injected with an automatic choke.
Follow the procedure indicated below.
Any Air Temperature
Press the start button with the throttle completely closed.
The engine will not start if the throttle is fully open (Because the
electronic control module cuts off the fuel supply).
Basic Operation & Riding
53
Starting & Stopping the Engine
Flooded Engine
If the engine fails to start after repeated attempts, it may be flooded with
excess fuel. To clear a flooded engine:
1. Leave the engine stop switch set to RUN ( ).
2. Open the throttle fully.
3. Press the start button for 5 seconds.
4. Follow the normal starting procedure.
5. If the engine starts, then open the throttle slightly if idling is unstable.
If the engine does not starts, wait 10 seconds, then follow steps 1−
4 again.
If the engine still won’t start, refer to If Your Engine Quits or Won’t
Start, page 174 .
Bank Angle Sensor Ignition Cut-off System
Your vehicle’s banking (lean angle) sensor system is designed to
automatically stop the engine if the vehicle is overturned.
Before restarting the engine, you must turn the ignition switch to the
OFF ( ) position and then back to ON ( ). The engine will not
restart until you perform this procedure.
54
Basic Operation & Riding
Starting & Stopping the Engine
Stalled Engine
You can restart the engine while the vehicle is stopped by squeezing the
front brake lever and pressing the start button.
Do not press the throttle lever while starting in gear. Your ATV is
equipped with a start inhibitor system that will cut off the ignition if the
throttle is open while attempting to start in gear.
Once you have started the engine, release the front brake lever, then
apply throttle gradually.
Basic Operation & Riding
55
Starting & Stopping the Engine
How to Stop the Engine
Normal Engine Stop
To stop the engine, make sure the transmission is in neutral by checking
that the neutral indicator lights, and turn the ignition switch OFF ( ).
The engine stop switch should normally remain in the RUN (
position even when the engine is OFF.
If your ATV is stopped with the engine stop switch OFF (
ignition switch ON ( ), the battery will discharge.
)
) and the
Emergency Engine Stop
To stop the engine in an emergency, use the engine stop switch. To
operate, slide the switch to either OFF ( ) position.
56
Basic Operation & Riding
Shifting Gears
UPSHIFTING SEQUENCE
DOWNSHIFTING SEQUENCE
Your ATV has five forward gears: 1, 2, 3, 4, and 5.
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.
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.
To select reverse, use the reverse selector knob (page 59 ).
After starting the engine and letting it warm up, follow these
procedures:
1. With the transmission in neutral, release the parking brake, but
continue squeezing the rear brake lever.
(cont’d)
Basic Operation & Riding
57
Shifting Gears
2. With the throttle closed, raise the shift lever one full stroke to shift
into 1st (first) gear.
3. Release the rear brake lever and increase engine speed by gradually
opening the throttle.
4. When speed increases, release the throttle and shift to 2nd gear by
raising the shift lever one full stroke.
5. Repeat this sequence to progressively upshift to 3rd, 4th and 5th (top)
gear.
6. To downshift, reverse this sequence. Remember to close the 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 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.
58
Basic Operation & Riding
Riding in Reverse
If you need to ride in reverse, make sure the area behind you is clear and
only operate the ATV at low speed.
Improperly operating in reverse could cause you
to hit an obstacle or person behind you,
resulting in serious injury.
Make sure there are no obstacles or people
behind you before selecting reverse gear. When
it is safe to proceed, go slowly.
1. Bring the vehicle to a complete stop, then make sure the transmission
is in neutral.
2. Be sure there are no obstacles or people in the way.
3. While pushing the reverse selector knob ( 1 ) in, squeeze the rear brake
lever/parking brake lever ( 2 ), then depress the shift lever.
LEFT HANDLEBAR
(1)
(2)
(1) reverse selector knob
(2) rear brake lever/parking brake lever
(cont’d)
Basic Operation & Riding
59
Riding in Reverse
4. Release the rear brake lever/parking brake lever.
5. Open the throttle gradually and ride slowly. Do not open the throttle
suddenly or make abrupt turns.
6. To stop, close the throttle and gradually apply both the front and rear
brakes. Do not abruptly apply the rear brake by itself.
7. To shift out of reverse and into neutral, raise the shift lever one stroke.
Applying only the rear brake abruptly when
operating in reverse gear could cause the front
wheels to lift off the ground and the ATV could
overturn backwards.
Carefully apply both the front and rear brakes
when stopping in reverse gear.
60
Basic Operation & Riding
Braking
Your ATV is equipped with disc brakes on both front wheels which are
hydraulically activated by operating the right brake lever. A single drum
brake on the rear axle housing is mechanically activated by depressing
the brake pedal or operating the left brake lever.
TRX420FM only:
Although the front and rear brakes have separate controls, all four
wheels are interconnected when your ATV is in the 4WD mode. So
operating any brake control in the 4WD mode will cause braking at both
the front and rear wheels.
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.
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.
Basic Operation & Riding
61
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.
Riding with your foot resting on the brake pedal or your hands on the
brake levers 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 .
62
Basic Operation & Riding
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.
Basic Operation & Riding
63
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.
64
Basic Operation & Riding
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.
Basic Operation & Riding
65
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.
66
Basic Operation & Riding
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.
Basic Operation & Riding
67
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.
TRX420FM only:
Remember that operating any brake control in the 4WD mode will cause
braking at both the front and rear wheels.
68
Basic Operation & Riding
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 rear brake lever with your right 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 rear brake
lever to control speed.
4. If you lose control of the ATV, for your safety, get away from the
vehicle.
Basic Operation & Riding
69
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.
70
Basic Operation & Riding
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.
TRX420FM only:
Remember that operating any brake control in the 4WD mode will cause
braking at both the front and rear wheels.
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.
Basic Operation & Riding
71
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.
72
Basic Operation & Riding
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.
Basic Operation & Riding
73
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.
If the brakes don’t regain effectiveness, stop your ATV and follow
the procedures on page 141 .
74
Basic Operation & Riding
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 through 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.
The brakelights are activated by applying the parking brake. When using
the parking brake, be sure to turn the ignition switch OFF ( ) to avoid
discharging the battery.
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.
Basic Operation & Riding
75
76
Basic Operation & Riding
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.
For information about replacing fuses, see page 182 .
For information about the exhaust emission and noise requirements of
the U.S. Environmental Protection Agency (EPA) and the California Air
Resources Board (CARB), see page 199 .
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 ............................................................79
Maintenance Safety ................................................................................80
Important Safety Precautions .............................................................81
Maintenance Schedule ...........................................................................82
Maintenance Record...............................................................................86
Service Preparations
Maintenance Component Locations .......................................................87
Tool Kit ..................................................................................................90
Owner’s Manual Storage........................................................................91
Seat Removal .........................................................................................92
Clip Removal .........................................................................................93
(cont’d)
Servicing Your Honda
77
Servicing Your Honda
Service Procedures
Fluids & Filters
Fuel ........................................................................................................94
Engine Oil & Filter.................................................................................97
Gear Case Oil ..................................................................................... 106
Differential Oil (TRX420FM only) .................................................... 108
Coolant ............................................................................................... 110
Air Cleaner ......................................................................................... 116
Engine
Throttle ...............................................................................................
Clutch System ....................................................................................
Reverse Lock System .........................................................................
Spark Plug ..........................................................................................
Valves.................................................................................................
Spark Arrester ....................................................................................
122
124
125
126
129
130
Chassis
Brakes.................................................................................................
Tires ...................................................................................................
Engine Guard & Skid Plate ................................................................
Driveshaft Boots (TRX420FM only)..................................................
Propeller Shaft Boots & Yoke Joint Boot ..........................................
131
142
149
150
151
Electrical
Battery ................................................................................................ 152
Appearance Care ................................................................................ 157
78
Servicing Your Honda
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.
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.
Servicing Your Honda
79
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.
80
Servicing Your Honda
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 genuine Honda 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 206 ).
Servicing Your Honda
81
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 206 ).
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 genuine Honda parts or their equivalents for
repair or replacement to ensure the best quality and reliability.
82
Servicing Your Honda
Maintenance Schedule
Perform the pre-ride inspection (page 35 ) 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 206 ).
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.
Servicing Your Honda
83
Maintenance Schedule
Maintenance Procedures:
I: inspect and clean, adjust, lubricate, or replace, if necessary
C: clean
A: adjust
L: lubricate
R: replace
FREQUENCY
ITEMS
FUEL LINE
THROTTLE OPERATION
AIR CLEANER
AIR CLEANER HOUSING
DRAIN TUBE
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL
ENGINE OIL FILTER
RADIATOR COOLANT
COOLING SYSTEM
WHICHEVER
INITIAL
MAINT.
COMES
mi
100
FIRST
km
150
NOTE HOURS
20
REGULAR
MAINT. INTERVAL
600
1000
100
1200
2000
200
I
I
C
I
NOTE 1
NOTE 2
C
I
NOTE 3
NOTE 2
I
I
I
I
I
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
Refer to
page
−
122
116
121
126
129
97
102
110
−
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 206 ).
84
Servicing Your Honda
Maintenance Schedule
FREQUENCY
ITEMS
DRIVESHAFT BOOTS
(TRX420FM only)
REAR FINAL GEAR CASE
OIL AND DIFFERENTIAL
OIL (TRX420FM only)
REAR FINAL GEAR CASE
OIL (TRX420TM only)
2WD/4WD SELECT
SYSTEM (TRX420FM only)
BRAKE FLUID
BRAKE SHOES WEAR
BRAKE PADS WEAR
BRAKELIGHT SWITCH
BRAKE SYSTEM
REVERSE LOCK SYSTEM
SKID PLATE, ENGINE
GUARD
CLUTCH SYSTEM
SUSPENSION
SPARK ARRESTER
NUTS, BOLTS,
FASTENERS
WHEELS/TIRES
TIE-ROD AND JOINT
BOOTS
STEERING SHAFT
HOLDER BEARINGS
STEERING SYSTEM
WHICHEVER
INITIAL
MAINT.
