Honda 2012 FOURTRAX RANCHER Owner'S Manual Download Page 94

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Servicing Your Honda

Service Procedures

Engine

Fluids & Filters

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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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Reverse Lock System

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Spark Plug

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Valves

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Spark Arrester

Chassis

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Fuel

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Engine Oil & Filter

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Differential Oil (Except

)

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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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Appearance Care

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Battery

Electrical

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Suspension

TRX420TM

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105
114
117
119
125

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133
134
135
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Summary of Contents for 2012 FOURTRAX RANCHER

Page 1: ...y 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 road...

Page 2: ...hecks detailed in this manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual...

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

Page 4: ...important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potent...

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

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

Page 7: ...da an owner maintenance schedule and instructions for specific maintenance and adjustment items What to do if you have a flat tire your engine won t start etc ID numbers technical specifications and o...

Page 8: ......

Page 9: ...ost important information and recommendations to help you ride your ATV safely Please take a few moments to read these pages This section also includes information about the location of safety labels...

Page 10: ...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 11: ...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 12: ...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 13: ...of the vehicle If a label comes off or becomes hard to read contact your dealer for replacements Your ATV comes with a hang tag and several labels containing important safety information Anyone who r...

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

Page 15: ...7 Safety Labels ATV Safety TRX420TM TRX420FM TRX420FPM...

Page 16: ...8 Safety Labels ATV Safety Except TRX420TM...

Page 17: ...Brake Rear Brake Pedal Front Brake Lever Reverse Selector Knob Throttle Lever Headlight Dimmer Switch Headlight Switch Engine Stop Switch Start Button Ignition Switch Fuel Valve Indicators Displays F...

Page 18: ...tton ignition switch throttle lever headlight switch parking brake lock lever rear brake lever parking brake lever headlight dimmer switch engine stop switch 2WD 4WD select lever Except TRX420TM 10 Op...

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

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

Page 21: ...er Steering indicator TRX420FPM only 4 4WD indicator Except TRX420TM 5 high coolant temperature indicator TRX420TM FM 6 8 TRX420FPM 13 Instruments Controls Indicators Displays The indicators and displ...

Page 22: ...ON and remains on until you shift out of 4WD mode The PS Electric Power Steering indicator comes on when you turn the ignition switch ON so you can check that it is working The indicator remains on un...

Page 23: ...tion display will temporarily show all the modes and digital segments so you can make sure the liquid crystal display is functioning properly The displays are identified in the table on page with the...

Page 24: ...rature indicator Lights when coolant temperature is high enough to adversely affect the service life of the engine If the high coolant temperature indicator comes on while you are riding immediately b...

Page 25: ...e interval for engine oil change is reached page Speedometer Shows riding speed Odometer Shows accumulated mileage page Shows mileage per trip page Tripmeter Hourmeter Shows hours and tenths of hours...

Page 26: ...ator 4 speedometer 5 odometer tripmeter hourmeter 18 Multi function Display TRX420FPM only Indicators Displays Instruments Controls The multi function display includes the following functions 1 Gear p...

Page 27: ...sition indicator 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...

Page 28: ...h oil change 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...

Page 29: ...is ON To change the display from odometer or hourmeter to tripmeter press and release the hourmeter odometer tripmeter select button To reset the tripmeter to zero press the hourmeter odometer tripmet...

Page 30: ...ntrols 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...

Page 31: ...ontrols When the gauge needle enters the red band fuel will be low and you should refill the tank as soon as possible The amount of fuel left in the tank when the needle enters the red band is approxi...

Page 32: ...you refuel If the fuel valve is left in the RES position you may run out of fuel with no reserve Reserve Fuel RES for extra fuel to get to a gas supply for refueling OFF for parking storing or transp...

Page 33: ...LEBAR Key Position Function 25 Ignition Switch Controls Features Instruments Controls The ignition switch is used for starting and stopping the engine page Insert the key and turn it to the right for...

