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Honda 2007 FourTrax Rancher 420, Owner'S Manual

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Honda 2007 FourTrax Rancher 420 Owner'S Manual Download Page 17

9

Instruments & Controls

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.

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

Indicators & Gauge

.

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Fuel Gauge

.

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Controls & Features

.

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Fuel Valve

.

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Ignition Switch

.

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Operation Component Locations

. 10

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Start Button

.

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Engine Stop Switch

.

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Headlight Switch

.

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Headlight Dimmer Switch

.

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Throttle Lever

.

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Reverse Selector Knob

.

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Parking Brake

.

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Front Brake Lever

.

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Rear Brake Lever

.

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

Rear Brake Pedal

.

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Flag Pole Bracket

.

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

Trailer Hitch

.

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

2WD/4WD Select Lever (TRX420FM only)

.

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Summary of Contents for 2007 FourTrax Rancher 420

Page 1: ...S 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 i...

Page 2: ...his 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...

Page 3: ...e harm 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 You may also want to...

Page 4: ...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 potent...

Page 5: ...u don t follow instructions A Few Words About Safety A Few Words About Safety Safety Headings Safety Section Instructions These signal words mean such as Important Safety Reminders or Important Safety...

Page 6: ...safety information you should know plus a look at the safety related labels on your ATV The location and function of indicators and controls on your ATV and operating instructions for various control...

Page 7: ...ntenance schedule and instructions for specific maintenance and adjustment items How to store and transport your ATV and how to be an environmentally responsible rider What to do if you have a flat ti...

Page 8: ......

Page 9: ...ost 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...

Page 10: ...e a few that we consider most important The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle Your ATV is designed for one person only There are...

Page 11: ...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 Even if you have ridden other...

Page 12: ...ake good judgments and ride safely 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 S...

Page 13: ...the vehicle If a label comes off or becomes hard to read contact your Honda dealer for replacements Your ATV comes with a hang tag and several labels containing important safety information Anyone wh...

Page 14: ...6 Safety Labels ATV Safety USA only...

Page 15: ...7 Safety Labels ATV Safety...

Page 16: ...8 Safety Labels ATV Safety TRX420FM only...

Page 17: ...d in other sections of this manual where they will be most useful Indicators Gauge Fuel Gauge Controls Features Fuel Valve Ignition Switch Operation Component Locations 10 Start Button Engine Stop Swi...

Page 18: ...utton ignition switch throttle lever headlight switch parking brake lock lever rear brake lever parking brake lever headlight dimmer switch engine stop switch 2WD 4WD select lever TRX420FM only 10 Ope...

Page 19: ...rear cargo rack rear brake pedal seat latch front cargo rack fuel valve 11 Operation Component Locations Instruments Controls...

Page 20: ...trailer hitch shift lever flag pole bracket 12 Operation Component Locations Instruments Controls...

Page 21: ...X420FM only 5 reverse indicator 1 2 3 13 Indicators Gauge Instruments Controls The indicators and gauge on your ATV keep you informed alert you to possible problems and make your riding safer and more...

Page 22: ...dicator and PGM FI indicator come on for a few seconds and then go off when you turn the ignition switch ON When applicable the 4WD indicator comes on when you turn the ignition switch ON and remains...

Page 23: ...a stop turn the engine off and let it cool See page PGM FI indicator Lights when there is any abnormality in the PGM FI Programmed Fuel Injection system Should also light for a few seconds and then go...

Page 24: ...trols When the gauge needle enters the red band 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 approxima...

Page 25: ...you refuel If the fuel valve is left in the RES position you may run out of fuel with no reserve Reserve Fuel RES for extra fuel to get to a gas supply for refueling OFF for parking storing or transp...

Page 26: ...TER OF HANDLEBAR 1 ignition switch 1 ON OFF OFF ON Key Position Function 18 Ignition Switch Controls Features Instruments Controls The ignition switch is used for starting and stopping the engine page...

Page 27: ...s 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 l...

Page 28: ...arter motor will not operate if the engine stop switch is in the OFF position when the start button is pushed The engine stop switch is used to stop the engine in an emergency To operate slide the swi...

Page 29: ...mer Switch Controls Features Instruments Controls The headlight switch is used to turn the headlight ON or OFF To operate turn the switch to ON or OFF The headlight dimmer switch is used to change bet...