COMES
mi
100
FIRST
km
150
NOTE HOURS
20
REGULAR
MAINT. INTERVAL
600
1000
100
I
1200
2000
200
I
Refer to
page
(R:EVERY
I
106,
108
I
106
I
−
I
I
I
I
I
I
I
131
139
134
140
131
125
149
2 YEARS)
(R:EVERY
150
2 YEARS)
NOTE 3
NOTE 1
I
NOTE 1,2
I
I
I
I
I
I
I
I
I
I
C
I
I
C
I
124
−
130
−
I
I
I
I
−
−
I
−
I
−
I
I
I
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 206 ).
In the interest of safety, we recommend these items be serviced only by your Honda dealer.
Servicing Your Honda
85
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
86
ODO or
HOUR
Servicing Your Honda
Date
Performed
By:
Notes
Maintenance Component Locations
rear brake lever/parking brake lever
front brake fluid reservoir
front brake lever
fuel fill cap
throttle lever
Servicing Your Honda
87
Maintenance Component Locations
differential oil filler cap (TRX420FM only)
differential oil drain bolt (TRX420FM only)
coolant reserve tank
air cleaner
housing
drain tube
air cleaner
rear brake pedal
rear brakelight switch
88
Servicing Your Honda
engine oil filter
front brake
caliper
Maintenance Component Locations
owner’s manual
air pressure gauge
spark plug
battery
fuse box
main fuse
tool kit
clutch
engine oil drain bolt
engine oil filler cap/dipstick
spark arrester
gear case oil filler cap
gear case oil drain bolt
Servicing Your Honda
89
Tool Kit
The tool kit ( 1 ) is stored in the storage compartment ( 2 ) below the rear
cargo rack.
To open the compartment, unhook the rubber strap ( 3 ).
An optional, larger tool kit may be available. Check with your Honda
dealer’s parts department.
REAR
(2)
(1)
(3)
(1) tool kit
(2) storage compartment
90
Servicing Your Honda
(3) rubber strap
Owner’s Manual Storage
Your ATV provides storage for the owner’s manual so you’ll have it
with you for easy reference. Store your owner’s manual ( 1 ) in the
plastic document bag underside of the seat ( 2 ).
The owner’s manual and air pressure gauge ( 3 ) should be stored in the
plastic document bag ( 4 ).
To remove the seat, see page 92 .
Be careful not to flood this area when washing your ATV.
SEAT UNDERSIDE
(1)
(2)
(3)
(4)
(1) owner’s manual
(2) seat
(3) air pressure gauge
(4) plastic document bag
Servicing Your Honda
91
Seat Removal
Refer to Saf ety Precautions on page 81 .
The seat must be removed for the air cleaner, engine oil, engine oil filter,
clutch, spark plug, battery and fuse maintenance and to remove the side
covers, rear fender cover and left tank side cover, to access the owner’s
manual, air pressure gauge, coolant reserve tank cap and color label.
(3)
(5)
(2)
(4)
(1)
(6)
(1) seat latch
(2) seat
(3) front prongs
(4) hooks
(5) studs
(6) grommets
Removal
1. Pull the seat latch ( 1 ) at the rear of the seat.
2. Slide the seat ( 2 ) back and lift it.
Installation
1. Insert the front prongs ( 3 ) into the hooks ( 4 ) on the frame and press
the studs ( 5 ) into the grommets ( 6 ).
2. Press down on the seat until locks.
92
Servicing Your Honda
Clip Removal
Removal
1. Press down on the center pin to release the lock.
2. Pull the clip out of the hole.
1.
2.
Installation
1. Push the bottom of the pin.
2. Insert the clip into the hole.
3. Lightly press down on the center pin to lock the clip.
1.
2.
3.
Servicing Your Honda
93
Fuel
Refer to Saf ety Precautions on page 81 .
Fuel Recommendation
type
pump octane number
unleaded
86 (or higher)
We recommend that you use unleaded fuel because it produces fewer
engine deposits and extends the life of exhaust system components.
Your engine is designed to use any gasoline that has a pump octane
number of 86 or higher. Gasoline pumps at service stations normally
display the pump octane number. For information on the use of
oxygenated fuels, see page 203 .
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.
94
Servicing Your Honda
Fuel
Fuel Capacity
Fuel tank capacity, including reserve:
3.62 US gal (13.7 )
Reserve capacity:
0.74 US gal (2.8 )
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
Refer to Saf ety Precautions on page 81 .
(3)
(2)
(4)
(1)
(1) fuel fill cap
(2) breather tube
(3) handlebar cover hole
(4) filler neck
Servicing Your Honda
95
Fuel
1. To open the fuel fill cap ( 1 ), turn it counterclockwise.
2. Pull the breather tube ( 2 ) out of the handlebar cover hole ( 3 ).
3. Add fuel until the level reaches the bottom of the filler neck ( 4 ).
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 until it clicks.
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 genuine Honda replacement
part.
96
Servicing Your Honda
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 98 ) 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
84 . When running in very dusty conditions, oil changes should be
performed more frequently than specified in the maintenance schedule.
Servicing Your Honda
97
Engine Oil & Filter
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 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.
98
Servicing Your Honda
Engine Oil & Filter
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
Servicing Your Honda
99
Engine Oil & Filter
Checking & Adding Oil
Refer to Saf ety Precautions on page 81 .
Check the engine oil level each day before operating your ATV and add
if needed.
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. Remove the seat (page 92 ).
4. Unsnap and remove the left side cover ( 1 ).
LEFT SIDE
(1)
(1) left side cover
100 Servicing Your Honda
Engine Oil & Filter
5. Remove the oil filler cap/dipstick ( 2 ) from the front crankcase and
wipe it clean.
6. Insert the oil filler cap/dipstick without screwing it in, then remove
the oil filler cap/dipstick and check the oil level. The oil level should
be between the upper level mark ( 3 ) and the lower level mark ( 4 ) on
the oil filler cap/dipstick.
7. If required, add the specified oil into the filler cap hole, up to the
upper level mark on the oil filler cap/dipstick. Do not overfill.
8. Reinstall the oil filler cap/dipstick.
9. Install the left side cover.
10. Install the seat.
Running the engine with an improper oil level can cause serious engine
damage.
LEFT SIDE
(2)
(3)
(4)
(2) oil filler cap/dipstick
(3) upper level mark
(4) lower level mark
Servicing Your Honda
101
Engine Oil & Filter
Changing Engine Oil & Filter
Refer to Saf ety Precautions on page 81 .
Your ATV’s oil filter has very specific performance requirements. Use a
new genuine Honda 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 and oil filter wrench, as well as a means for disposing of
the drained fluid (page 170 ). If you do not have the skills or the tools,
see your Honda dealer.
Drain the Engine Oil:
1. With the ATV on the level ground, remove the seat (page 92 ), left
side cover (page 100 ) and the oil filler cap/dipstick from the front
crankcase.
2. Place an oil drain pan under the crankcase and remove the engine oil
drain plug ( 1 ) and sealing washer ( 2 ).
UNDER ENGINE
(2)
(1)
(1) engine oil drain plug
102 Servicing Your Honda
(2) sealing washer
Engine Oil & Filter
Install a New Engine Oil Filter:
1. Remove the seat (page 92 ).
2. Unsnap and remove the right side cover ( 1 ).
RIGHT SIDE
(1)
(1) right side cover
(cont’d)
Servicing Your Honda
103
Engine Oil & Filter
3. Remove the oil filter cover ( 2 ) by removing the bolts ( 3 ). Let the
remaining oil drain out. Discard the oil filter ( 4 ) in an approved
manner (page 170 ).
4. Check that the oil filter cover O-rings ( 5 ) are in good condition and
then install a new oil filter. Use only the Honda genuine oil filter or a
filter of equivalent quality specified for your model. Using the wrong
Honda filter or a non-Honda filter which is not of equivalent quality
may cause engine damage.
5. Reposition the spring ( 6 ) to the engine crankcase and install a new oil
filter with the rubber seal ( 7 ) facing out, away from the engine. You
will see the ‘‘OUTSIDE (TOWARDS FILTER COVER)’’ mark ( 8 )
on the filter body, near the seal.
Improper installation of the oil f ilter can cause serious engine damage.
RIGHT SIDE
(4)
(6)
(8)
(5)
(2)
(7)
(2)
(3)
(2) oil filter cover
(3) bolts
(4) oil filter
(5) O-rings
104 Servicing Your Honda
(3)
(6) spring
(7) rubber seal
(8) ‘‘OUTSIDE’’ mark
Engine Oil & Filter
6. Reinstall the oil filter cover, making sure the bolts are tightened to the
specified torque:
7 lbf·ft (10 N·m , 1.0 kgf·m)
7. Pour the drained oil into a suitable container and dispose of it in an
approved manner (page 170 ).
8. Install the right side cover.
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 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:
2.9 US qt (2.7 )
4. Reinstall the oil filler cap/dipstick.
5. Start the engine and let it idle for 3−5 minutes.
6. Stop the engine, wait 2−3 minutes and check the oil level. Make sure
the oil is between the upper and lower level marks on the oil filler
cap/dipstick. If necessary, add more oil but do not overfill.
