Honda 2009 SPORTRAX 90X Owner'S Manual Download Page 133 | Manualshive

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(1) arrow
(2) brake arm

(3) reference mark

(1)

(2)

(3)

RIGHT FRONT

LEFT FRONT

(2)

(1)

(3)

REAR

(2)

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Brake Shoe Wear

Brakes

Servicing Your Honda

Saf ety Precautions

Refer to

on page

.

The front and rear brakes are equipped with external brake wear
indicators that let you check brake wear without disassembly.
Application of the brake control (lever or pedal) causes the arrow on the
brake arm to move toward a reference mark on the brake panel.

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Summary of Contents for 2009 SPORTRAX 90X

Page 1: ...latest production information available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publicati...

Page 2: ...ission 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 veh...

Page 3: ...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 4: ...atisfaction You may also want to visit our website at www honda com Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important product...

Page 5: ...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 6: ...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 7: ...f indicators and controls on your ATV and operating instructions for various controls and features The importance of wearing a helmet and other protective gear how to make sure you and your ATV are re...

Page 8: ...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 9: ......

Page 10: ...nformation 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 Imp...

Page 11: ...to ride Therefore before parents allow any youngster to ride this ATV we urge them to carefully read the beginning on page and the booklet that came with the ATV USA only It s a proven fact helmets s...

Page 12: ...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 13: ...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 14: ...help determine whether a youngster is big enough for this ATV have them stand up on the footpegs and grasp the handgrips While the youngster holds this position check that they have at least three inc...

Page 15: ...handgrips If not the youngster is not physically ready to ride this ATV Before you let a youngster ride an ATV decide whether they are physically mentally and emotionally ready to ride ATHLETIC ABILI...

Page 16: ...ongly recommend that young riders take the free hands on training course Honda offers to all new ATV owners and immediate family members We also recommend that you take or observe the course with your...

Page 17: ...d your ATV do make sure that any riders under 16 years old will have adult supervision Your youngster should understand that the decision to lend the ATV is yours SAFE AND RESPONSIBLE RIDING must be a...

Page 18: ...ould 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 replac...

Page 19: ...10 Safety Labels ATV Safety...

Page 20: ...For Canada 11 Safety Labels ATV Safety...

Page 21: ...12 Safety Labels ATV Safety...

Page 22: ...ction Instructions for other components are presented in other sections of this manual where they will be most useful Operation Component Locations 14 Indicator 17 Neutral Indicator Lamp 17 Controls F...

Page 23: ...engine stop switch start button throttle lever ignition switch front brake lever parking brake lock lever rear brake lever parking brake lever 14 Indicator Controls Operation Component Locations...

Page 24: ...flag pole bracket rear brake pedal storage compartment 15 Indicator Controls Operation Component Locations...

Page 25: ...fuel valve choke lever seat lock lever shift lever 16 Indicator Controls Operation Component Locations...

Page 26: ...ls The neutral indicator lamp will light when the transmission is in neutral and the ignition switch is ON If the indicator does not come on when it should have your Honda dealer check for a burned ou...

Page 27: ...ng 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 th...

Page 28: ...1 A A B B LEFT SIDE 1 choke lever A fully ON B fully OFF 19 Choke Lever Indicator Controls Controls Features The choke lever may be used when starting the engine See page 56 1...

Page 29: ...ignition switch 1 CENTER OF HANDLEBAR OFF ON ON OFF Key Position Function 20 Ignition Switch Indicator Controls Controls Features The ignition switch is used for starting and stopping the engine page...

Page 30: ...Procedure The start button is used for starting the engine Pushing the button in starts the engine See page When the start button is pushed the starter motor will crank the engine The starter motor wi...

Page 31: ...mergency To operate slide the switch to the OFF position The switch must be in the RUN position to start the engine and it should normally remain in the RUN position even when the engine is OFF If you...

Page 32: ...Controls Features 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 throttle will a...

Page 33: ...Indicator Controls Controls Features The front brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see page The rear brake lever parking brake...