Page 30: ...ures Instruments Controls The throttle controls engine rpm speed To increase engine rpm press the throttle lever with your thumb To reduce engine rpm release pressure on the throttle lever The throttl...

Page 31: ...ls Riding in Reverse The reverse selector knob located on the rear brake lever parking brake lever is used to shift into reverse To operate with your ATV stopped and the transmission in neutral make s...

Page 32: ...ATV To operate pull the lever For information on braking techniques see page The rear brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see...

Page 33: ...r parking brake lever 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 rig...

Page 34: ...tures Instruments Controls Flag poles are optional equipment available from your Honda dealer To mount a pole in the bracket follow the instructions that come with the flag pole kit Flag poles are req...

Page 35: ...railer hitch is located on the rear axle housing To use the hitch you ll need a proper size ball as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the t...

Page 36: ...28 Instruments Controls...

Page 37: ...nd adjustments to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride Protective Apparel Rider Training Age Recommendation...

Page 38: ...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 prop...

Page 39: ...ng 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...

Page 40: ...for the ATV Rider 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...

Page 41: ...cause a crash and you or your passenger could be injured or killed Never carry a passenger on this ATV 33 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended a...

Page 42: ...ume alcohol or drugs before or while operating this ATV 34 No Alcohol or Drugs Are You Ready to Ride Before Riding Alcohol drugs and ATVs don t mix Even a small amount of alcohol can impair your abili...

Page 43: ...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...

Page 44: ...Adjust if needed Also look for signs of damage or excessive wear page Check for damage page Walk around your ATV and look for anything that appears unusual such as a leak or loose cable Check for dep...

Page 45: ...ere is no brake fluid leakage 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 steerin...

Page 46: ...k for proper function page Check for proper function page 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...

Page 47: ...erfere 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...

Page 48: ...he 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 The weight...

Page 49: ...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 ha...

Page 50: ...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...

Page 51: ...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...

Page 52: ...44 Before Riding...

Page 53: ...njoy optimum performance and service life refer to Break in Guidelines page cont d Safe Riding Precautions Off Road Use Only Keep Hands and Feet on Controls Control Speed Use Care on Unfamiliar or Rou...

Page 54: ...c Operation Riding Braking Riding Your ATV Making Turns Skidding or Sliding Riding Up Hills Riding Down Hills Crossing or Turning on Hills or Slopes Riding Over Obstacles Riding Through Water Parking...

Page 55: ...e 1 and the section beginning on page 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 ac...

Page 56: ...Feet on Controls Safe Riding Precautions Basic Operation Riding You should never ride your ATV on public streets roads or highways even if they are not paved Drivers of street vehicles may have diffi...

Page 57: ...cle the terrain visibility and other operating conditions and your experience 49 Control Speed Basic Operation Riding Safe Riding Precautions Riding at excessive speed increases the chance of an accid...

Page 58: ...errain Always be alert to changing terrain conditions when operating the ATV 50 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Page 59: ...on these kinds of terrain 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 51 D...

Page 60: ...g 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 Before...

Page 61: ...cle has a fuel injected with an automatic choke Follow the procedure indicated below Any Air Temperature The engine will not start if the throttle is fully open Because the electronic control module c...

Page 62: ...n for 5 seconds Follow the normal starting procedure If the engine starts then open the throttle slightly if idling is unstable If the engine still won t start refer to page Your vehicle s banking lea...

Page 63: ...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 thro...

Page 64: ...en when the engine is OFF To stop the engine make sure the transmission is in neutral by checking that the neutral indicator lights and turn the ignition switch OFF If your ATV is stopped with the eng...

Page 65: ...e 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 st...

Page 66: ...ing 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...

Page 67: ...or knob 2 rear brake lever parking brake lever 59 Basic Operation Riding Riding in Reverse cont d If you need to ride in reverse make sure the area behind you is clear and only operate the ATV at low...

Page 68: ...g in reverse gear 60 Riding in Reverse Basic Operation Riding To shift out of reverse and into neutral raise the shift lever one stroke To stop close the throttle and gradually apply both the front an...

Page 69: ...quickly while turning Either action may cause one or more wheels to slip and reduce your control of your ATV Applying the brakes too hard may cause the wheels to lock and slide reducing control of you...

