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Honda 2010 FOURTRAX RANCHER, Owner'S Manual

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Honda 2010 FOURTRAX RANCHER Owner'S Manual Download Page 95

86

Servicing Your Honda

Servicing Your Honda

Service Procedures

Engine

Fluids & Filters

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Fuel

.

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Engine Oil & Filter

.

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Gear Case Oil

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Coolant

.

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Air Cleaner

.

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Throttle

.

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Clutch System

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Chassis

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Spark Arrester

.

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Valves

.

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Spark Plug

.

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Reverse Lock System

.

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Appearance Care

.

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Battery

.

Electrical

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Drivetrain Boots

.

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Guards

.

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Tires

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Brakes

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Suspension

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Differential Oil (Except

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102
105
114
116
118
124

130
132
133
134
137
138

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142
153
160
162

164

169

TRX420TE

０９／０５／１１ １４：５４：３１ ３１ＨＰ４８３０ ００９５ 

Summary of Contents for 2010 FOURTRAX RANCHER

Page 1: ...nent part of the ATV and should remain with the ATV when it is resold No part of this publication may be reproduced without written permission The vehicle pictured on the front cover may not match you...

Page 2: ...only It conforms to US EPA Noise Emission regulations but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations and operation on public streets r...

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: ...ive 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 t...

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: ...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 8: ...da an owner maintenance 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...

Page 9: ......

Page 10: ...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 11: ...important The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle Refer to the age warnings provided in this manual and on the ATV Your ATV is desi...

Page 12: ...off road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards Even if you have ridden ot...

Page 13: ...ke 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 So...

Page 14: ...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 15: ...6 Safety Labels ATV Safety...

Page 16: ...7 Safety Labels ATV Safety TRX420FPE TRX420TE TRX420FE...

Page 17: ...8 Safety Labels ATV Safety Except TRX420TE...

Page 18: ...he 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 cont d Operation Component Lo...

Page 19: ...itch Headlight Dimmer Switch Throttle Lever Gearshift Switch Reverse Selector Knob Front Brake Lever Rear Brake Pedal Parking Brake Flag Pole Bracket Trailer Hitch PS Electric Power Steering only Rear...

Page 20: ...ion switch throttle lever rear brake lever parking brake lever gearshift switches headlight switch headlight dimmer switch parking brake lock lever engine stop switch 2WD 4WD select lever Except TRX42...

Page 21: ...rear cargo rack rear brake pedal seat latch front cargo rack fuel valve 12 Instruments Controls Operation Component Locations...

Page 22: ...trailer hitch flag pole bracket 13 Instruments Controls Operation Component Locations...

Page 23: ...ys on your ATV keep you informed alert you to possible problems and make your riding safer and more enjoyable Refer to the indicators frequently Their functions are described on the following pages La...

Page 24: ...ould have your Honda dealer check for problems The displays are identified in the table on page with the words When the ignition switch is turned ON the multi function display will temporarily show al...

Page 25: ...w seconds and then go off when the ignition switch is turned ON If the indicator comes on at any other time reduce speed and take your vehicle to a Honda dealer as soon as possible PGM FI indicator Li...

Page 26: ...al for engine oil change is reached page Speedometer Shows riding speed Odometer Shows accumulated mileage page Tripmeter Shows mileage per trip page Hourmeter Shows hours and tenths of hours of engin...

Page 27: ...ndicator 1 5 4 speedometer 5 odometer tripmeter hourmeter 18 Multi function Display Indicators Displays Instruments Controls The multi function display includes the following functions 1 Gear position...

Page 28: ...icator when the transmission is not shifted into gear properly Before riding check that the gear position is properly displayed on the gear position indicator If the gear position indicator shows or b...

Page 29: ...hange To reset the indicator press and hold the hourmeter odometer tripmeter select button and turn the ignition switch to ON for more than 5 seconds The indicator message will disappear If the oil is...

Page 30: ...ion is ON To change the display from tripmeter or hourmeter to odometer press and release the hourmeter odometer tripmeter select button When selected the tripmeter shows mileage per trip while the ig...

Page 31: ...When selected the hourmeter shows accumulated hours while the ignition is ON The hourmeter provides accurate service period information for initial and regular maintenance To change the display from o...

Page 32: ...ontrols The fuel gauge shows the approximate fuel supply available At F Full the fuel tank capacity including reserve is When the gauge needle enters the red band fuel will be low and you should refil...