Page 34: ...ake pedal RIGHT SIDE 25 Rear Brake Pedal Indicator Controls Controls Features The rear brake pedal is used to slow or stop your ATV To operate depress the pedal For information on braking techniques s...

Page 35: ...ntrols Features Lock it with the lock lever Squeeze the rear brake lever parking brake lever The lock lever on the rear brake lever parking brake lever allows it to be used as a parking brake Unlock t...

Page 36: ...ontrols Controls Features Flag poles are required in some riding areas Check local regulations before riding Flag poles are optional equipment available from your Honda dealer To mount a pole in the b...

Page 37: ...28 Indicator Controls...

Page 38: ...nd 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 Recomm...

Page 39: ...ection and other protective clothing You don t have any alcohol or drugs in your system For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gl...

Page 40: ...ng Riding pants with knee and hip pads a riding jersey with padded elbows and a chest shoulder protector Off road motorcycle gloves to help protect your hands Sturdy off road motorcycle boots to help...

Page 41: ...gster ATVs 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 ar...

Page 42: ...jury or death A child under 10 should never operate this ATV 33 Age Recommendation No Passengers Are You Ready to Ride Before Riding This ATV is designed as an operator only vehicle The long seat is d...

Page 43: ...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 44: ...ride inspection procedures it s your responsibility to provide careful supervision and make sure they are performed safely Before each ride it s important to inspect your ATV and make sure any problem...

Page 45: ...for leaks Use a gauge to check the air pressure Adjust if needed Also look for signs of damage or excessive wear page Check the condition and slack Adjust and lubricate if needed Also check the chain...

Page 46: ...ased in all steering positions page Check these items after you get on the ATV Check the cable housings for wear Check the fittings for looseness Replace or tighten as needed Squeeze the front and rea...

Page 47: ...to maintain your balance and control of the ATV More specific information on load limits accessories and modifications follows In addition exceeding the weight limits or carrying an unbalanced load ca...

Page 48: ...ssenger Check that the tires are properly inflated As discussed on page we recommend that you do not carry any cargo on this ATV However if you decide to carry cargo ride at reduced speeds and follow...

Page 49: ...en 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 C...

Page 50: ...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...

Page 51: ...42 Before Riding...

Page 52: ...life refer to Break in Guidelines page For information about carburetor adjustment for riding at high altitude see page cont d Safe Riding Precautions 45 Speed Restrictors for New Riders 45 Off road U...

Page 53: ...c Operation Riding Braking 63 Riding Your ATV 66 Making Turns 66 Skidding or Sliding 68 Riding Up Hills 69 Riding Down Hills 73 Crossing or Turning on Hills or Slopes 74 Riding Over Obstacles 76 Ridin...

Page 54: ...V works and handles Practice in a safe area until you build your skills and get accustomed to the ATV s size and weight Your ATV is not equipped with lights Do not ride at night To limit top speed to...

Page 55: ...g turns Remove the screw and stay Loosen the lock nut Turn the throttle limiter screw clockwise to reduce throttle lever movement or counterclockwise to increase throttle lever movement Hold the throt...

Page 56: ...speed To restore the original setting approximately 15 mph 24 km h top speed follow the procedure below Reinstall the air intake restrictor Adjust the throttle lever freeplay to the specified range 1...

Page 57: ...e restrictor 48 Safe Riding Precautions Basic Operation Riding Air Intake Restrictor Removal Remove the seat page Unlatch the four retainer clips Remove the air cleaner housing cover Remove the air in...

Page 58: ...Off road Use Only Safe Riding Precautions Basic Operation Riding Your ATV and its tires are designed and manufactured for off road use only not for pavement Riding on pavement can affect handling and...

Page 59: ...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 60: ...cle the terrain visibility and other operating conditions and your experience 51 Control Speed Basic Operation Riding Safe Riding Precautions Riding at excessive speed increases the chance of an accid...