Page 70: ...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 th...

Page 71: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 63 Making Turns Basic Operation Riding Riding Your ATV Learn how to tur...

Page 72: ...rating from a full stop 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 wh...

Page 73: ...Basic Operation Riding 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...

Page 74: ...ing 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 l...

Page 75: ...start up any hill 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 sudd...

Page 76: ...neutral set the parking brake and turn the engine off Then assess the situation If the ATV starts rolling backwards before you begin braking Keep your weight uphill Carefully apply the front brakes f...

Page 77: ...ot 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 Stand with your body facing downhill...

Page 78: ...scribed in this owner s manual 70 Riding Down Hills Riding Your ATV Basic Operation Riding It s usually advisable to descend hills with the ATV pointed straight downhill Avoid angles that would cause...

Page 79: ...nded 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 rid...

Page 80: ...f 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 excess...

Page 81: ...as described in this owner s manual 73 Riding Over Obstacles Riding Your ATV Basic Operation Riding Before operating in a new area check for obstacles Watch out for bumps rain ruts potholes and other...

Page 82: ...y the brakes repeatedly until they dry out and operate normally Riding through water can make the brakes less effective than normal and may reduce stopping ability After leaving the water always test...

Page 83: ...back and forth to allow shifting the transmission into neutral If rocks or other objects are available you can block the wheels as shown for additional security If the ATV begins to move either while...

Page 84: ...76 Basic Operation Riding...

Page 85: ...r 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...

Page 86: ...fferential Oil only Coolant Air Cleaner Throttle Clutch System Reverse Lock System Spark Plug Valves Spark Arrester Chassis Brakes Tires Engine Guard Skid Plate Driveshaft Boots only Propeller Shaft B...

Page 87: ...educe 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...

Page 88: ...rform 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...

Page 89: ...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 flamm...

Page 90: ...dule 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...

Page 91: ...e 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 o...

Page 92: ...LANT COOLING SYSTEM Refer to page 122 116 121 126 129 97 102 110 600 1000 100 C I I I R I I REGULAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL INITIAL REGULAR HOURS MAINT INTERVAL MAINT 84 Maintena...

Page 93: ...YSTEM NOTE NOTE 3 NOTE 1 100 150 20 I I I I I I I 600 1000 100 I I I I I I I I C I I 1200 2000 200 I I I I I I I I I I I I I C I I I I I Refer to page 150 106 108 106 131 139 134 140 131 125 149 124 1...

Page 94: ...our 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...

Page 95: ...front brake fluid reservoir fuel fill cap front brake lever throttle lever rear brake lever parking brake lever 87 Servicing Your Honda Maintenance Component Locations...

Page 96: ...ight switch coolant reserve tank differential oil filler cap TRX420FM only differential oil drain bolt TRX420FM only front brake caliper rear brake pedal air cleaner housing drain tube 88 Servicing Yo...

Page 97: ...g gear case oil filler cap gear case oil drain bolt engine oil drain bolt battery owner s manual air pressure gauge engine oil filler cap dipstick tool kit fuse box main fuse 89 Servicing Your Honda M...

Page 98: ...p 90 Tool Kit Servicing Your Honda To open the compartment unhook the rubber strap The tool kit is stored in the storage compartment below the rear cargo rack An optional larger tool kit may be availa...

Page 99: ...V provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual in the plastic document bag underside of the seat The owner s manual and air pressure...

Page 100: ...sert the front prongs into the hooks on the frame and press the studs into the grommets Pull the seat latch at the rear of the seat The seat must be removed for the air cleaner engine oil engine oil f...

Page 101: ...al Removal Press down on the center pin to release the lock Pull the clip out of the hole Installation Push the bottom of the pin Insert the clip into the hole Lightly press down on the center pin to...

Page 102: ...pump octane number For information on the use of oxygenated fuels see page Use of lower octane gasoline can cause persistent pinging or spark knock a loud rapping noise which if severe can lead to en...

Page 103: ...fueling Procedure Servicing Your Honda Fuel Safety Precautions Fuel tank capacity including reserve Reserve capacity Refer to on page The tank should be refilled as soon as possible after switching to...

Page 104: ...ottom of the filler neck Avoid over filling the tank There should be no fuel in the filler neck If the fuel valve was set to RES turn the fuel valve ON If you replace the fuel fill cap use only a genu...