7. Check that there are no oil leaks.
8. Install the left side cover.
9. Install the seat.
If a torque wrench is not used for installation, see your Honda dealer as
soon as possible to verify proper assembly.
Servicing Your Honda
105
Gear Case Oil
Oil Recommendation
type
viscosity (weight)
suggested oil
hypoid gear oil
SAE 80
Honda shaft drive oil or equivalent
Changing Oil
Refer to Saf ety Precautions on page 81 .
Change the oil with the gear case at normal operating temperature to
assure complete and rapid draining.
106 Servicing Your Honda
Gear Case Oil
1. Park the ATV on level ground.
2. Place an oil drain pan under the oil drain plug ( 1 ).
3. Remove the oil filler cap ( 2 ) and the drain plug.
4. After the oil has completely drained, reinstall the drain plug and
tighten it to the specified torque:
9 lbf·ft (12 N·m , 1.2 kgf·m)
5. Fill the gear case with the recommended oil.
2.5 US oz (75 cm )
6. Remove the oil level check bolt ( 3 ). Make sure the oil level reaches
the oil level check hole ( 4 ).
7. Install the oil filler cap and oil level check bolt.
REAR
(2)
(4)
(3)
(1) oil drain plug
(2) oil filler cap
(1)
(3) oil level check bolt
(4) oil level check hole
Servicing Your Honda
107
Differential Oil (TRX420FM only)
Oil Recommendation
type
viscosity (weight)
suggested oil
hypoid gear oil
SAE 80
Honda shaft drive oil or equivalent
Changing Oil
Refer to Saf ety Precautions on page 81 .
Change the oil with the differential at normal operating temperature to
assure complete and rapid draining.
108 Servicing Your Honda
Differential Oil (TRX420FM only)
1. Park the ATV on level ground.
2. Place an oil drain pan under the oil drain plug ( 1 ).
3. Remove the oil filler cap ( 2 ) and the drain plug.
4. After the oil has completely drained, reinstall the drain plug and
tighten it to the specified torque:
9 lbf·ft (12 N·m , 1.2 kgf·m)
5. Fill the differential with the recommended oil.
7.8 US oz (230 cm )
Make sure the oil level is at the lower edge of the oil filler inspection
hole ( 3 ).
6. Install the oil filler cap.
FRONT
(3)
(2)
(1)
(1) oil drain plug
(2) oil filler cap
(3) oil filler inspection hole
Servicing Your Honda
109
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.
110 Servicing Your Honda
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
Refer to Saf ety Precautions on page 81 .
Check the engine coolant level each day before operating your ATV and
add if needed.
RIGHT REAR
(1)
(2)
(3)
(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
level in the reserve tank ( 1 ). It should be between the UPPER ( 2 )
and LOWER ( 3 ) level marks.
If the reserve tank is empty, or if coolant loss is excessive, check for
leaks and see your Honda dealer for repair.
(cont’d)
Servicing Your Honda
111
Coolant
3. Remove the seat (page 92 ).
4. Unhook the rubber strap ( 4 ).
5. Remove the rear fender cover ( 5 ) and reserve tank cap ( 6 ).
Always add coolant to the reserve tank. Do not attempt to add coolant
by removing the radiator cap.
6. Add coolant to the reserve tank as required to bring the coolant level
to the UPPER level mark.
REAR
(5)
(6)
(4)
(4) rubber strap
(5) rear fender cover
(6) reserve tank cap
7. After adding coolant, install the reserve tank cap and rear fender
cover.
8. Fasten the rubber strap.
9. Install the seat.
112 Servicing Your Honda
Coolant
Coolant Replacement
Refer to Saf ety Precautions on page 81 .
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 206 ).
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 170 .
Improper disposal of drained f luids is harmf ul to the environment.
Servicing Your Honda
113
Coolant
Radiator Core
Refer to Saf ety Precautions on page 81 .
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 plate:
1. Unhook the tabs A ( 1 ) and remove the radiator grill under cover ( 2 ).
2. Remove the clips ( 3 ) (page 93 ) and radiator grill covers ( 4 ).
3. Unhook the tabs B ( 5 ) and remove the couplers ( 6 ).
Do not apply pressured water directly to the radiator core. The
pressured water can damage the radiator core.
FRONT
(3)
(6)
(3)
(5)
(4)
(1)
(2)
(1) tabs A
(2) radiator grill under cover
(3) clips
114 Servicing Your Honda
(4) radiator grill covers
(5) tabs B
(6) couplers
Coolant
4. Remove the radiator grill plate ( 7 ).
5. Wash the radiator core ( 8 ) and radiator grill plate.
6. Install the removed parts in reverse order of removal.
FRONT
(7)
(8)
(7) radiator grill plate
(8) radiator core
Servicing Your Honda
115
Air Cleaner
Refer to Saf ety Precautions on page 81 .
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 genuine Honda 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.
116 Servicing Your Honda
Air Cleaner
Cleaning
1. Remove the seat (page 92 ).
UNDER SEAT
(1)
(2)
(1) retainer clips
(2) air cleaner housing cover
2. Unlatch the retainer clips ( 1 ).
3. Remove the air cleaner housing cover ( 2 ).
(cont’d)
Servicing Your Honda
117
Air Cleaner
4. Loosen the screw ( 3 ) and remove the air cleaner assembly ( 4 ) from
the air cleaner housing.
5. Unscrew the clamp ( 5 ).
6. Remove the air cleaner ( 6 ) from the air cleaner body ( 7 ).
7. 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.
8. Inspect for tears or cracks in the foam or seams of the air cleaner.
Replace the air cleaner if it is damaged.
9. Allow the air cleaner to dry thoroughly before applying oil. A wet air
cleaner will not fully absorb the oil.
10. 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)
(3)
(4)
(3)
(5) (6)
(3) screw
(4) air cleaner assembly
(5) clamp
118 Servicing Your Honda
(6) air cleaner
(7) air cleaner body
Air Cleaner
11. Install the air cleaner on the air cleaner body.
12. Apply a thin coat of grease to the sealing surface of the air cleaner
assembly.
13. Install the clamp.
14. Insert the air cleaner assembly into the air cleaner housing.
15. Fasten the screw.
16. Reassemble by reversing the disassembly sequence.
Install the air cleaner housing cover with the FRONT mark ( 8 )
facing forward and fit the cut out of the tab ( 9 ) at the end of the
air cleaner.
UNDER SEAT
(8)
(9)
(9)
(8) FRONT mark
(9) tab
Servicing Your Honda
119
Air Cleaner
Dust Cover
UNDER SEAT
(1)
(2)
(1) dust cover
(2) breather joint
Do not push the dust cover ( 1 ) too far into the breather joint ( 2 ).
If the dust cover is dirty, clean it.
120 Servicing Your Honda
Air Cleaner
Air Cleaner Housing Drain Tube
The air cleaner housing drain tube should be serviced in accordance with
the Maintenance Schedule. (Riding through water may require more
frequent inspection.) If deposits can be seen in the drain tube, the tube
must be cleaned before starting the vehicle.
REAR
(3)
(2)
(1)
(1) drain tube
(2) clip
(3) air cleaner housing
1. Remove the drain tube ( 1 ) by removing the clip ( 2 ) under the air
cleaner housing ( 3 ).
2. Drain the deposits.
3. Reinstall the drain tube, securing it with the clip.
Servicing Your Honda
121
Throttle
Throttle Freeplay
Refer to Saf ety Precautions on page 81 .
RIGHT HANDLEBAR
(A)
(B)
1/8−5/16 in
(3−8 mm)
(2)
(3)
(4)
(1)
(1) throttle lever
(2) rubber sleeve
(3) throttle cable adjuster
(4) lock nut
(A) decrease freeplay
(B) increase freeplay
Inspection
Check freeplay at the throttle lever ( 1 ).
Freeplay:
1/8−5/16 in (3−8 mm)
Adjustment
1. Slide the rubber sleeve ( 2 ) back to expose the throttle cable adjuster
( 3 ).
2. Loosen the lock nut ( 4 ).
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.
122 Servicing Your Honda
Throttle
Throttle Inspection
Refer to Saf ety Precautions on page 81 .
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 throttle body. 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.
Servicing Your Honda
123
Clutch System
Your ATV’s shift-activated, wet, multiplate clutch is part of the primary
drive system. Proper adjustment allows a smooth, gradual engagement
when shifting gears.
Clutch Adjustment
Refer to Saf ety Precautions on page 81 .
LEFT FRONT
(1)
(2)
(1) lock nut
(2) clutch adjuster
1. Make sure the engine is cool.
2. Make sure the ignition switch is OFF ( ).
3. Remove the seat (page 92 ) and left side cover (page 100 ).
4. Loosen the lock nut ( 1 ).
5. Turn the clutch adjuster ( 2 ) counterclockwise until you feel slight
resistance.
6. Turn the adjuster 1/4 turn clockwise, then tighten the lock nut to hold
the adjuster in this position.
7. After adjustment, start the engine and test ride your ATV to be sure
the clutch is operating properly.
8. Install the removed parts in reverse order of removal.
If you cannot get proper adjustment, or the clutch does not work
properly, the clutch friction discs may be worn. See your Honda dealer
or refer to official Honda Service Manual (page 206 ).
124 Servicing Your Honda
Reverse Lock System
Reverse Lock System Adjustment
Refer to Saf ety Precautions on page 81 .