Page 61: ...errain Always be alert to changing terrain conditions when operating the ATV 52 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Page 62: ...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 53 Safe Riding Pre...

Page 63: ...y Is Good Safe Riding Precautions Basic Operation Riding You should always operate your ATV in a safe and reasonable manner When riding always keep all four wheels on the ground Your ATV is not equipp...

Page 64: ...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 Confirm the...

Page 65: ...transmission is in neutral Normal Air Temperature 10 35 C 50 95 F Pull the choke lever up all the way to fully ON if the engine is cold With the throttle 1 8 1 4 open press the start button If the th...

Page 66: ...rting Stopping the Engine Warm up the engine by opening and closing the throttle slightly After the engine has warmed up push the choke lever down all the way to fully OFF If idling is unstable open t...

Page 67: ...10 C 50 F or below Pull the choke lever up all the way to fully ON if the engine is cold Warm up the engine by opening and closing the throttle slightly If idling is unstable open the throttle slight...

Page 68: ...es not start wait 10 seconds then follow the procedure page If the engine still won t start refer to page Normal Engine Stop Push the choke lever down all the way to fully OFF To stop the engine make...

Page 69: ...ne full stroke To downshift step on the shift lever and depress it one full stroke The shift lever is located near the left footpeg One full stroke of the shift lever shifts the transmission to the ne...

Page 70: ...e lever and increase engine speed by gradually opening the throttle With the throttle closed raise the shift lever one full stroke to shift into 1st first gear When speed increases release the throttl...

Page 71: ...elationship 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 rp...

Page 72: ...the pedal and lever simultaneously Using both braking systems will stop your ATV faster with greater stability Your ATV is equipped with drum brakes on both front wheels which are mechanically activat...

Page 73: ...g 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 comp...

Page 74: ...action may cause one or more wheels to slip and reduce your control of your ATV Your ability to brake in a turn and to brake hard in an emergency situation are important riding skills When descending...

Page 75: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 66 Making Turns Riding Your ATV Basic Operation Riding Learn how to tur...

Page 76: ...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 77: ...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 78: ...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 79: ...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 80: ...t off the ATV while you continue holding the brakes Shift into neutral set the parking brake and turn the engine off Then assess the situation If the ATV starts rolling backwards before you begin brak...

Page 81: ...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 82: ...scribed in this owner s manual 73 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 83: ...ft 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...

Page 84: ...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 85: ...as described in this owner s manual 76 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 86: ...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 87: ...ATV in gear and is stopped on a grade rock the vehicle back and forth to allow shifting the transmission into neutral If you must park your ATV on a steep incline or loose or slippery surface use the...

Page 88: ...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 infor...

Page 89: ...Fluids Filters Engine Throttle 109 Clutch System 111 Engine Idle Speed 112 Spark Plug 113 Valves 116 Spark Arrester 117 Chassis Appearance Care 147 Brakes 118 Tires 126 Skid Plates 133 Drive Chain 13...

Page 90: ...od maintenance are especially important because your ATV is designed to be ridden over rough off road terrain More frequent service is needed if you subject your ATV to severe use or ride in unusually...

Page 91: ...in safe operating condition For youngsters learning how to take care of an ATV and perform basic maintenance can be an important part of their riding experience However if you allow a youngster to per...

Page 92: ...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 93: ...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 94: ...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 95: ...er In the interest of safety we recommend these items be serviced only by your Honda dealer Service more frequently when riding in dusty areas sand or snow Should be serviced by your Honda dealer unle...

Page 96: ...AINT INTERVAL MAINT INITIAL 100 mi 150 km 20 operating hours or 1 month R REGULAR Every 600 mi 1000 km 100 operating hours or 12 months R 87 Servicing Your Honda Maintenance Schedule Maintenance Proce...

Page 97: ...I I I I Refer to page 134 136 124 118 133 111 117 100 150 20 I L I I I I I FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITIAL HOURS MAINT INTERVAL MAINT I L EVERY 300 mi 500 km or 50 operating hour...

Page 98: ...V 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 perfor...