Page 105: ...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 oi...

Page 106: ...ter Servicing Your Honda 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 rec...

Page 107: ...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...

Page 108: ...r to on page Check the engine oil level each day before operating your ATV and add if needed Park your ATV on a firm level surface Start the engine in a well ventilated area and let it idle for 3 5 mi...

Page 109: ...he oil filler cap dipstick and check the oil level The oil level should be between the upper level mark and the lower level mark on the oil filler cap dipstick Reinstall the oil filler cap dipstick If...

Page 110: ...il filter specified for your model or a filter of equal quality This procedure requires mechanical skill and professional tools such as a torque wrench and oil filter wrench as well as a means for dis...

Page 111: ...1 RIGHT SIDE 1 right side cover 103 Engine Oil Filter Servicing Your Honda Install a New Engine Oil Filter cont d Unsnap and remove the right side cover Remove the seat page 1 2 92 1...

Page 112: ...manner page Check that the oil filter cover O rings 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...

Page 113: ...y Reinstall the oil drain plug and tighten it to the specified torque Check that the drain plug sealing washer is in good condition If necessary replace the sealing washer Install the left side cover...

Page 114: ...Honda shaft drive oil or equivalent type 106 Changing Oil Oil Recommendation Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the gear case at normal operatin...

Page 115: ...Place an oil drain pan under the oil drain plug Remove the oil filler cap and the drain plug After the oil has completely drained reinstall the drain plug and tighten it to the specified torque Fill...

Page 116: ...shaft drive oil or equivalent 108 Oil Recommendation Changing Oil Differential Oil TRX420FM only Servicing Your Honda Safety Precautions Refer to on page Change the oil with the differential at norma...

Page 117: ...TV on level ground Place an oil drain pan under the oil drain plug Remove the oil filler cap and the drain plug After the oil has completely drained reinstall the drain plug and tighten it to the spec...

Page 118: ...rrosion 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 anti...

Page 119: ...rovide additional protection against freezing Check the cooling system frequently during freezing weather Refer to on page Check the engine coolant level each day before operating your ATV and add if...

Page 120: ...nt level to the UPPER level mark Remove the seat page After adding coolant install the reserve tank cap and rear fender cover Install the seat Fasten the rubber strap Remove the rear fender cover and...

Page 121: ...lacement Servicing Your Honda Coolant Safety Precautions You the Environment Improper disposal of drained fluids is harmful to the environment Refer to on page Coolant should be replaced by your Honda...

Page 122: ...ater can damage the radiator core Refer to on page 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 d...

Page 123: ...tor grill plate 8 radiator core 7 8 115 Servicing Your Honda Coolant Remove the radiator grill plate Wash the radiator core and radiator grill plate Install the removed parts in reverse order of remov...

Page 124: ...r 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...

Page 125: ...SEAT 2 1 retainer clips 2 air cleaner housing cover 1 117 Cleaning Air Cleaner Servicing Your Honda cont d Remove the seat page Unlatch the retainer clips Remove the air cleaner housing cover 1 2 3 9...

Page 126: ...or tears or cracks in the foam or seams of the air cleaner Replace the air cleaner if it is damaged Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not fully absorb...

Page 127: ...o the sealing surface of the air cleaner assembly Install the clamp Insert the air cleaner assembly into the air cleaner housing Fasten the screw Reassemble by reversing the disassembly sequence Insta...

Page 128: ...1 2 UNDER SEAT 1 dust cover 2 breather joint 120 Dust Cover Air Cleaner Servicing Your Honda Do not push the dust cover too far into the breather joint If the dust cover is dirty clean it 1 2...

Page 129: ...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...

Page 130: ...Safety Precautions Refer to on page After adjustment check for smooth operation of the throttle lever from fully closed to fully open in all steering positions Tighten the lock nut and reinstall the s...

Page 131: ...om fully open to fully closed in all steering positions If there is a problem see your Honda dealer Check the cables for tension or stress in all steering positions Lubricate the cables with a commerc...

Page 132: ...on discs may be worn See your Honda dealer or refer to official Honda Service Manual page Make sure the ignition switch is OFF Remove the seat page and left side cover page Loosen the lock nut Turn th...