Page 34: ...handlebar while machine is in motion and come to a complete stop before using the 2WD 4WD select lever The 2WD 4WD select lever is located on the left side of the fuel tank To select the drive mode s...

Page 35: ...starter motor will not operate if the engine stop switch is in the OFF position when the start button is pushed The engine stop switch is used to stop the engine in an emergency To operate slide the s...

Page 36: ...mer Switch Controls Features Instruments Controls The headlight switch is used to turn the headlight ON or OFF To operate turn the switch to ON or OFF The headlight dimmer switch is used to change bet...

Page 37: ...ures Instruments Controls The throttle controls engine rpm speed To increase engine rpm press the throttle lever with your thumb To reduce engine rpm release pressure on the throttle lever The throttl...

Page 38: ...ctor 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 sure the neutral indicator lights make...

Page 39: ...ATV To operate pull the lever For information on braking techniques see page The rear brake lever parking brake lever is used to slow or stop your ATV To operate pull the lever For information on bra...

Page 40: ...parking brake lever allows it to be used as a parking brake To operate first squeeze the rear brake lever parking brake lever using your left hand and then lock it with the lock lever using your righ...

Page 41: ...Features Instruments Controls Flag poles are optional equipment available from your dealer To mount a pole in the bracket follow the instructions that come with the flag pole kit Flag poles are requir...

Page 42: ...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 43: ...assist 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 switc...

Page 44: ...36 Instruments Controls...

Page 45: ...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 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...our 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...

Page 52: ...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 53: ...re 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 steering...

Page 54: ...heck 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 backl...

Page 55: ...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 56: ...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 57: ...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 58: ...y 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 59: ...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 60: ...52 Before Riding...

Page 61: ...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 62: ...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 63: ...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 64: ...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 65: ...hicle the terrain visibility and other operating conditions and your experience 57 Control Speed Basic Operation Riding Safe Riding Precautions Riding at excessive speed increases the chance of a cras...

Page 66: ...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 67: ...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 68: ...operating the engine in an enclosed area such as a garage Your ATV s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Before star...

Page 69: ...ow the procedure indicated below Any Air Temperature The engine will not start if the throttle is fully open because the electronic control module cuts off the fuel supply Press the start button with...

Page 70: ...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 Your vehicle s banking le...

Page 71: ...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 72: ...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 73: ...e The shift lever automatically returns to the horizontal position when released To upshift to a higher gear put the toe of your boot under the shift lever and raise it one full stroke To downshift st...

Page 74: ...ving in a straight line Close the throttle completely before shifting Improper shifting may damage the engine transmission and drivetrain Upshift to a higher gear or reduce throttle before engine rpm...

Page 75: ...or knob 2 rear brake lever parking brake lever 67 Basic Operation Riding Riding in Reverse cont d If you need to ride in reverse make sure the area behind you is clear and only operate the ATV at low...

Page 76: ...ATV may be equipped with a reverse speed limiter which helps the vehicle to maintain a safe speed while riding in reverse gear To shift out of reverse and into neutral raise the shift lever one strok...

Page 77: ...uickly while turning Either action may cause one or more wheels to slip and reduce your control of your ATV Applying the brakes too hard may cause the wheels to lock and slide reducing control of your...

Page 78: ...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 79: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 71 Making Turns Basic Operation Riding Riding Your ATV Learn how to tur...

Page 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...scribed in this owner s manual 78 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 87: ...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 88: ...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 89: ...as described in this owner s manual 81 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 90: ...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 91: ...e 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 whil...

Page 92: ...84 Basic Operation Riding...

Page 93: ...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 94: ...ir Cleaner Throttle Clutch System Reverse Lock System Spark Plug Valves Spark Arrester Chassis Fuel Engine Oil Filter Differential Oil Except Drivetrain Boots Guards Tires Brakes Appearance Care Batte...

Page 95: ...p reduce air pollution Careful pre ride inspections and good maintenance are especially important because your ATV is designed to be ridden over rough off road terrain To help you properly care for yo...