LEFT HANDLEBAR
(1)
(6)
1/16−3/16 in
(2−4 mm)
(2)
(4)
(3)
(5)
(1) dust cover
(2) reverse assist lever
(3) rear brake lever
(4) rubber sleeve
(5) lock nut
(6) adjusting nut
1. Turn over the dust cover ( 1 ).
2. Check the reverse assist lever ( 2 ) freeplay, measured at the rear brake
lever ( 3 ) end near the cable:
1/16−3/16 in (2−4 mm)
3. To adjust, slide the rubber sleeve ( 4 ), loosen the lock nut ( 5 ) and turn
the adjusting nut ( 6 ).
After adjustment, tighten the lock nut securely.
4. Return the dust cover and rubber sleeve.
Other Checks
Check the reverse assist lever and cable for loose connections or other
damage. If the cable is worn or kinked, have it replaced by your Honda
dealer.
Servicing Your Honda
125
Spark Plug
Spark Plug Recommendation
standard spark plug
BKR5E-11 (NGK)
or
K16PR-U11 (DENSO)
Use only the recommended type of spark plug in the recommended heat
range.
Using spark plugs with an improper heat range can cause engine
damage.
Spark Plug Replacement & Inspection
Refer to Saf ety Precautions on page 81 .
1. Remove the seat (page 92 ) and left side cover (page 100 ).
2. Remove the left tank side cover ( 1 ) by removing the bolts ( 2 ).
LEFT SIDE
(1)
(2)
(1) left tank side cover
126 Servicing Your Honda
(2) bolts
Spark Plug
3. Clean any dirt from around the spark plug base.
4. Disconnect the spark plug cap ( 3 ). Take care to avoid damaging the
spark plug wire when disconnecting the cap.
5. Using a spark plug wrench provided in the tool kit, remove the spark
plug.
6. Inspect the electrodes and center porcelain for deposits, corrosion, or
carbon fouling. If the corrosion or deposits are heavy, replace the
plug. Clean a carbon or wet-fouled plug with a plug cleaner, if
available, or a wire brush. Inspect the spark plug electrodes for wear.
The center electrode ( 4 ) should have a flat tip and sharp edges, and
the side electrode ( 5 ) should not be eroded. If the electrodes and
insulator tip appear unusually fouled or burned, we suggest that you
contact your Honda dealer.
7. Discard the spark plug if there is apparent wear or if the insulator is
cracked or chipped.
8. Using a wire-type feeler gauge, check the spark plug gap ( 6 ). If
adjustment is necessary, bend the side electrode carefully.
The gap should be:
0.039−0.043 in (1.00−1.10 mm)
LEFT SIDE
(6)
0.039−0.043 in
(1.00−1.10 mm)
(5)
(4)
(3)
(3) spark plug cap
(4) center electrode
(5) side electrode
(6) spark plug gap
(cont’d)
Servicing Your Honda
127
Spark Plug
9. With the plug washer attached, thread the spark plug in by hand to
prevent cross-threading.
10. 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:
3/4 turn after it seats.
DENSO: 1/2 turn after it seats.
b) Then loosen the plug.
c) Next, tighten the plug again:
1/8 turn after it seats.
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.
11. Connect the spark plug cap. Take care to avoid pinching any cables or
wires.
12. Install the remaining parts in the reverse order of removal.
128 Servicing Your Honda
Valves
Valve Inspection
Refer to Saf ety Precautions on page 81 .
Valve clearance should be:
intake: 0.006 in (0.15 mm)
exhaust: 0.009 in (0.23 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.
Servicing Your Honda
129
Spark Arrester
Refer to Saf ety Precautions on page 81 .
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.
The use of safety glasses is recommended for this procedure.
Because of the possible fire hazard, check that there are no combustible
materials in the area before purging the spark arrester.
REAR
(1)
(1) bolt
1. Select a well-ventilated area free of combustible materials and make
sure the exhaust pipe is cool.
2. Remove the bolt ( 1 ).
3. Start the engine and rev it up approximately twenty times while
momentarily creating exhaust system back pressure by blocking the
end of the muffler with a shop towel.
4. Stop the engine and allow the exhaust pipe to cool.
5. Reinstall the bolt securely.
130 Servicing Your Honda
Brakes
The hydraulic disc brakes (front) and single mechanical drum brake
(rear) on your ATV dissipate heat generated by the friction of the brake
pads on the disc (front) and the brake shoes on the drums (rear) as the
wheels are slowed.
Hydraulic Disc Front Brake
As the front brake pads wear, 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 right brake lever freeplay does not feel within the normal range
while riding, check the brake pads for wear (page 134 ).
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.
Mechanical Drum Rear Brake
If the rear brake lever/parking brake lever or brake pedal freeplay does
not feel within the normal range while riding, check the brake shoes for
wear (page 139 ).
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.
Servicing Your Honda
131
Brakes
Fluid Level Inspection
Refer to Saf ety Precautions on page 81 .
RIGHT HANDLEBAR
(1)
(1) LOWER level mark
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.
With the ATV in an upright position, check the fluid level.
It should be above the LOWER level mark ( 1 ). If the level is at or
below the LOWER level mark, check the brake pads for wear
(page 134 ).
Worn brake pads should be replaced. If the pads are not worn, have your
brake system inspected for leaks.
132 Servicing Your Honda
Brakes
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.
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.
Servicing Your Honda
133
Brakes
Brake Pad Wear
Refer to Saf ety Precautions on page 81 .
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)
(1) wear indicator
(1)
(2) edge of reference mark
Check the wear indicator ( 1 ). If the wear indicator aligns with the edge
of the reference mark ( 2 ), both pads must be replaced, see your Honda
dealer for this replacement.
Always inspect both pads in both the right and left front brake calipers.
134 Servicing Your Honda
Brakes
Rear Brake Pedal Freeplay
RIGHT SIDE
(1)
9/16−13/16 in
(15−20 mm)
(1) rear brake pedal
Inspection
Measure the distance the rear brake pedal ( 1 ) moves before the brake
starts to take hold. Freeplay, measurement at the tip of the end of the
pedal, should be:
9/16−13/16 in (15−20 mm)
If necessary, adjust to the specified range.
Servicing Your Honda
135
Brakes
Adjustment
RIGHT REAR
(2)
(3)
(2) brake pedal adjusting nut
(3) brake arm pin
Turn the brake pedal adjusting nut ( 2 ), located on the brake operating
rod at the rear of the frame. Make sure the cutout on the adjusting nut is
properly seated on the brake arm pin ( 3 ).
136 Servicing Your Honda
Brakes
Rear Brake Lever Freeplay
LEFT HANDLEBAR
(1)
9/16−13/16 in
(15−20 mm)
(1) rear brake lever/parking brake lever
Inspection
Measure the distance the rear brake lever/parking brake lever ( 1 ) moves
before the brake starts to take hold. Freeplay, measurement at the tip of
the end of the brake lever, should be:
9/16−13/16 in (15−20 mm)
If necessary, adjust to the specified range.
Servicing Your Honda
137
Brakes
Adjustment
RIGHT REAR
(3)
(2)
(2) brake lever adjusting nut
(3) brake arm pin
Turn the brake lever adjusting nut ( 2 ), located on the brake operating
rod at the rear of the frame. Make sure the cutout on the adjusting nut is
properly seated on the brake arm pin ( 3 ).
Other Inspections
Check that the brake lever and brake pedal assemblies are positioned
properly and the securing bolts are tight.
Make sure that the brake cables, brake arm, spring, and fasteners are
in good condition.
138 Servicing Your Honda
Brakes
Brake Shoe Wear
Refer to Saf ety Precautions on page 81 .
The rear brake is equipped with an external brake wear indicator that lets
you check brake wear without disassembly. Application of the brake
control causes the arrow on the brake arm to move toward a reference
mark on the brake panel.
RIGHT REAR
(2)
(1) (3)
(1) arrow
(2) brake arm
(3) reference mark
1. Apply the brake control and check the movement of the arrow ( 1 ) on
the brake arm ( 2 ).
2. Replace the brake shoe if the arrow aligns with the reference mark
( 3 ) on the brake panel upon full application of the brake. If
replacement is necessary, see your Honda dealer.
Servicing Your Honda
139
Brakes
Brakelight Switch Adjustment
Refer to Saf ety Precautions on page 81 .
Rear Brake Only:
Check the operation of the rear brakelight switch ( 1 ) at the right side
behind the engine from time to time. The brakelight should turn on at
0.6 in (15 mm) of pedal stroke. See Rear Brake Pedal Freeplay, page
135 . Adjustment is done by turning the adjusting nut ( 2 ). Turn the nut
in direction (A) if the switch operates too late and in direction ( B) if the
switch operates too soon.
RIGHT SIDE
(1)
(A)
(B)
(2)
(1) rear brakelight switch
(2) adjusting nut
140 Servicing Your Honda
Brakes
Draining Water from Brakes
Refer to Saf ety Precautions on page 81 .
RIGHT REAR
(1)
(1) rear brake drain bolt
1. Make sure the engine is off and the parking brake is set.
2. Remove the rear brake drain bolt ( 1 ) from the bottom of the rear
brake panel.
If any water drains, the brake seals must be replaced by your Honda
dealer as soon as possible.
Servicing Your Honda
141
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.
142 Servicing Your Honda
Tires
Air Pressure
Refer to Saf ety Precautions on page 81 .
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 a new cap.
Servicing Your Honda
143
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:
WITH
NO
CARGO CARGO
FRONT
REAR
RECOMMENDED
PRESSURE
3.6 psi (25 kPa , 3.6 psi (25 kPa ,
0.25 kgf/cm )
0.25 kgf/cm )
RECOMMENDED
PRESSURE
3.6 psi (25 kPa , 3.6 psi (25 kPa ,
0.25 kgf/cm )
0.25 kgf/cm )
144 Servicing Your Honda
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
Refer to Saf ety Precautions on page 81 .