Page 133: ...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 Refer to on page Return the dust cover and rubber s...

Page 134: ...ment Inspection Spark Plug Servicing Your Honda Using spark plugs with an improper heat range can cause engine damage Safety Precautions Use only the recommended type of spark plug in the recommended...

Page 135: ...rrosion 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 f...

Page 136: ...ent cross threading 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 First tighten the plug NGK turn after it seats...

Page 137: ...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 you...

Page 138: ...ed for this procedure Because of the possible fire hazard check that there are no combustible materials in the area before purging the spark arrester The spark arrester must be serviced every 100 oper...

Page 139: ...ght brake lever freeplay does not feel within the normal range while riding check the brake pads for wear page Worn pads should be replaced If the pads are not worn beyond the recommended limit there...

Page 140: ...uld be above the LOWER level mark If the level is at or below the LOWER level mark check the brake pads for wear page Worn brake pads should be replaced If the pads are not worn have your brake system...

Page 141: ...contact with skin or eyes In case of contact wash thoroughly and call a doctor immediately if it contacts your eyes Make sure there are no fluid leaks Check for deterioration or cracks in the hoses an...

Page 142: ...sage 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 Always inspect both pads in bot...

Page 143: ...T SIDE 135 Rear Brake Pedal Freeplay Brakes Servicing Your Honda Measure the distance the rear brake pedal moves before the brake starts to take hold Freeplay measurement at the tip of the end of the...

Page 144: ...rm pin RIGHT REAR 136 Brakes Servicing Your Honda Adjustment Turn the brake pedal adjusting nut located on the brake operating rod at the rear of the frame Make sure the cutout on the adjusting nut is...

Page 145: ...lever 137 Rear Brake Lever Freeplay Brakes Servicing Your Honda If necessary adjust to the specified range Inspection Measure the distance the rear brake lever parking brake lever moves before the bra...

Page 146: ...ng nut 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 Check that the brake lever and brake pedal assembli...

Page 147: ...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 Replace the brake shoe if the arrow aligns w...

Page 148: ...er to on page Rear Brake Only Check the operation of the rear brakelight switch 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...

Page 149: ...ng Your Honda Safety Precautions Refer to on page Make sure the engine is off and the parking brake is set Remove the rear brake drain bolt from the bottom of the rear brake panel If any water drains...

Page 150: ...es must be the proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tires Although the tires are designed specifically for...

Page 151: ...dling 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 harshl...

Page 152: ...ck 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...

Page 153: ...e 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 pr...

Page 154: ...ur Honda 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 For best performance you should replace a tire...

Page 155: ...temporary repairs see page A tire that is repaired either temporarily or permanently will have lower speed and performance limits than a new or undamaged tire If you have a tire professionally repaire...

Page 156: ...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 mu...

Page 157: ...rotects the frame and engine crankcase The skid plate 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...

Page 158: ...eshaft boots 150 Driveshaft Boots TRX420FM only Servicing Your Honda Safety Precautions Refer to on page Check the rubber driveshaft boots for damage or leaking grease If necessary have your Honda dea...

Page 159: ...e joint boot 151 Servicing Your Honda Propeller Shaft Boots Yoke Joint Boot Safety Precautions Refer to on page Check the rubber propeller shaft boots and rubber yoke joint boot for damage or leaking...

Page 160: ...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 freque...

Page 161: ...tery Charging Refer to on page 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...

Page 162: ...Make sure the ignition switch is OFF Removal The battery is located in a compartment under the seat Disconnect the negative terminal lead from the battery first then disconnect the positive terminal l...

Page 163: ...e and direct sunlight Slow charge the battery see following section once every 30 days Installation Reinstall in the reverse order of removal Be sure to connect the positive terminal first then the ne...

Page 164: ...arging may damage the battery We recommend using a trickle charger for home charging These units can be left connected for long periods without risking damage to the battery However do not intentional...

Page 165: ...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...

Page 166: ...s Start the engine and let it idle for several minutes The engine heat will help dry moist areas As a precaution ride your ATV at a slow speed and apply the brakes several times This will help dry the...

Page 167: ...ply 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 Dull corroded chrome or aluminum Heavy grime Oil leaks Brak...

Page 168: ...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...

Page 169: ...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 P...