Page 99: ...fuel fill cap front brake lever throttle lever rear brake lever parking brake lever 90 Servicing Your Honda Maintenance Component Locations...

Page 100: ...oil filler cap dipstick rear brake pedal spark plug clutch engine oil drain bolt 91 Servicing Your Honda Maintenance Component Locations...

Page 101: ...fuel valve spark arrester air cleaner main fuse tool kit owner s manual drive chain throttle stop screw engine idle speed 92 Servicing Your Honda Maintenance Component Locations...

Page 102: ...and simple repairs Any extensive work requiring additional tools should be performed by your Honda dealer The tool kit includes the following items The tool kit is stored under the seat page After us...

Page 103: ...Be careful not to flood this area when washing your ATV Your ATV 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...

Page 104: ...nstallation Slide the seat back and lift it Removal Pull the seat lock lever up behind the seat Insert the front prongs into the hooks on the frame and press the studs into the grommets on the storage...

Page 105: ...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 106: ...ueling Procedure Fuel Servicing Your Honda 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 107: ...terclockwise Pull the breather tube out of the handlebar cover hole Add fuel until the level reaches the bottom of the filler neck Avoid over filling the tank There should be no fuel in the filler nec...

Page 108: ...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 ca...

Page 109: ...Your Honda Engine 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 recomm...

Page 110: ...rt 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 Th...

Page 111: ...ick 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 Insert the oil filler cap dipstick without screwing it in then...

Page 112: ...vel ground remove the oil filler cap dipstick from the right crankcase cover Place an oil drain pan under the crankcase and remove the oil drain plug This procedure requires mechanical skill and profe...

Page 113: ...ll the oil drain plug and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Check that there are no oil leaks If a torque wrench is not used for instal...

Page 114: ...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 115: ...ng cover 106 Cleaning Air Cleaner Servicing Your Honda Remove the seat by pulling the seat lock lever up Unlatch the four retainer clips Remove the air cleaner housing cover Remove the set plate and r...

Page 116: ...move the air cleaner from the air cleaner body Remove the sub air cleaner from the air cleaner joint Gently wash the air cleaner and sub air cleaner in clean non flammable high flash point solvent suc...

Page 117: ...l 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 o...

Page 118: ...on page Inspection Check freeplay at the throttle lever Freeplay Adjustment Slide the rubber sleeve back to expose the throttle cable adjuster Loosen the lock nut Turn the adjuster to obtain the corr...

Page 119: ...g positions Inspect the condition of the throttle cables from the throttle lever down to the carburetor If the cable is kinked or chafed have it replaced Check for smooth operation of the throttle lev...

Page 120: ...adjustment or the clutch does not work properly the cable or clutch friction discs may be worn See your Honda dealer or refer to official Honda Service Manual page After adjustment start the engine a...

Page 121: ...ngine s fuel delivery system Adjusting the idle will not compensate for a fault elsewhere Park your ATV on a firm level surface Connect a tachometer to the engine Shift into neutral Start the engine I...

Page 122: ...g 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 heat range Refer to on pa...

Page 123: ...cleaner if available or a wire brush Inspect the spark plug electrodes for wear The center electrode should have a flat tip and sharp edges and the side electrode should not be eroded If the electrod...

Page 124: ...he spark plug in by hand to prevent 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...

Page 125: ...e 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 adjustin...

Page 126: ...onment 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 Reins...

Page 127: ...the brake lever moves before the brakes start to take hold Freeplay measured at the tip of the front brake lever should be The mechanical drum brakes on your ATV dissipate heat generated by the fricti...

Page 128: ...es Servicing Your Honda Adjustment Turn the front brake lever adjusting nut located under the front fender Make sure the cutout on the adjusting nut is properly seated on the brake arm pin Adjust the...

Page 129: ...1 120 Rear Brake Pedal Freeplay Brakes Servicing Your Honda If necessary adjust to the specified range Inspection Measure the distance the rear brake pedal moves before the brake starts to take hold...