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.
Servicing Your Honda
145
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
NEW
Replace
3/16 in
(4 mm)
(2)
REAR
3/16 in
(4 mm)
(1)
(3)
Replace
NEW
(1) groove depth
(2) wear indicator
(3) wear indicator
location mark
To check the condition of a tire tread, measure the groove depth ( 1 ) in
the center of the tire, or check the wear indicator ( 2 ).
For best performance, you should replace a tire before the tread depth at
the center reaches the following limits:
front
rear
146 Servicing Your Honda
3/16 in (4 mm)
3/16 in (4 mm)
Tires
Tire Repair
Refer to Saf ety Precautions on page 81 .
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, preferably without any cargo, 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 177 .)
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.
Servicing Your Honda
147
Tires
Tire Replacement
Refer to Saf ety Precautions on page 81 .
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
AT24 × 8-12 ★★
AT24 × 10-11 ★★
MAXXIS M977
MAXXIS M978
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
recommended that you have the work checked by your Honda dealer.
148 Servicing Your Honda
Engine Guard & Skid Plate
Refer to Saf ety Precautions on page 81 .
(1)
(1) engine guard
(2)
(2) skid plate
The engine guard ( 1 ) protects the frame and engine crankcase.
The skid plate ( 2 ) protects the rear final gear case. Check the guard and
plate for cracks, damage or looseness at intervals shown in the
Maintenance Schedule.
Have the engine guard and skid plate replaced if they are cracked or
damaged. If the guard and plate bolts are loose, tighten them securely.
Servicing Your Honda
149
Driveshaft Boots (TRX420FM only)
Refer to Saf ety Precautions on page 81 .
FRONT
(1)
(1) rubber driveshaft boots
Check the rubber driveshaft boots ( 1 ) for damage or leaking grease. If
necessary, have your Honda dealer replace them.
150 Servicing Your Honda
Propeller Shaft Boots &
Yoke Joint Boot
Refer to Saf ety Precautions on page 81 .
(1)
(2)
(1) rubber propeller shaft boots (TRX420FM only)
(2) rubber yoke joint boot
Check the rubber propeller shaft boots ( 1 ) and rubber yoke joint boot
( 2 ) for damage or leaking grease. If necessary, have your Honda dealer
replace them.
Servicing Your Honda
151
Battery
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 156 ).
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 153 .
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.
152 Servicing Your Honda
Battery
Battery Storage
Refer to Saf ety Precautions on page 81 .
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 156 ).
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.
Servicing Your Honda
153
Battery
The battery is located in a compartment under the seat.
UNDER SEAT
(1)
(3)
(4)
(1)
(2)
(1) rubber band
(2) negative (−) terminal lead
(3) battery
(4) positive (＋) terminal lead
Removal
1. Make sure the ignition switch is OFF ( ).
2. Remove the seat (page 92 ).
3. Remove the rear fender cover (page 112 ).
4. Release the rings and remove the rubber band ( 1 ).
5. Disconnect the negative (−) terminal lead ( 2 ) from the battery ( 3 )
first, then disconnect the positive (＋) terminal lead ( 4 ).
154 Servicing Your Honda
Battery
6. Remove the battery.
7. Charge the battery (see following section), unless you have been
riding regularly.
8. Store your battery in an easy-to-reach location off the floor, in an area
protected from freezing temperature and direct sunlight.
9. Clean the compartment after removing the battery for storage. Dry the
compartment and, if paint is missing, re-paint the area.
10. 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.
Servicing Your Honda
155
Battery
Battery Charging
Refer to Saf ety Precautions on page 81 .
(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.
We recommend using a ‘‘trickle’’ charger ( 1 ) for home charging. These
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.
156 Servicing Your Honda
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
Refer to Saf ety Precautions on page 81 .
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).
Servicing Your Honda
157
Appearance Care
Washing Your ATV with a Mild Detergent
Refer to Saf ety Precautions on page 81 .
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.
158 Servicing Your Honda
Appearance Care
Spray Cleaning Your ATV
Refer to Saf ety Precautions on page 81 .
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.
Servicing Your Honda
159
Appearance Care
Finishing Touches
Refer to Saf ety Precautions on page 81 .
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 193 ) 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.
160 Servicing Your Honda
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 ...........................................................................
What to Take to the Riding Area ...................................................
What to Take on the Trail ..............................................................
Transporting Your Honda ..................................................................
Storing Your Honda ...........................................................................
Preparation for Storage ..................................................................
Removal from Storage ...................................................................
You & the Environment .....................................................................
Tips
162
162
163
164
166
167
169
170
161
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, which begins
on page 171 .
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.
162 Tips
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 40 ).
Tips
163
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.
164 Tips
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)
(2)
(3)
(1) front cargo rack
(2) rear cargo rack
(3) trailer hitch
Tips
165
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.
166 Tips
Storing Your Honda
Preparation for Storage
Refer to Saf ety Precautions on page 81 .
1. Change the engine oil and filter (page 102 ).
2. Make sure the cooling system is filled with a 50/50% antifreeze
solution (page 110 ).
3. Fill the fuel tank. Make sure the fuel fill cap is properly installed.
4. Check that the fuel valve is OFF.
5. 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.
Pour a tablespoon (15−20 cc) of clean engine oil into cylinder
and cover the spark plug hole with a piece of cloth.
With the engine stop switch in the RUN ( ) position, press the
start button several times to crank the engine and distribute the oil.
Reinstall the spark plug and spark plug cap.
(cont’d)
Tips
167
Storing Your Honda
6. Remove the battery and charge it fully. Store it in an area protected
from freezing temperatures and direct sunlight. Slow charge the
battery (page 156 ) 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.
7. Wash and dry your ATV. Wax all painted surfaces.
8. Inflate the tires to their recommended pressures (page 144 ).
9. Store your ATV in an unheated area, free of dampness, away from
sunlight, with a minimum of daily temperature variation.
10. Place your ATV on blocks to lift all tires off the floor.
11. 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.
168 Tips
Storing Your Honda
Removal from Storage
Refer to Saf ety Precautions on page 81 .
1. Uncover and clean your ATV.
2. If your ATV has been stored for more than four months − change
the engine oil (page 102 ).
3. If your ATV has been stored for more than two months − ask your
Honda dealer to drain and replace the fuel.
4. Charge the battery (page 156 ) as required. Install the battery.
5. Perform a pre-ride inspection (page 35 ), then test-ride your ATV at
low speeds.
Tips
169
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.
170 Tips
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 162 ).
General Guidelines .............................................................................
If Your Engine Quits or Won’t Start ..................................................
If You Have a Flat Tire ......................................................................
If the High Coolant Temperature Indicator Lights.............................
If a Fuse Blows ..................................................................................
If You Crash.......................................................................................
If You Lose Your Key .......................................................................
If the Battery Is Low (or Dead) ..........................................................
If a Component Fails ..........................................................................
Taking Care of the Unexpected
172
174
177
180
182
186
187
188
189
171
Taking Care of the Unexpected
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.
172 Taking Care of the Unexpected
Taking Care of the Unexpected
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.
Taking Care of the Unexpected
173
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.
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.
174 Taking Care of the Unexpected
If Your Engine Quits or Won’t Start
SYMPTOM: Starter motor doesn’t operate.
POSSIBLE CAUSE
WHAT TO DO
ignition switch OFF
Turn the ignition switch ON.
engine stop switch
Slide the engine stop switch to RUN.
OFF
transmission not in
Shift into neutral.
neutral
blown fuse
Replace with a new fuse of the
same rating (page 182 ).
battery lead loose
Tighten the battery lead.
low (or dead) battery
Charge the battery (page 156 ).
If charging doesn’t help, see your
Honda dealer.
faulty starter motor
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.
POSSIBLE CAUSE
WHAT TO DO
out of fuel
Fill the fuel tank.
flooded engine
See F looded Engine (page 54 ).
loose or
Install the spark plug cap securely. If
unconnected spark
the engine still won’t start, see your
plug cap
Honda dealer.
loose battery cables
Tighten the battery terminal bolts.
weak battery
Charge the battery (page 156 ). If
charging doesn’t help, see your
Honda dealer.
Taking Care of the Unexpected
175
If Your Engine Quits or Won’t Start
SYMPTOM: Engine starts, but runs poorly.
POSSIBLE CAUSE
WHAT TO DO
high coolant
Check the high coolant temperature
temperature
indicator. Refer to If the High
Coolant T emperature Indicator
Lights, page180 .
runs erratically,
See your Honda dealer.
misfires
blubbers (rich fuel
See your Honda dealer.
mixture)
sooty exhaust (rich
See your Honda dealer.
fuel mixture)
detonates or pings
If applicable, switch to the
under load
recommended octane gasoline
(page 94 ) or change your brand of
gasoline. If the problem persists, see
your Honda dealer.
afterfires (backfires)
See your Honda dealer.
pre-ignition (runs on
See your Honda dealer.
after ignition
switched OFF)
176 Taking Care of the Unexpected
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 148 ). Replacing a tire involves removing and re-installing the
wheel (page 178 ).
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.
Taking Care of the Unexpected
177
If You Have a Flat Tire
Emergency Wheel Removal/Installation
Refer to Saf ety Precautions on page 81 .
(1)
(2)
(1)
(1) wheel nuts
(2) wheel rim
Removal
1. Park your ATV on a firm, level surface.
2. Raise the front (or rear) wheels off the ground and place a support
block under the vehicle.