Page 96: ...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 97: ...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 98: ...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 99: ...ay require more technical information and tools Consult your dealer In the interest of safety we recommend these items be serviced only by your dealer Service more frequently when riding in dusty area...

Page 100: ...PARK PLUG VALVE CLEARANCE ENGINE OIL ENGINE OIL FILTER ENGINE IDLE SPEED RADIATOR COOLANT COOLING SYSTEM REGULAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL INITIAL REGULAR MONTH HOURS MAINT INTERVA...

Page 101: ...PARK ARRESTER NUTS BOLTS FASTENERS WHEELS TIRES TIE ROD AND JOINT BOOTS STEERING SHAFT HOLDER BEARINGS STEERING SYSTEM Refer to page 163 114 117 114 143 151 146 152 143 134 161 133 140 139 154 FREQUEN...

Page 102: ...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 103: ...front brake fluid reservoir fuel fill cap front brake lever throttle lever rear brake lever parking brake lever 95 Servicing Your Honda Maintenance Component Locations...

Page 104: ...cleaner housing drain tube front brake caliper front suspension spring pre load adjuster Except TRX420TM differential oil fill cap Except TRX420TM differential oil drain bolt Except TRX420TM rear bra...

Page 105: ...ry fuse box main fuse gear case oil drain bolt rear suspension spring pre load adjuster Except TRX420TM engine oil fill cap dipstick gear case oil fill cap PS fuse TRX420FPM only owner s manual air pr...

Page 106: ...trap 98 Tool Kit Servicing Your Honda To open the compartment unhook the rubber strap The tool kit is stored in the storage compartment below the rear cargo rack An optional larger tool kit may be ava...

Page 107: ...V provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual in the plastic document bag underside of the seat The owner s manual and air pressure...

Page 108: ...nsert the front prongs into the hooks on the frame and press the studs into the grommets Pull the seat latch at the rear of the seat The seat must be removed for the air cleaner engine oil engine oil...

Page 109: ...l Servicing Your Honda Removal Installation Pull up the center pin to release the lock Pull out the clip of the hole Insert the clip into the hole Press down the center pin securely to lock the clip 1...

Page 110: ...rmally display the 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 sev...

Page 111: ...fueling Procedure Servicing Your Honda Fuel Safety Precautions Fuel tank capacity including reserve Reserve capacity Refer to on page The tank should be refilled as soon as possible after switching to...

Page 112: ...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 113: ...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 114: ...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 115: ...when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two cl...

Page 116: ...your ATV and add if needed Unsnap and remove the left side cover Remove the seat page Start the engine in a well ventilated area and let it idle for 3 5 minutes If the air temperature is below 10 C 5...

Page 117: ...tick and check the oil level The oil level should be between the upper level mark and the lower level mark on the oil fill cap dipstick Remove the oil fill cap dipstick from the front crankcase and wi...

Page 118: ...lter specified for your model or a filter of equal quality This procedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid...

Page 119: ...ter Servicing Your Honda Install a New Engine Oil Filter cont d Unsnap and remove the right side cover Remove the seat page Place shop towels under the oil filter cover because oil will flow out Place...

Page 120: ...ner page Apply engine oil to a new O rings and install them to the oil filter cover Then install a new oil filter Use only the Honda Genuine oil filter or a filter of equivalent quality specified for...

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

Page 122: ...Honda shaft drive oil or equivalent type 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 123: ...ove the skid plate bolts and the skid plate Place an oil drain pan under the oil drain bolt Remove the oil fill cap and the drain bolt cont d After the oil has completely drained reinstall the drain b...

Page 124: ...e gear case with the recommended oil until oil start to flow out of the oil level check hole Allow oil to settle for 2 3 minutes before moving to next step to prevent overfilling Install the skid plat...

Page 125: ...shaft drive oil or equivalent 117 Oil Recommendation Changing Oil Differential Oil Except TRX420TM Servicing Your Honda Safety Precautions Refer to on page Change the oil with the differential at norm...