Page 130: ...urn 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 properly seated on the brake arm pin Adjust the freeplay of t...

Page 131: ...ever 122 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 brak...

Page 132: ...ioned properly and the securing bolts are tight Adjust the freeplay of the rear brake lever parking brake lever Push the brake arm then check the clearance between the brake arm and the brake arm pin...

Page 133: ...cing Your Honda Safety Precautions Refer to on page The front and rear brakes are equipped with external brake wear indicators that let you check brake wear without disassembly Application of the brak...

Page 134: ...mark on the brake panel upon full application of the brake If replacement is necessary see your Honda dealer Apply the brake control lever and pedal and check the movement of the arrow on the brake ar...

Page 135: ...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 136: ...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 137: ...en 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 th...

Page 138: ...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 139: ...o 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 before the...

Page 140: ...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 141: ...r 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 possi...

Page 142: ...skid plates protect the frame lower arm the drive components and the rear brake Check the plates for cracks damage or looseness at intervals shown in the Maintenance Schedule Have the skid plates rep...

Page 143: ...re and dirt The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets Under severe usage or when th...

Page 144: ...age the engine cases Measure the amount of chain slack midway between the sprockets Drive chain slack should allow the following vertical movement by hand Check drive chain slack at several points alo...

Page 145: ...ged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack...

Page 146: ...e Chain With the upper or lower section of drive chain tight between the sprockets measure the distance between a span of pins from pin center to pin center If the distance exceeds the service limit t...

Page 147: ...CE Normal Sprocket Teeth 138 Servicing Your Honda Drive Chain Use of a new chain with worn sprockets will cause rapid chain wear Inspect the front and rear sprocket teeth for excessive wear or damage...

Page 148: ...Refer to on page To adjust slack loosen the rear axle holder fixing bolts Turn the adjusting nut to decrease or increase chain slack Retighten the rear axle holder fixing bolts Rear axle holder fixin...

Page 149: ...every 30 days of riding or sooner if chain appears dry Lubricant Pro Honda HP Chain Lube or an equivalent chain lubricant designed specifically for use on O ring chains Commercial chain lubricants no...

Page 150: ...by steam cleaning high pressure washers and certain solvents Clean the side surfaces of the chain with a dry cloth Use a high flashpoint solvent such as kerosene not gasoline Do not brush the rubber...

Page 151: ...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 152: ...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 153: ...ur Honda The battery is located in a compartment under the seat Make sure the ignition switch is OFF Remove the seat page Disconnect the negative terminal lead from the battery first then disconnect t...

Page 154: ...emperature and direct sunlight Clean the battery box after removing the battery for storage Dry the battery box and if paint is missing re paint the area Slow charge the battery see following section...

Page 155: ...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 156: ...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 syste...

Page 157: ...ling and water spots As you dry inspect for chips and scratches 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 s...

Page 158: ...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 159: ...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 160: ...and store your Honda and how to be an environmentally responsible ATV owner Preparing for a Ride 152 What to Take to The Riding Area 152 What to Take on The Trail 153 Transporting Your Honda 154 Stor...

Page 161: ...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 162: ...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 This ATV is not design...

Page 163: ...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 164: ...wn 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 Rock the vehicle back and forth to make su...

Page 165: ...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 166: ...Refer to on page This procedure requires a means for draining and disposing of drained fuel page Fill the fuel tank Make sure the fuel fill cap is properly installed cont d Drain the carburetor into a...

Page 167: ...e spark plug Do not connect the spark plug to the spark plug cap Pour a tablespoon 15 20 cc of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth Reinstall the spar...

Page 168: ...lastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate Refer to on page Uncover and clean your ATV If your ATV has been stored for more than...

Page 169: ...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 170: ...o 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 page General Guidelines 162 If Your En...

Page 171: ...doesn t feel right If you continue riding you could cause more damage and endanger your own safety After stopping take time to assess the situation Carefully inspect your ATV to identify the problem...