3. Remove the wheel nuts ( 1 ).
4. Remove the wheel.
Avoid getting grease, oil, or dirt on the front brake disc or pad surfaces
when removing and installing each wheel. Any contamination can
cause poor brake performance or rapid pad wear after reassembly.
178 Taking Care of the Unexpected
If You Have a Flat Tire
Installation
1. Position the wheel.
2. Position the wheel nuts so that the tapered sides face the wheel rim
( 2 ).
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.
Taking Care of the Unexpected
179
If the High Coolant Temperature
Indicator Lights
Normally, the high coolant temperature indicator will only light
momentarily when you turn the ignition ON ( ). 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 to 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, turn the engine off. Open the fuse box (page
183 ) and check the radiator fan fuse. If the fuse is blown, replace it
with the proper (same rating) spare fuse. Start the engine. If the high
coolant temperature indicator comes on and stays on, turn the engine
off.
If the radiator fan is working, visually check the coolant level in the
reserve tank, located under the rear fender. It isn’t necessary to touch
the radiator system.
180 Taking Care of the Unexpected
If the High Coolant Temperature
Indicator Lights
If the reserve tank is low or empty, don’t ride without adding coolant
(page 110 ). 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 164 ).
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 100 )
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 you are able to resume riding, continue to monitor the high coolant
temperature indicator frequently.
If there is an oil leak − do not ride the ATV until the leak is repaired by
Honda dealer (page 164 ).
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
164 ).
Taking Care of the Unexpected
181
If a Fuse Blows
All of the electrical circuits on your ATV have fuses 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
should check for is a blown fuse ( 1 ).
Check all the fuses before looking elsewhere for another possible cause
of the problem. Replace any blown fuses and check component
operation.
(1)
(1) blown fuse
The main fuse and the circuit fuses are located in the battery
compartment.
Recommended Fuses
main fuse
other fuse
30 A
15 A
10 A × 3
182 Taking Care of the Unexpected
If a Fuse Blows
Main Fuse Access
1. To prevent an accidental short circuit, turn the ignition switch OFF
( ) before checking or replacing the fuses.
2. Remove the seat (page 92 ).
3. Remove the rear fender cover (page 112 ).
4. To access the main fuse ( 2 ), remove the fuse box cover ( 3 ).
UNDER SEAT
(3)
(2)
(2) main fuse
(3) fuse box cover
(4)
(4) spare main fuse
5. Pull the main fuse out.
If it is blown, install the spare main fuse ( 4 ).
(cont’d)
Taking Care of the Unexpected
183
If a Fuse Blows
Circuit Fuse Access
(6)
(5)
(5) circuit fuses
(6) spare fuses
6. To check or replace a circuit fuse ( 5 ), pull the old fuse out of its
retaining clips.
If the fuse is blown, replace it with a spare fuse ( 6 ) of the same rating.
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.
7. Install the fuse box cover.
8. Install the rear fender cover.
9. Install the seat.
184 Taking Care of the Unexpected
If a Fuse Blows
If you do not have a spare fuse and you cannot ride the ATV without
fixing the problem, take a fuse of the same rating or a lower rating from
one of the other circuits that you can do without temporarily.
If you replace a blown fuse with a spare fuse that has a lower rating,
replace the fuse with the correct rating as soon as you can. Also
remember to replace any spare fuses that were installed.
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.
Taking Care of the Unexpected
185
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.
186 Taking Care of the Unexpected
If You Lose Your Key
Be sure to record your key number ( 1 ) in the Quick Reference section
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 you purchased your Honda from. 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
Taking Care of the Unexpected
187
If the Battery Is Low (or Dead)
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.
188 Taking Care of the Unexpected
If a Component Fails
The brake 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.
Taking Care of the Unexpected
189
190 Taking Care of the Unexpected
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 .........................................................................
Specifications .....................................................................................
Break-in Guidelines ...........................................................................
Emission Control Systems..................................................................
Oxygenated Fuels ...............................................................................
Technical Information
192
194
198
199
203
191
Vehicle Identification
Serial Numbers
The VIN and engine serial numbers 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.
The VIN ( 1 ) is stamped on the front of the frame.
FRONT
(1)
(1) VIN
The engine number ( 2 ) is stamped on the upper side of the rear
crankcase.
LEFT SIDE
(2)
(2) engine number
192 Technical Information
Vehicle Identification
Color Label & Code
The color label ( 1 ) is attached to the frame under the seat. Remove the
seat (page 92 ) to check the label.
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.
UNDER SEAT
(1)
(1) color label
Technical Information
193
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
194 Technical Information
80.9 in (2,055 mm)
46.1 in (1,172 mm)
45.2 in (1,148 mm)
45.1 in (1,146 mm)
49.4 in (1,256 mm)
49.2 in (1,249 mm)
6.5 in (165 mm)
……TRX420TM
……TRX420FM
……TRX420TM
……TRX420FM
unleaded gasoline, pump octane
number of 86 or higher
3.62 US gal (13.7 )
including reserve
0.74 US gal (2.8 )
after disassembly:
3.3 US qt (3.1 )
after draining:
2.9 US qt (2.7 )
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
Specifications
Fuel & Lubricants (cont’d)
Pro Honda HP Coolant or an
cooling system
equivalent high quality ethylene
recommendation
glycol antifreeze containing
corrosion protection inhibitors
specifically recommended for use
in aluminum engines
1.6 US qt (1.5 )
cooling system
capacity
Capacities
passenger capacity
maximum weight
capacity
operator only
485 lbs (220 kg)
rider, all cargo and accessories
Engine Specifications
displacement
bore & stroke
compression ratio
spark plug
(standard)
valve clearance
(cold)
spark plug gap
idle speed
25.6 cu-in (420 cm )
3.41 × 2.81 in (86.5 × 71.5 mm)
9.8 : 1
BKR5E-11 (NGK)
or K16PR-U11 (DENSO)
intake:
0.006 in (0.15 mm)
exhaust: 0.009 in (0.23 mm)
0.039−0.043 in (1.00−1.10 mm)
1,400 ± 100 rpm
Technical Information
195
Specifications
Power Transmission
primary reduction
secondary reduction
final reduction
transmission ratio
final drive
front (TRX420FM only)
rear
1st
2nd
3rd
4th
5th
reverse
2.103
1.818
3.231
3.154
3.857
2.235
1.571
1.178
0.848
4.831
shaft
Chassis & Suspension
caster
6.34° …TRX420TM
3.0° …TRX420FM
trail
0.99 in (25.1 mm) …TRX420TM
0.37 in (9.5 mm) …TRX420FM
tire size, front
AT24 × 8-12 ★★ MAXXIS M977
tire size, rear
AT24 × 10-11 ★★ MAXXIS M978
tire pressure, front &
3.6 psi (25 kPa , 0.25 kgf/cm )
rear (cold)
196 Technical Information
Specifications
Electrical
battery
generator
Lights
headlight
brake/tail light
neutral indicator
reverse indicator
high coolant
temperature indicator
PGM-FI indicator
4WD indicator
(TRX420FM only)
Fuses
main
other
Torque Specification
engine oil drain bolt
engine oil filter cover
bolts
rear final gear case
oil drain bolt
differential oil drain
plug (TRX420FM only)
wheel nuts
12 V−12 Ah
0.343 kW/5,000 rpm
12 V 30/30 W × 2
LED
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
30 A
15 A
10 A × 3
18 lbf·ft (25 N·m , 2.5 kgf·m)
7 lbf·ft (10 N·m , 1.0 kgf·m)
9 lbf·ft (12 N·m , 1.2 kgf·m)
9 lbf·ft (12 N·m , 1.2 kgf·m)
47 lbf·ft (64 N·m , 6.5 kgf·m)
Technical Information
197
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.
198 Technical Information
Emission Control Systems
Exhaust Emission Requirements (USA only)
The U.S. Environmental Protection Agency (EPA) and the California
Air Resources Board (CARB) require that your ATV comply with
applicable exhaust emission standards during its useful life, when
operated and maintained according to the instructions provided.
The Vehicle Emission Control Information Label ( 1 ) is attached on the
right side of the frame.
RIGHT FRONT
(1)
(1) vehicle emission control infomation label
Technical Information
199
Emission Control Systems
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 includes a PGM-FI system.
No adjustment to this system should be made although periodic
inspection of the components is recommended.
The exhaust emission control system is separate from the crankcase
emission control system.
Crankcase Emission Control System
The engine is equipped with a closed crankcase system to prevent
discharging crankcase emissions into the atmosphere. Blow-by gas is
returned to the combustion chamber through the air cleaner.
200 Technical Information
Emission Control Systems
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.
Technical Information
201
Emission Control Systems
Noise Emission Control System
TAMPERING WITH THE NOISE CONTROL SYSTEM IS
PROHIBITED:
State laws prohibit, or Canadian provincial laws may prohibit the
following acts or the causing thereof: ( 1 ) The removal or rendering
inoperative by any person, other than for purposes of maintenance,
repair or replacement, of any device or element of design incorporated
into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use; or ( 2 ) the use of
the vehicle after such device or element of design has been removed or
rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE
TAMPERING ARE THE 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.
202 Technical Information
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.
Technical Information
203
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.
204 Technical Information
Consumer Information
This section contains information on your warranty and how to get an
official Honda service manual.
Authorized Manuals ...........................................................................
Warranty Coverage ............................................................................
Warranty Service................................................................................
Contacting Honda ..............................................................................
Your Honda Dealer ............................................................................