Page 33: ...g Reserve Fuel Remember to check that the fuel valve is in the ON position each time you refuel If the fuel valve is left in the RES position you may run out of fuel with no reserve For complete infor...

Page 34: ...N OFF ON OFF Key Position Function 25 Ignition Switch Instruments Controls Controls Features The ignition switch is used for starting and stopping the engine page Insert the key and turn it to the rig...

Page 35: ...er is located on the left side of the fuel tank To select the drive mode shift the 2WD 4WD select lever to the desired position Keep both hands on the handlebar while machine is in motion and come to...

Page 36: ...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 When the start button is...

Page 37: ...er 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 betw...

Page 38: ...ontrols 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 throttl...

Page 39: ...ntrols Features Instruments Controls Shifting Gears These switches are used to select the next higher or lower gear in the transmission To operate press the upshift switch to engage the next higher ge...

Page 40: ...rols 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...

Page 41: ...ATV To operate pull the lever For information on braking techniques see page The rear brake pedal is used to slow or stop your ATV To operate depress the pedal For information on braking techniques s...

Page 42: ...ying the parking brake When using the parking brake be sure to turn the ignition switch OFF to avoid discharging the battery The lock lever on the rear brake lever parking brake lever allows it to be...

Page 43: ...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 44: ...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 45: ...sist The steering will perform as a normal non PS system during this brief period After cooling down it will then return to normal PS operation The PS indicator should light when the ignition switch i...

Page 46: ...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 47: ...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 pro...

Page 48: ...Riding 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 h...

Page 49: ...e Guide 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 A...

Page 50: ...cause a crash and you or your passenger could be injured or killed Never carry a passenger on this ATV 41 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended a...

Page 51: ...ume alcohol or drugs before or while operating this ATV 42 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 52: ...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 53: ...ive wear page Check for damage pages Check for damage or looseness pages Check the wheels to see that the axle nuts are tightened Use a wrench to make sure all accessible nuts bolts and fasteners are...

Page 54: ...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 55: ...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 56: ...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 57: ...g 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 of added ac...

Page 58: ...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 59: ...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 60: ...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 61: ...52 Before Riding...

Page 62: ...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 63: ...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 64: ...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 65: ...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 66: ...e terrain visibility and other operating conditions and your experience 1 footpeg 1 57 Control Speed Basic Operation Riding Safe Riding Precautions Riding at excessive speed increases the chance of an...

Page 67: ...errain Always be alert to changing terrain conditions when operating the ATV 58 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Page 68: ...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 59 D...

Page 69: ...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 The engine...

Page 70: ...has a fuel injected engine with an automatic choke Follow the procedure indicated below Any Air Temperature Press the start button with the throttle completely closed The engine will not start if the...

Page 71: ...on 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 If the engine does not st...

Page 72: ...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 73: ...cator light is on then turn the ignition switch OFF To stop the engine in an emergency use the engine stop switch To operate slide the switch to either OFF position Emergency Engine Stop If your ATV i...

Page 74: ...With the transmission in neutral release the parking brake but continue squeezing the rear brake lever With the throttle closed press the upshift switch once to shift into 1st first gear cont d To up...

Page 75: ...ctric shift system malfunctions the transmission cannot be shifted by pressing the gearshift switches See your Honda dealer In an emergency a gear may be selected manually so you may move the vehicle...

Page 76: ...high Downshifting when engine speed is near its allowable maximum may over rev the engine and possibly cause damage To prevent transmission damage do not coast or tow the ATV for long distances with t...

Page 77: ...ear brake lever parking brake lever LEFT HANDLEBAR 68 Riding in Reverse Basic Operation Riding If you need to ride in reverse make sure the area behind you is clear and only operate the ATV at low spe...

Page 78: ...afe speed while riding in reverse gear The transmission cannot be shifted from neutral back into reverse when the engine speed is above 3 000 rpm or speed of your ATV is above 2 mph 3 km h To shift ou...

Page 79: ...se the brake controls steer straight ahead until you regain control then reapply the brakes more gently Gradually increase braking as you feel the brakes slowing your speed The increase in engine comp...

Page 80: ...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 81: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 72 Making Turns Riding Your ATV Basic Operation Riding Learn how to tur...

Page 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 fi...

Page 87: ...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 88: ...scribed in this owner s manual 79 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 89: ...ded 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 ridi...