Page 172: ...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 173: ...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 174: ...ion not in neutral Shift into neutral blown fuse Replace with a new fuse of the same rating page battery lead loose Tighten the battery lead low or dead battery Charge the battery page If charging doe...

Page 175: ...blubbers rich fuel mixture See your Honda dealer sooty exhaust rich fuel mixture See your Honda dealer If applicable switch to the recommended octane gasoline page or change your brand of gasoline If...

Page 176: ...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 If the leak is more serious or a temporary r...

Page 177: ...f the temporary repair fails you can crash and be seriously injured or killed If you must ride with a temporary tire repair ride slowly and carefully until the tire is permanently repaired or replaced...

Page 178: ...Taking Care of the Unexpected Safety Precautions Refer to on page Removal Park your ATV on a firm level surface Remove the wheel Remove the wheel nuts Raise the front or rear wheels off the ground an...

Page 179: ...tighten the wheel nuts on the wheel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque If a torque wrench was not used fo...

Page 180: ...excess current flow short circuit or overload Recommended Fuses If something electrical on your ATV stops working the first thing you should check for is a blown fuse Check the fuse before looking els...

Page 181: ...a Fuse Blows Taking Care of the Unexpected To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuse Remove the fuse case cover To access the fuse remo...

Page 182: ...e that has a higher rating greatly increases the chance of damage to the electrical system If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating...

Page 183: ...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...

Page 184: ...e If you lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer where you purchased your Honda ATV They may have it list...

Page 185: ...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 186: ...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 187: ...178 Taking Care of the Unexpected...

Page 188: ...sions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 180 Specifications 182 Break in Guidelines 185 High Altitude C...

Page 189: ...tion The VIN engine serial number and key number may be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN is stamp...

Page 190: ...Technical 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 191: ...ng 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 including reserve after d...

Page 192: ...U20FSR U DENSO U24FSR U DENSO rider and all accessories or or or chain or passenger capacity bore stroke maximum weight capacity displacement spark plug standard compression ratio primary reduction i...

Page 193: ...t 54 N m 5 5 kgf m 12V 3 4W 2 9 psi 20 0 kPa CHENG SHIN CHENG SHIN 7 5A caster trail tire size front tire pressure front rear cold tire size rear battery generator neutral indicator lamp main oil drai...

Page 194: ...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 195: ...ill also foul the spark plug and cause hard starting Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitud...

Page 196: ...cal Information The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Environment Canada EC require that your ATV comply with applicable exhaust emissions standards d...

Page 197: ...emical 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 hydro...

Page 198: ...mptoms have the vehicle inspected and repaired by your Honda ATV dealer Symptoms Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burning backfirin...

Page 199: ...E ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of...

Page 200: ...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 201: ...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 202: ...This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 194 Warranty Coverage 197 Warranty Service 198 Contacting Honda 199 Your Honda De...

Page 203: ...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...

Page 204: ...7 25 Handling Charge Grand Total 3 75 195 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 205: ...e 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 Discover...

Page 206: ...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 th...

Page 207: ...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 208: ...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 209: ...roducts Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the pa...

Page 210: ...Club USA only Consumer Information www hrca honda com You may be eligible for a Honda Rider s Club of America HRCA membership with the purchase of your new Honda You can log on to the HRCA Clubhouse w...

Page 211: ...Safety Information 2 Important Message to Parents 5 Safety Labels 9 Operation Component Locations 14 Indicator 17 Neutral Indicator 17 Controls Features 18 Fuel Valve 18 Choke Lever 19 Ignition Switc...

Page 212: ...tective 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 36 Load Limits Guidelines 38 Loading 38 Load Limits...

Page 213: ...or Rough Terrain 52 Do Not Perform Stunts 54 Ride Only When Visibility Is Good 54 Starting Stopping the Engine 55 Preparation 55 Starting Procedure 56 Flooded Engine 59 How to Stop the Engine 59 Shif...