The Honda Rider’s Club (USA only).................................................
Consumer Information
206
209
210
211
212
213
205
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.
61HP400
61CM002
31HP4600
＊
Price Each＊
Description
2007 TRX420TM/TE/FM/FE Service
Manual
Common Service Manual
2007 TRX420TM/FM Owner’s
Manual
$48.00
$48.00
$16.00
Prices are subject to change without notice and without incurring obligation.
206 Consumer Information
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
Sub Total
＊
Prices are subject to change without notice and
Purchaser’s Sales Tax
without incurring obligation.
Mich. Add 6 %
Orders are mailed within 10 days. Please allow
Calif. Add 8.25 %
adequate time for delivery.
Handling Charge
$5.00
Grand Total
Consumer Information
207
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
Apartment Number
City
State
Daytime Telephone 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
MasterCard
Discover
Account Number
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
208 Consumer Information
Warranty Coverage
Your new Honda is covered by these warranties:
TRX Limited Warranty
Exhaust Emission Warranty (USA Only)
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.
Consumer Information
209
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.
210 Consumer Information
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) 7841870.
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.
Consumer Information
211
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 Genuine Honda parts, Pro Honda products,
Hondaline accessories (USA only), and Honda accessories and products
(Canada only). The same quality that went into your Honda can be
found in Genuine Honda 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.
212 Consumer Information
The Honda Rider’s Club (USA only)
One of the best ways to get the most enjoyment from owning and riding
your Honda is through the Honda Rider’s Club of America. Your
purchase of a new motorcycle, scooter, ATV or PWC from a
participating U.S. Honda dealer entitles you to a complimentary oneyear membership in the Club. There are hundreds of HRCA Chaptersponsoring dealers across the USA with events and activities almost
every weekend. Membership benefits include:
24-hour, toll-free roadside assistance for your new Honda (includes
roadside assistance for your transport vehicle [up to one ton] as long
as your Honda is aboard or in tow). For street-legal motorcycles and
scooters only.
An exclusive HRCA website complete with access to the official
Honda Common Service Manual, contests, insider information and
more.
Reimbursement (up to $75) for successful completion of a
Motorcycle Safety Foundation training course. Separate,
complimentary training from the Specialty Vehicle Institute of
America for purchasers of new ATVs.
One full year of Honda Red Rider magazine (six issues).
Discounts from HRCA partners for experienced rider courses.
Discounted vehicle insurance from the HRCA’s insurance partner.
Racing contingency programs and assistance at selected dual-sport,
off-road and motocross events for off-road motorcycles and selected
ATVs.
If you purchased an of f -road motorcycle, ATV or PWC, your benef its
do not include roadside assistance or trip interruption protection.
Contact your Honda dealer for more information or call: 1-800-8474722 or log on to www.hrca.honda.com.
Consumer Information
213
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
INSTRUMENTS & CONTROLS ........................................................ 9
Operation Component Locations ...........................................................10
Indicators & Gauge ................................................................................13
Fuel Gauge .........................................................................................16
Controls & Features ...............................................................................17
Fuel Valve ..........................................................................................17
Ignition Switch ...................................................................................18
2WD/4WD Select Lever (TRX420FM only) .................................... 19
Start Button ........................................................................................20
Engine Stop Switch ............................................................................20
Headlight Switch ................................................................................21
Headlight Dimmer Switch ..................................................................21
Throttle Lever ....................................................................................22
Reverse Selector Knob .......................................................................23
Front Brake Lever ..............................................................................24
Rear Brake Lever ...............................................................................24
Rear Brake Pedal ................................................................................24
Parking Brake .....................................................................................25
Flag Pole Bracket ...............................................................................26
Trailer Hitch .......................................................................................27
214 Table of Contents
Table of Contents
BEFORE RIDING .............................................................................. 29
Are You Ready to Ride? ........................................................................30
Protective Apparel..............................................................................30
Rider Training ....................................................................................32
Age Recommendation ........................................................................33
No Passengers ....................................................................................33
No Alcohol or Drugs ..........................................................................34
Is Your ATV Ready to Ride? .................................................................35
Pre-ride Inspection .............................................................................35
Load Limits & Guidelines ......................................................................39
Loading ..............................................................................................39
Load Limits ........................................................................................40
Loading Guidelines ............................................................................41
Accessories & Modifications .................................................................42
Accessories.........................................................................................42
Modifications .....................................................................................43
Table of Contents
215
Table of Contents
BASIC OPERATION & RIDING ..................................................... 45
Safe Riding Precautions .........................................................................47
Off-Road Use Only ............................................................................47
Keep Hands and Feet on Controls ......................................................48
Control Speed .....................................................................................49
Use Care on Unfamiliar or Rough Terrain .........................................50
Do Not Perform Stunts.......................................................................51
Starting & Stopping the Engine .............................................................52
Preparation .........................................................................................52
Starting Procedure ..............................................................................53
Flooded Engine ..................................................................................54
Bank Angle Sensor Ignition Cut-off System .....................................54
Stalled Engine ....................................................................................55
How to Stop the Engine .....................................................................56
Shifting Gears ........................................................................................57
Riding in Reverse ...................................................................................59
Braking ...................................................................................................61
Riding Your ATV ..................................................................................63
Making Turns .....................................................................................63
Skidding or Sliding ............................................................................65
Riding Up Hills ..................................................................................66
Riding Down Hills .............................................................................70
Crossing or Turning on Hills or Slopes ..............................................71
Riding Over Obstacles .......................................................................73
Riding Through Water .......................................................................74
Parking ...................................................................................................75
216 Table of Contents
Table of Contents
SERVICING YOUR HONDA............................................................ 77
Bef ore You Service Your Honda
The Importance of Maintenance ............................................................79
Maintenance Safety ................................................................................80
Important Safety Precautions .............................................................81
Maintenance Schedule ...........................................................................82
Maintenance Record...............................................................................86
Service Preparations
Maintenance Component Locations .......................................................87
Tool Kit ..................................................................................................90
Owner’s Manual Storage........................................................................91
Seat Removal .........................................................................................92
Clip Removal .........................................................................................93
Service Procedures
Fluids & Filters
Fuel ........................................................................................................94
Engine Oil & Filter.................................................................................97
Gear Case Oil ..................................................................................... 106
Differential Oil (TRX420FM only) .................................................... 108
Coolant ............................................................................................... 110
Air Cleaner ......................................................................................... 116
Engine
Throttle ...............................................................................................
Clutch System ....................................................................................
Reverse Lock System .........................................................................
Spark Plug ..........................................................................................
Valves.................................................................................................
Spark Arrester ....................................................................................
122
124
125
126
129
130
(cont’d)
Table of Contents
217
Table of Contents
Chassis
Brakes.................................................................................................
Tires ...................................................................................................
Engine Guard & Skid Plate ................................................................
Driveshaft Boots (TRX420FM only)..................................................
Propeller Shaft Boots & Yoke Joint Boot ..........................................