Page 90: ...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 91: ...as described in this owner s manual 82 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 92: ...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 93: ...le 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 whi...

Page 94: ...e for required service and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking...

Page 95: ...Gear Case Oil Coolant Air Cleaner Throttle Clutch System Chassis Spark Arrester Valves Spark Plug Reverse Lock System Appearance Care Battery Electrical Drivetrain Boots Guards Tires Brakes Suspension...

Page 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...ng hours or 12 months R 1200 2000 12 200 I I C I I I I I NOTE NOTE 1 NOTE 2 NOTE 3 NOTE 2 REGULAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL INITIAL REGULAR MONTH HOURS MAINT INTERVAL MAINT 92 Main...

Page 102: ...KE SYSTEM REVERSE LOCK SYSTEM GUARDS CLUTCH SYSTEM SUSPENSION SPARK ARRESTER NUTS BOLTS FASTENERS WHEELS TIRES TIE ROD AND JOINT BOOTS STEERING SHAFT HOLDER BEARINGS STEERING SYSTEM FREQUENCY ITEMS WH...

Page 103: ...e whoever performs the maintenance completes this record All scheduled maintenance including the 100 mile 150 km or 1 month or 20 hours initial maintenance is considered a normal owner operating cost...

Page 104: ...rear brake lever parking brake lever front brake lever front brake fluid reservoir throttle lever fuel fill cap 95 Servicing Your Honda Maintenance Component Locations...

Page 105: ...t brake caliper air cleaner housing drain tube rear brakelight switch front suspension spring pre load adjuster Except TRX420TE differential oil filler cap Except TRX420TE differential oil drain bolt...

Page 106: ...e oil filler cap gear case oil drain bolt tool kit spark arrester rear suspension spring pre load adjuster Except TRX420TE owner s manual air pressure gauge gear change tool battery fuse box main fuse...

Page 107: ...Kit Servicing Your Honda The tool kit is stored in the storage compartment below the rear cargo rack To open the compartment unhook the rubber strap The gear change tool is stored underside of the se...

Page 108: ...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 Be careful not to flood this area wh...

Page 109: ...front prongs into the hooks on the frame and press the studs into the grommets The seat must be removed for the air cleaner engine oil engine oil filter clutch spark plug battery and fuse maintenance...

Page 110: ...nda 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 111: ...nock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer Use of lower octane gasoline can cause persistent pinging...

Page 112: ...fueling 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 113: ...bottom 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 Hon...

Page 114: ...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 115: ...da Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label Your ATV does not need oil additives Use the recommended oil Do not us...

Page 116: ...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 117: ...he engine oil level Refer to on page Check the engine oil level each day before operating your ATV and add if needed Unsnap and remove the left side cover Remove the seat page Start the engine in a we...

Page 118: ...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 119: ...ine oil filter specified for your model or a filter of equal quality With the ATV on the level ground remove the seat page left side cover page and the oil filler cap dipstick from the front crankcase...

Page 120: ...1 RIGHT SIDE 1 right side cover 111 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 2 100 1...

Page 121: ...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 122: ...with a new sealing washer and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Reinstall the oil filler cap dipstick Start the engine and let it idle...

Page 123: ...oil Honda shaft drive oil or equivalent 114 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 124: ...ler cap and the drain plug Install the oil filler cap and oil level check bolt Remove the oil level check bolt Make sure the oil level reaches the oil level check hole Fill the gear case with the reco...

Page 125: ...shaft drive oil or equivalent 116 Oil Recommendation Changing Oil Servicing Your Honda Differential Oil Except TRX420TE Safety Precautions Refer to on page Change the oil with the differential at norm...

Page 126: ...Remove the oil filler cap and the drain plug Install the oil filler cap Make sure the oil level is at the lower edge of the oil filler inspection hole Fill the differential with the recommended oil P...

Page 127: ...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 128: ...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 129: ...t level to the UPPER level mark Remove the seat page Unhook the rubber strap Remove the rear fender cover and reserve tank cap Always add coolant to the reserve tank Do not attempt to add coolant by r...

Page 130: ...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 131: ...ter 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 de...

Page 132: ...adiator grill plate 8 radiator core 123 Coolant Servicing Your Honda Remove the radiator grill plate Wash the radiator core and radiator grill plate Install the removed parts in reverse order of remov...

Page 133: ...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 134: ...NDER SEAT 1 retainer clips 2 air cleaner housing cover 125 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 2...