Page 214: ...Importance of Maintenance 81 Maintenance Safety 83 Important Safety Precautions 84 Maintenance Schedule 85 Maintenance Record 89 Fuel 96 Engine oil 99 Air Cleaner 105 Maintenance Component Locations 9...

Page 215: ...52 What to Take to The Riding Area 152 What to Take on The Trail 153 Transporting Your Honda 154 Storing Your Honda 156 Preparation for Storage 157 Removal from Storage 159 You the Environment 160 Gen...

Page 216: ...QUICK REFERENCE Vehicle Identification 180 Specifications 182 Break in Guidelines 185 High Altitude Carburetor Adjustment 186 Emission Control Systems 187 Oxygenated Fuels 191 Authorized Manuals 194...

Page 217: ...ontacting 199 apparel protective 30 appearance care 147 authorized manuals 194 Battery 142 Brakes cables 123 draining water from 125 front brake lever 24 front brake lever freeplay 118 parking 26 rear...

Page 218: ...ppearance 147 choke lever 19 cleaning appearance care 149 climbing hills 69 clutch system 111 color label 181 compartment owner s manual 94 tool kit 93 component fails 177 consumer information 193 cra...

Page 219: ...E drive chain 134 emission control system 187 engine flooded 59 idle speed 112 number 180 oil 99 pinging 96 starting 55 stop switch 22 stopping 59 won t start 164 environment 160 exhaust system cleani...

Page 220: ...re 167 flooded engine 59 fuel fill cap 97 high altitude fuel mixture adjustment 186 oxygenated 191 recommendation 96 refueling 97 reserve fuel supply 97 tank capacity 97 valve 18 fuse 171 gap spark pl...

Page 221: ...74 riding down hills 73 riding up hills 69 stopping on hills 71 Honda contacting 199 Rider s Club 201 dealer 200 Honda service manual 194 identification vehicle 180 idle speed engine 112 ignition swi...

Page 222: ...limit weight 39 load limits 39 loading guidelines 39 lubrication engine oil 99 maintenance component location 90 importance 81 precautions 84 record 89 safety 83 schedule 85 manual service 194 maximu...

Page 223: ...plug spark 113 pre ride inspection 36 problems unexpected 161 protective apparel 30 neutral indicator 17 noise emission control systems 190 numbers serial 180 obstacles riding over 76 oil engine 99 o...

Page 224: ...c operations 43 clothing 30 precautions 45 preparing for 152 over obstacles 76 safety 2 safety precautions 45 through water 77 safety important precautions 84 labels 9 riding precautions 45 schedule m...

Page 225: ...ing 68 spark arrester 117 spark knock 96 spark plug 113 specifications 182 speed restrictor 45 stalling on a hill 71 start button 21 starting engine 55 troubleshooting 164 stop switch engine 22 stoppi...

Page 226: ...67 repairing 131 replacing 132 thread conditions 130 tool kit 93 training rider 32 transporting your ATV 154 trouble unexpected 161 troubleshooting starting 164 turning on level ground 66 on hills or...

Page 227: ...218 Index Index W warning labels 10 warranty coverage 197 extended 197 service 198 washing your ATV 148 water draining from brakes 125 riding through 77 weight limit 39 wheel removal 169...

Page 228: ...219 Memo...

Page 229: ...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 230: ...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 231: ...he following items each time before you ride page engine oil fuel tires drive chain nuts bolts underbody exhaust system air cleaner housing drain tube leaks loose parts cables throttle brakes switches...

Page 232: ...NSO CR6HSA NGK U20FSR U DENSO CR8HSA NGK U24FSR U DENSO 7 5A 2 9 psi 20 0 kPa 2 9 psi 20 0 kPa Front Rear or or or standard cold climate high speed riding Front Rear CHENG SHIN CHENG SHIN main Quick R...

Page 233: ...ick Reference These symbols are used in Controls Features section SYMBOL COMPONENT SEE PAGE 19 20 20 21 21 22 OFF engine stop switch RUN engine stop switch START button OFF ignition switch ON ignition...

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