131
142
149
150
151
Electrical
Battery ................................................................................................ 152
Appearance Care ................................................................................ 157
TIPS .................................................................................................... 161
Preparing for a Ride ........................................................................... 162
What to Take to the Riding Area ................................................... 162
What to Take on the Trail .............................................................. 163
Transporting Your Honda .................................................................. 164
Storing Your Honda ........................................................................... 166
Preparation for Storage .................................................................. 167
Removal from Storage ................................................................... 169
You & the Environment ..................................................................... 170
TAKING CARE OF THE UNEXPECTED .................................... 171
General Guidelines ............................................................................. 172
If Your Engine Quits or Won’t Start .................................................. 174
If You Have a Flat Tire ...................................................................... 177
If the High Coolant Temperature Indicator Lights............................. 180
If a Fuse Blows .................................................................................. 182
If You Crash....................................................................................... 186
If You Lose Your Key ....................................................................... 187
If the Battery Is Low (or Dead) .......................................................... 188
If a Component Fails .......................................................................... 189
218 Table of Contents
Table of Contents
TECHNICAL INFORMATION ...................................................... 191
Vehicle Identification ......................................................................... 192
Specifications ..................................................................................... 194
Break-in Guidelines ........................................................................... 198
Emission Control Systems.................................................................. 199
Oxygenated Fuels ............................................................................... 203
CONSUMER INFORMATION ....................................................... 205
Authorized Manuals ........................................................................... 206
Warranty Coverage ............................................................................ 209
Warranty Service................................................................................ 210
Contacting Honda .............................................................................. 211
Your Honda Dealer ............................................................................ 212
The Honda Rider’s Club (USA only)................................................. 213
TABLE OF CONTENTS .................................................................. 214
INDEX ................................................................................................ 220
QUICK REFERENCE
Table of Contents
219
Index
A
accessories ............................................................................................. 42
age recommendation ............................................................................. 33
air cleaner,
dust cover ........................................................................................ 120
filter ................................................................................................. 116
housing drain tube ........................................................................... 121
air pressure,
gauge ................................................................................................. 91
tire ................................................................................................... 143
American Honda, contacting ............................................................... 211
apparel, protective ................................................................................. 30
appearance care ................................................................................... 157
authorized manuals.............................................................................. 206
B
battery.................................................................................................. 152
bank angle sensor ignition cut-off system............................................. 54
brakelight switch adjustment ............................................................... 140
brakes,
cables............................................................................................... 138
draining water from......................................................................... 141
fluid ................................................................................................. 131
front brake lever ................................................................................ 24
pad wear .......................................................................................... 134
parking .............................................................................................. 25
rear brake lever.................................................................................. 24
rear brake lever freeplay ................................................................. 137
rear brake pedal ................................................................................. 24
rear brake pedal freeplay ................................................................. 135
220 Index
Index
shoe wear......................................................................................... 139
braking .................................................................................................. 61
break-in guidelines .............................................................................. 198
C
capacity, fuel ......................................................................................... 95
care, appearance .................................................................................. 157
cargo,
loading and operational guidelines .................................................... 41
weight limit ....................................................................................... 40
cleaning, appearance care.................................................................... 157
climbing hills ......................................................................................... 66
clip......................................................................................................... 93
clutch system ....................................................................................... 124
color label............................................................................................ 193
compartment,
owner’s manual ................................................................................. 91
tool kit ............................................................................................... 90
component fails ................................................................................... 189
consumer information ......................................................................... 205
controls & features ................................................................................ 17
crash, if you......................................................................................... 186
crossing or turning on hills or slopes..................................................... 71
customer service .................................................................................. 211
D
differential oil (TRX420FM only) ...................................................... 108
dimmer switch, headlight ...................................................................... 21
dipstick ................................................................................................ 101
driveshaft boots (TRX420FM only) ................................................... 150
Index
221
Index
E
emission control systems ..................................................................... 199
engine,
flooded .............................................................................................. 54
guard ............................................................................................... 149
number ............................................................................................ 192
oil ...................................................................................................... 97
pinging .............................................................................................. 94
starting ............................................................................................... 52
stop switch......................................................................................... 20
stopping ............................................................................................. 56
won’t start ....................................................................................... 174
environment ........................................................................................ 170
exhaust system,
cleaning ............................................................................................. 36
purging ............................................................................................ 130
F
final gear case oil ................................................................................ 106
flag pole bracket.................................................................................... 26
flat tire ................................................................................................. 177
flooded engine....................................................................................... 54
222 Index
Index
fuel,
fill cap .............................................................................................. 95
gauge ................................................................................................ 16
oxygenated ...................................................................................... 203
recommendation ................................................................................ 94
refueling ............................................................................................ 95
reserve fuel supply ............................................................................ 95
tank capacity ..................................................................................... 95
valve .................................................................................................. 17
fuses .................................................................................................... 182
G
gap, spark plug .................................................................................... 127
gasohol ................................................................................................ 203
gasoline ................................................................................................. 94
gear case oil ......................................................................................... 106
gear shifting .......................................................................................... 57
H
headlight dimmer switch ....................................................................... 21
headlight switch .................................................................................... 21
hills,
crossing or turning on slopes............................................................. 71
riding down hills ............................................................................... 70
riding up hills .................................................................................... 66
stopping on hills ................................................................................ 68
(cont’d)
Index
223
Index
Honda,
contacting ........................................................................................ 211
Rider’s Club .................................................................................... 213
dealer ............................................................................................... 212
Honda service manual ......................................................................... 206
I
identification, vehicle .......................................................................... 192
ignition switch ....................................................................................... 18
indicators,
high coolant temperature indicator ...................................... 13, 15, 180
neutral indicator .......................................................................... 13, 15
PGM-FI indicator ........................................................................ 13, 15
reverse indicator .......................................................................... 13, 15
4WD indicator (TRX420FM only) ....................................... 13, 15, 19
inspection, pre-ride ................................................................................ 35
K
key,
lost ................................................................................................... 187
number ............................................................................................ 187
kit, tool .................................................................................................. 90
224 Index
Index
L
labels, safety ............................................................................................ 5
lamp check ............................................................................................ 14
lever, 2WD/4WD select (TRX420FM only) ......................................... 19
limit, weight .......................................................................................... 40
load limits .............................................................................................. 40
loading guidelines ................................................................................. 41
lubrication,
differential oil (TRX420FM only) .................................................. 108
engine oil ........................................................................................... 97
gear case oil ..................................................................................... 106
M
maintenance,
component locations.......................................................................... 87
importance ......................................................................................... 79
precations .......................................................................................... 81
record ................................................................................................ 86
safety ................................................................................................. 80
schedule............................................................................................. 82
manual, service.................................................................................... 206
maximum weight limit .......................................................................... 40
modifications......................................................................................... 43
Index
225
Index
N
neutral indicator .............................................................................. 13, 15
noise emission control system ............................................................. 202
numbers, serial .....................................................................................192
O
obstacles, riding over ............................................................................ 73
oil,
differential (TRX420FM only) ....................................................... 108
engine ................................................................................................ 97
gear case .......................................................................................... 106
operation component locations.............................................................. 10
owner’s manual storage......................................................................... 91
oxygenated fuels ................................................................................. 203
226 Index
Index
P
parking .................................................................................................. 75
passenger no carrying............................................................................ 33
pavement, no riding on.......................................................................... 47
pinging, engine ...................................................................................... 94
plug, spark ........................................................................................... 126
pre-ride inspection ................................................................................. 35
problems, unexpected .......................................................................... 171
propeller shaft boots & yoke joint boot............................................... 151
protective apparel .................................................................................. 30
R
rear final gear case oil ......................................................................... 106
removal, seat ......................................................................................... 92
reverse,
assist cable ....................................................................................... 125
assist lever ....................................................................................... 125
gear, shifting into .............................................................................. 59
indicator ...................................................................................... 13, 15
riding in ............................................................................................. 59
selector knob ..................................................................................... 23
rider training .......................................................................................... 32
Rider’s Club, Honda............................................................................ 213
(cont’d)
Index
227
Index
riding,
basic operations ................................................................................. 45
clothing.............................................................................................. 30
precautions ........................................................................................ 47
preparing for ................................................................................... 162
over obstacles .................................................................................... 73
safety ................................................................................................... 2
safety precautions.............................................................................. 47
through water .................................................................................... 74
S
safety,
important precautions ........................................................................ 81
labels ................................................................................................... 5
riding precautions .............................................................................. 47
schedule, maintenance........................................................................... 82
seat removal .......................................................................................... 92
serial numbers ..................................................................................... 192
service,
customer .......................................................................................... 211
manuals ........................................................................................... 206
warranty .......................................................................................... 210
shifting gears ......................................................................................... 57
skid plate ............................................................................................. 149
skidding or sliding ................................................................................. 65
spark arrester ....................................................................................... 130
spark knock ........................................................................................... 94
spark plug ............................................................................................ 126
specifications....................................................................................... 194
228 Index
Index
stalling on a hill ..................................................................................... 68
start button............................................................................................. 20
starting,
engine ................................................................................................ 52
troubleshooting................................................................................ 174
stop switch, engine ................................................................................ 20
stopping engine ..................................................................................... 56
storage,
ATV ................................................................................................ 166
owner’s manual ................................................................................. 91
switch,
engine stop ........................................................................................ 20
headlight ............................................................................................ 21
headlight dimmer .............................................................................. 21
ignition .............................................................................................. 18
Index
229
Index
T
throttle,
cable ................................................................................................ 123
lever................................................................................... 22, 122, 123
tires,
air pressure ...................................................................................... 143
flat ................................................................................................... 177
replacing .......................................................................................... 148
repairing .......................................................................................... 147
tread conditions ....................................................................... 145, 146
tool kit ................................................................................................... 90
trailer hitch ............................................................................................ 27
trailer towing,
operational guidelines ....................................................................... 41
weight limits ...................................................................................... 40
training, rider ......................................................................................... 32
transporting your ATV ........................................................................ 164
trouble, unexpected ............................................................................. 171
troubleshooting, starting ...................................................................... 174
turning,
on level ground...................................................................................63
on hills or slopes................................................................................ 71
230 Index
Index
V
valve, fuel.............................................................................................. 17
valve clearance .................................................................................... 129
vehicle indentification no. (VIN) ........................................................ 192
W
warning labels ......................................................................................... 5
warranty,
coverage .......................................................................................... 209
extended .......................................................................................... 209
service ............................................................................................. 210
washing your ATV .............................................................................. 158
water,
riding through.................................................................................... 74
draining from brakes ....................................................................... 141
weight limit ........................................................................................... 40
wheel removal ..................................................................................... 178
Index
231
232 Memo
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
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
Quick Reference
Scheduled
Maintenance
Pre-ride Inspection
Fuel/Capacity
Engine Oil
Maximum Weight
Capacity
Initial: 100 miles (150 km)
Regular: every 600 miles (1,000 km)
Check the following items each time
before you ride (page 35 ): engine oil,
radiator coolant, fuel, tires, driveshaft
boots (TRX420FM only), propeller shaft
boots & yoke joint boot, nuts & bolts,
underbody & exhaust system, air cleaner
housing drain tube, leaks, loose parts,
cables, lights, throttle, brakes, reverse
assist lever, switches, steering.
unleaded gasoline, pump octane number
86 or higher
3.62 US gal (13.7 )
reserve:
0.74 US gal (2.8 )
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
485 lbs (220 kg)
rider, all cargo and accessories
Quick Reference
Quick Reference
Tires
Tire Pressure (cold)
Front: AT24 × 8-12 ★★
MAXXIS M977
Rear: AT24 × 10-11 ★★
MAXXIS M978
Front:
3.6 psi (25 kPa , 0.25 kgf/cm )
Rear:
3.6 psi (25 kPa , 0.25 kgf/cm )
Spark Plugs
Coolant
Fuses
Quick Reference
standard:
BKR5E-11 (NGK)
or
K16PR-U11 (DENSO)
ethylene glycol antifreeze (silicate-free)
for aluminum engines in 50/50 solution
with Pro Honda HP Coolant or an
equivalent distilled water
main: 30 A
other: 15 A
10 A × 3