Page 135: ...tear the foam Inspect for 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...

Page 136: ...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 137: ...1 dust cover 1 2 UNDER SEAT 2 breather joint 128 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 138: ...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 139: ...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 140: ...y open to fully closed in all steering positions If there is a problem see your Honda dealer Inspect the condition of the throttle cable from the throttle lever down to the throttle body If the cable...

Page 141: ...n discs may be worn See your Honda dealer or refer to official Honda Service Manual page Turn the clutch adjuster counterclockwise until you feel slight resistance Turn the adjuster 1 4 turn clockwise...

Page 142: ...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 143: ...on Replacement 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 h...

Page 144: ...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 145: ...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 146: ...those who are mechanically proficient and have the proper tools instructions on adjusting valve clearances are given in the official Honda Service Manual Otherwise the valves should be adjusted by you...

Page 147: ...ocess in your engine from reaching the environment The use of safety glasses is recommended for this procedure Because of the possible fire hazard check that there are no combustible materials in the...

Page 148: ...d whenever you change your normal load by adding or subtracting cargo accessories or when riding conditions change The spring pre loads for your front and rear suspension systems adjust the amount of...

Page 149: ...spanner 140 Suspension Spring Pre Load Except TRX420TE Servicing Your Honda Suspension Safety Precautions Refer to on page The spring pre load adjuster has 5 positions for different load or riding co...

Page 150: ...o 5 for when the ATV is more heavily loaded Also increase spring pre load for stiffer suspension Make sure that both shock absorbers are adjusted to the same position Always adjust the shock absorber...

Page 151: ...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 152: ...ve your Honda dealer add the recommended fluid Do not add or replace brake fluid except in an emergency If you do add fluid have your Honda dealer check the system as soon as possible Wipe up spills i...

Page 153: ...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 inspected for leaks Check for deteriorat...

Page 154: ...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 Check the wear indicator If the...

Page 155: ...T SIDE 146 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 156: ...djust the freeplay of the rear brake pedal Push the brake arm then check the clearance between the brake arm and the brake arm pin Turn the brake pedal adjusting nut located on the brake operating rod...

Page 157: ...lever 148 Rear Brake Lever Freeplay Brakes Servicing Your Honda Inspection Measure the distance the rear brake lever parking brake lever moves before the brake starts to take hold Freeplay measurement...

Page 158: ...ith the front wheels pointed straight ahead Turn the brake lever 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...

Page 159: ...ontrol and check the movement of the arrow on the brake arm Refer to on page The rear brake is equipped with an external brake wear indicator that lets you check brake wear without disassembly Applica...

Page 160: ...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 161: ...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 162: ...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 163: ...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 164: ...e when your tires are cold If you check air pressure when your tires are warm even if your ATV has only been ridden for a few miles the readings will be higher If you let air out of warm tires to matc...

Page 165: ...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 166: ...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 167: ...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 168: ...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 169: ...d protects 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...

Page 170: ...eshaft Guards Except TRX420TE Guards Servicing Your Honda Safety Precautions Check the front boot guards and front driveshaft guards for cracks damage or looseness Tighten any loose fasteners Replace...

Page 171: ...boot 162 Propeller Shaft Boots Yoke Joint Boot Drivetrain Boots Servicing Your Honda Safety Precautions Refer to on page Check the rubber propeller shaft boots and rubber yoke joint boot for damage or...

Page 172: ...ront Driveshaft Boots Except TRX420TE Drivetrain Boots Servicing Your Honda Safety Precautions Refer to on page Check the rubber driveshaft boots for cuts damage or leaking grease If necessary have yo...

Page 173: ...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 174: ...Battery 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...

Page 175: ...emoval Make sure the ignition switch is OFF Remove the seat page Remove the rear fender cover page Release the rings and remove the rubber band Disconnect the negative terminal lead from the battery f...

Page 176: ...llowing section once every 30 days Installation Remove the battery Clean the compartment after removing the battery for storage Dry the compartment and if paint is missing re paint the area Make sure...

Page 177: ...recommend using a charger designed specifically for your Honda which can be purchased from your Honda dealer These units can be left connected for long periods without risking damage to the battery Ho...

Page 178: ...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 179: ...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 180: ...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 181: ...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 182: ...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 183: ...Bureau of Land Management 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 supplies in case you have a prob...

Page 184: ...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 185: ...port your ATV we recommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking gas...