Page 170: ...USA only the Ministry of Natural Resources Canada only riding clubs and off road magazines are good sources of information Along with your ATV and riding gear you should take along some tools and supp...

Page 171: ...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...

Page 172: ...ecommend 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 h...

Page 173: ...wn straps in the areas shown Using tie down straps in any other areas can damage your ATV Suitable tie down straps are available from your Honda dealer Ordinary rope is not recommended because it can...

Page 174: ...y 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 available from your Honda dea...

Page 175: ...l valve is OFF 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...

Page 176: ...cted from freezing temperatures and direct sunlight Slow charge the battery page once a month Cover your ATV with a porous material Avoid using plastic or similar non breathing coated materials that r...

Page 177: ...as been stored for more than two months ask your Honda dealer to drain and replace the fuel Perform a pre ride inspection page then test ride your ATV at low speeds Charge the battery page as required...

Page 178: ...y increase noise they also reduce engine performance and may be illegal Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which da...

Page 179: ...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 page General Guidelines If Your Engine Quits or Won t Start If th...

Page 180: ...t 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 t...

Page 181: ...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 perma...

Page 182: ...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...

Page 183: ...CAUSE WHAT TO DO SYMPTOM If all possible causes are negative the starter motor may be faulty See your Honda dealer faulty starter motor low or dead battery Charge the battery page If charging doesn t...

Page 184: ...r Honda dealer detonates or pings under load If applicable switch to the recommended octane gasoline page or change your brand of gasoline If the problem persists see your Honda dealer afterfires back...

Page 185: ...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...

Page 186: ...V on a firm level surface Raise the front or rear wheels off the ground and place a support block under the vehicle Remove the wheel Removal Remove the wheel nuts 1 1 2 3 4 81 Avoid getting grease oil...

Page 187: ...heel nuts so that the tapered sides face the wheel rim 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 t...

Page 188: ...t don t touch the engine or radiator system Let everything cool off first Check the radiator fan If the fan is not working turn the engine off Open the fuse box page and check the radiator fan fuse If...

Page 189: ...or an oil leak Check the oil level If necessary add the recommended oil page to the upper level mark If you must leave your ATV to get oil secure it as much as possible If you are able to resume ridin...

Page 190: ...ed 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 Check all the fuses before looking elsewhere...

Page 191: ...Fuse Access Pull the main fuse out If it is blown install the spare main fuse To access the main fuse remove the fuse box cover Remove the seat page To prevent an accidental short circuit turn the ign...

Page 192: ...electrical system Circuit Fuse Access To check or replace a circuit fuse pull the old fuse out of its retaining clips If the fuse is blown replace it with a spare fuse of the same rating If you do not...

Page 193: ...n 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...

Page 194: ...ly 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 the...

Page 195: ...ade 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...

Page 196: ...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...

Page 197: ...he 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 slow...

Page 198: ...190 Taking Care of the Unexpected...

Page 199: ...ction 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 Emissio...

Page 200: ...on 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 is st...

Page 201: ...echnical Information The color label is attached to the frame under the seat Remove the seat page to check the label The color code is helpful when ordering replacement parts You may record the color...

Page 202: ...lar 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 49 4 in 1 256 mm including reserve after...

Page 203: ...0 cm 3 41 2 81 in 86 5 71 5 mm BKR5E 11 NGK K16PR U11 DENSO 0 006 in 0 15 mm 0 039 0 043 in 1 00 1 10 mm 1 400 100 rpm 9 8 1 0 009 in 0 23 mm or intake exhaust cooling system recommendation cooling sy...

Page 204: ...IS M977 MAXXIS M978 1 818 TRX420TM TRX420FM TRX420TM TRX420FM TRX420FM only caster trail tire size front tire size rear tire pressure front rear cold final drive final reduction secondary reduction pr...

Page 205: ...18 lbf ft 25 N m 2 5 kgf m TRX420FM only battery generator brake tail light neutral indicator headlight reverse indicator PGM FI indicator 4WD indicator other main high coolant temperature indicator...

Page 206: ...on 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 ra...

Page 207: ...ly 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...

Page 208: ...onoxide 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 The exhaust emission control system inc...

Page 209: ...Rough idle Misfiring or backfiring during acceleration After burning backfiring Poor performance driveability and poor fuel economy Federal regulations prohibit removing or disabling a device or eleme...