Page 186: ...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 Using tie down straps in any other areas c...

Page 187: ...problem before storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again We suggest you perform the following procedures to keep your ATV in top condit...

Page 188: ...n the cylinder perform the following Check that the fuel 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 tab...

Page 189: ...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 190: ...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 191: ...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 192: ...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 the Shift Switches Do Not Function Emergen...

Page 193: ...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 194: ...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 195: ...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 196: ...al Shift into neutral engine stop switch OFF SYMPTOM POSSIBLE CAUSE WHAT TO DO out of fuel Fill the fuel tank flooded engine See page loose or unconnected spark plug cap Install the spark plug cap sec...

Page 197: ...asoline page or change your brand of gasoline If the problem persists see your Honda dealer afterfires backfires See your Honda dealer pre ignition runs on after ignition switched OFF See your Honda d...

Page 198: ...position Turn the ignition switch to the ON position Press both shift switches and check that they are functioning If both switches are functioning shift into neutral and restart the engine If one or...

Page 199: ...ral indicator If the transmission is in neutral go to step 5 If the transmission is not in neutral remove the left side cover page use the gear change tool to shift to neutral so you will be able to s...

Page 200: ...e tool counterclockwise To upshift turn the tool clockwise If the transmission does not shift rock the vehicle back and forth and try again Return the gear change tool to underside of the seat Do not...

Page 201: ...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 202: ...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 203: ...face Removal Avoid getting grease oil or dirt on the front brake disc or pad surfaces when removing and installing each wheel Any contamination can cause poor brake performance or rapid pad wear after...

Page 204: ...ce the wheel rim Hand 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 w...

Page 205: ...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 206: ...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 207: ...ess 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 for anoth...

Page 208: ...Main Fuse Access To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuses Remove the seat page To access the main fuse and shift motor fuse remove the...

Page 209: ...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 210: ...teering Fuse Access Turn the ignition switch OFF before checking the fuse Remove the seat page Install the seat Install the PS fuse box cover To access the PS fuse remove the PS fuse box cover If the...

Page 211: ...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 212: ...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 213: ...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 214: ...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 215: ...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 216: ...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 217: ...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 218: ...echnical Information The color code is helpful when ordering replacement parts You may record the color and code in the Quick Reference section at the rear of this manual The color label is attached t...

Page 219: ...unleaded gasoline pump octane number of 86 or higher 6 5 in 165 mm 45 1 in 1 146 mm 45 2 in 1 148 mm 49 2 in 1 249 mm 49 4 in 1 256 mm including reserve after disassembly after draining after draining...

Page 220: ...minum engines 1 400 100 rpm 0 039 0 043 in 1 00 1 10 mm 0 009 in 0 23 mm 1 6 US qt 1 5 0 006 in 0 15 mm 485 lb 220 kg K16PR U11 DENSO or intake exhaust NO ADJUSTMENT displacement bore stroke compressi...

Page 221: ...5 0 kPa front rear TRX420TE TRX420FE TRX420FPE TRX420TE TRX420FE front rear 1st 2nd 3rd 4th 5th reverse Except TRX420TE TRX420FPE TRX420TE TRX420FE TRX420FPE primary reduction secondary reduction fina...

Page 222: ...PE only Except TRX420TE generator battery headlight reverse indicator neutral indicator brake tail light high coolant temperature indicator PGM FI indicator 4WD indicator PS Electric Power Steering ot...

Page 223: ...1 0 kgf m 18 lbf ft 25 N m 2 5 kgf m 47 lbf ft 64 N m 6 5 kgf m engine oil drain bolt engine oil filter cover bolts rear final gear case oil drain bolt differential oil drain bolt wheel nuts Except TR...

Page 224: ...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 225: ...he U S Environmental Protection Agency EPA and the California Air Resources Board CARB require that your ATV comply with applicable exhaust emissions standards during its useful life when operated and...

Page 226: ...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 227: ...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 228: ...SUMED 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 any part...

Page 229: ...ns cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and...

Page 230: ...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 231: ...222 Technical Information...

Page 232: ...ation 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 Ho...

Page 233: ...y your authorized Honda dealer is available from Helm Inc Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service...

Page 234: ...s Sales Tax Mich add 6 Calif add 8 25 Handling Charge Grand Total 3 75 225 Consumer Information Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR NOTE For Credit Card Orders Only 1 888 29...