Page 210: ...of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or the use of the vehicle after such device or element of design has been removed or rendered inoperative...

Page 211: ...ed 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 e...

Page 212: ...toms 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...

Page 213: ...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 R...

Page 214: ...ble 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 o...

Page 215: ...rge Grand Total 5 00 Item Description 207 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00...

Page 216: ...time Telephone Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Check here if your billing address is different from the shipping address shown above VISA Disco...

Page 217: ...o 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...

Page 218: ...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 rep...

Page 219: ...o 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 Mot...

Page 220: ...roducts 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 pa...

Page 221: ...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 An exclusive HRCA website complete with acce...

Page 222: ...ion Component Locations Indicators Gauge Fuel Gauge Controls Features Fuel Valve Ignition Switch 2WD 4WD Select Lever TRX420FM only Start Button Engine Stop Switch Headlight Switch Headlight Dimmer Sw...

Page 223: ...tive Apparel Rider Training Age Recommendation No Passengers No Alcohol or Drugs Is Your ATV Ready to Ride Pre ride Inspection Load Limits Guidelines Loading Load Limits Loading Guidelines Accessories...

Page 224: ...ing the Engine Preparation Starting Procedure Flooded Engine Bank Angle Sensor Ignition Cut off System Stalled Engine How to Stop the Engine Shifting Gears Riding in Reverse Braking Riding Your ATV Ma...

Page 225: ...y Precautions Maintenance Schedule Maintenance Record Maintenance Component Locations Tool Kit Owner s Manual Storage Seat Removal Clip Removal Fluids Filters Fuel Engine Oil Filter Gear Case Oil Diff...

Page 226: ...rea What to Take on the Trail Transporting Your Honda Preparation for Storage Storing Your Honda Removal from Storage You the Environment General Guidelines If Your Engine Quits or Won t Start If You...

Page 227: ...NTENTS 214 INDEX 220 QUICK REFERENCE Vehicle Identification Specifications Break in Guidelines Emission Control Systems Oxygenated Fuels Authorized Manuals Warranty Coverage Warranty Service Contactin...

Page 228: ...ontacting 211 apparel protective 30 appearance care 157 authorized manuals 206 battery 152 bank angle sensor ignition cut off system 54 brakelight switch adjustment 140 brakes cables 138 draining wate...

Page 229: ...ppearance 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...

Page 230: ...99 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 final gear case oil 106 flag p...

Page 231: ...ing 57 cont d fuel fill cap 95 gauge 16 oxygenated 203 recommendation 94 refueling 95 reserve fuel supply 95 tank capacity 95 valve 17 fuses 182 headlight dimmer switch 21 headlight switch 21 hills cr...

Page 232: ...e manual 206 key lost 187 number 187 kit tool 90 identification vehicle 192 ignition switch 18 indicators high coolant temperature indicator 13 15 180 neutral indicator 13 15 PGM FI indicator 13 15 re...

Page 233: ...rd 86 safety 80 schedule 82 manual service 206 maximum weight limit 40 modifications 43 labels safety 5 lamp check 14 lever 2WD 4WD select TRX420FM only 19 limit weight 40 load limits 40 loading guide...

Page 234: ...dicator 13 15 noise emission control system 202 numbers serial 192 obstacles riding over 73 oil differential TRX420FM only 108 engine 97 gear case 106 operation component locations 10 owner s manual s...

Page 235: ...rk 126 pre ride inspection 35 problems unexpected 171 propeller shaft boots yoke joint boot 151 protective apparel 30 rear final gear case oil 106 removal seat 92 reverse assist cable 125 assist lever...

Page 236: ...precautions 47 through water 74 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...

Page 237: ...talling 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 dimm...

Page 238: ...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 unexpec...

Page 239: ...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 valve fuel 17 valve clearance 129 vehicl...

Page 240: ...232 Memo...

Page 241: ...tant notes 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 Frequen...

Page 242: ...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...

Page 243: ...r 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 rider all cargo...

Page 244: ...Front Rear Front Rear standard 3 6 psi 25 kPa 0 25 kgf cm 3 6 psi 25 kPa 0 25 kgf cm Quick Reference Quick Reference Tires Tire Pressure cold Spark Plugs Fuses Coolant ethylene glycol antifreeze silic...

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