Page 235: ...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 236: ...overed 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 u...

Page 237: ...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 238: ...d and operated That s why it s important to work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comm...

Page 239: ...d Honda Genuine Accessories 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 fro...

Page 240: ...rmation The Honda Rider s Club 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 websi...

Page 241: ...29 air pressure gauge 99 tire 154 American Honda contacting 229 apparel protective 38 appearance care 169 authorized manuals 224 bank angle sensor ignition cut off system 62 battery 164 brakelight swi...

Page 242: ...er select 14 17 20 21 22 capacity fuel 103 care appearance 169 cargo loading and operational guidelines 49 weight limit 48 cleaning appearance care 169 climbing hills 75 clip 101 clutch system 132 col...

Page 243: ...09 display check 15 display multi function 18 drivetrain boots 162 electric power steering PS 36 emission control systems 216 engine flooded 62 guard 160 number 208 oil 105 pinging 102 starting 60 sto...

Page 244: ...front driveshaft boots Except TRX420TE 163 front driveshaft guards Except TRX420TE 161 fuel fill cap 103 gauge 23 oxygenated 220 recommendation 102 refueling 103 reserve fuel supply 103 tank capacity...

Page 245: ...tch 28 hills crossing or turning on slopes 80 riding down hills 79 riding up hills 75 stopping on hills 77 Honda contacting 229 dealer 230 Rider s Club 231 hourmeter 17 18 22 hourmeter odometer tripme...

Page 246: ...indicator 17 18 19 high coolant temperature indicator 14 16 196 neutral indicator 14 16 oil change indicator 17 18 20 PGM FI indicator 14 16 PS Electric Power Steering indicator 14 16 36 reverse indi...

Page 247: ...ety 5 lamp check 14 lever 2WD 4WD select Except TRX420TE 26 limit weight 48 load limits 48 loading guidelines 49 lubrication differential oil Except TRX420TE 116 engine oil 105 gear case oil 114 key l...

Page 248: ...239 Index Index M maintenance component locations 95 importance 87 precautions 89 record 94 safety 88 schedule 90 manual service 224 maximum weight limit 48 modifications 51 multi function display 18...

Page 249: ...16 noise emission control system 219 numbers serial 208 obstacles riding over 82 odometer 17 18 21 oil differential Except TRX420TE 116 engine 105 gear case 114 operation component locations 11 owner...

Page 250: ...tion 43 problems unexpected 183 propeller shaft boots yoke joint boot 162 protective apparel 38 PS Electric Power Steering TRX420FPE only 36 rear final gear case oil 114 removal seat 100 reverse assis...

Page 251: ...for 174 over obstacles 82 safety 2 safety precautions 55 through water 83 safety important precautions 89 labels 5 riding precautions 55 schedule maintenance 90 seat removal 100 select lever 2WD 4WD E...

Page 252: ...eedometer 17 18 stalling on a hill 77 start button 27 starting engine 60 troubleshooting 186 stop switch engine 27 stopping engine 64 storage ATV 178 owner s manual 99 suspension adjustment Except TRX...

Page 253: ...159 repairing 158 thread conditions 156 157 tool kit 98 trailer hitch 35 trailer towing operational guidelines 49 weight limits 48 training rider 40 transporting your ATV 176 tripmeter 17 18 21 troub...

Page 254: ...el 24 valve clearance 137 vehicle identification no VIN 208 warning labels 5 warranty coverage 227 extended 227 service 228 washing your ATV 170 water draining from brakes 152 riding through 83 weight...

Page 255: ...246 Memo...

Page 256: ...247 Memo...

Page 257: ...248 Memo...

Page 258: ...249 Memo...

Page 259: ...250 Memo...

Page 260: ...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 261: ...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 262: ...guards nuts bolts underbody exhaust system air cleaner housing drain tube leaks loose parts cables lights throttle brakes reverse assist lever switches steering Maximum Weight Capacity Engine Oil Fuel...

Page 263: ...main shift motor other PS Electric Power Steering TRX420FPE only Front Rear TRX420TE TRX420FPE TRX420FE MAXXIS M977 MAXXIS M978 Quick Reference Quick Reference Tires Tire Pressure cold Fuses Coolant...

Page 264: ...switch OFF ignition switch 2WD 4WD select lever 4WD indicator lights when the 4WD drive mode engages START button RUN engine stop switch OFF engine stop switch ON headlight switch OFF headlight switch...

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