Page 126: ...l drain pan under the oil drain bolt Remove the oil fill cap and the drain bolt After the oil has completely drained reinstall the drain bolt with the new sealing washer and tighten it to the specifie...

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: ...d to provide 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 a...

Page 129: ...parts in the reverse order of removal Disengage the pins from the grommets Slide the rear fender cover forward to disengage the tabs Add coolant to the reserve tank as required to bring the coolant l...

Page 130: ...Replacement Coolant Servicing Your Honda 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 de...

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 dealer i...

Page 132: ...tor grill plate 8 radiator core 7 8 124 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: ...ner 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 dealer can help you determine the cor...

Page 134: ...DER SEAT 2 1 retainer clips 2 air cleaner housing cover 1 126 Cleaning Air Cleaner Servicing Your Honda Remove the seat page Unlatch the retainer clips Remove the air cleaner housing cover 1 2 3 1 100...

Page 135: ...r 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 wi...

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 2 UNDER SEAT 1 dust cover 2 breather joint 129 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: ...ully open to fully closed in all steering positions If there is a problem see your dealer Inspect the condition of the throttle cable from the throttle lever down to the throttle body If the cable is...

Page 141: ...tion discs may be worn See your dealer or refer to official Honda Service Manual page Make sure the ignition switch is OFF Remove the seat page and left side cover page Loosen the lock nut Turn the cl...

Page 142: ...cks 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 dealer Refer to on page Return the dust cover and rubber slee...

Page 143: ...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 heat...

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: ...or 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...

Page 147: ...ed for this procedure Because of the possible fire hazard check that there are no combustible materials in the area before purging the spark arrester The spark arrester must be serviced every 100 oper...

Page 148: ...ide you want to experience can also influence your suspension needs Lower spring pre load provides a softer ride and is usually preferred for light loads and smooth terrain Higher spring pre load prov...

Page 149: ...spanner 141 Suspension Spring Pre Load Except TRX420TM Suspension Servicing Your Honda Safety Precautions Refer to on page The spring pre load adjuster has 5 positions for different load or riding co...

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

Page 151: ...right 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 the...

Page 152: ...in an upright position check the fluid level If your inspection indicates a low fluid level have your dealer add the recommended fluid Do not add or replace brake fluid except in an emergency If you d...

Page 153: ...ake pads should be replaced If the pads are not worn have your brake system inspected for leaks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings If the ho...

Page 154: ...f usage and riding conditions The pads will wear faster in wet or muddy conditions Inspect the pads visually during all regular service intervals to determine the pad wear Always inspect both pads in...

Page 155: ...T SIDE 147 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: ...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 157: ...lever 149 Rear Brake Lever Freeplay Brakes Servicing Your Honda If necessary adjust to the specified range Inspection Measure the distance the rear brake lever parking brake lever moves before the bra...

Page 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: ...rol and check the movement of the arrow on the brake arm The rear brake is equipped with an external brake wear indicator that lets you check brake wear without disassembly Application of the brake co...

Page 160: ...da Safety Precautions Refer to on page Rear Brake Only Check the operation of the rear brake light switch at the right side behind the engine from time to time Adjustment is done by turning the adjust...

Page 161: ...recautions 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 the brake seals must b...

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: ...on 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 repa...

Page 168: ...V were designed to match the performance capabilities of your ATV and provide the best combination of handling braking and comfort It is best to replace all four tires however if that is not possible...

Page 169: ...protects the rear final gear case Check the guard and plate for cracks damage or looseness at intervals shown in the Maintenance Schedule The engine guard protects the frame and engine crankcase Have...

Page 170: ...eshaft Guards Except TRX420TM 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: ...nt boot 163 Propeller Shaft Boots Yoke Joint Boot Drivetrain Boots Servicing Your Honda Safety Precautions Check the rubber propeller shaft boots and rubber yoke joint boot for damage or leaking greas...

Page 172: ...164 Front Driveshaft Boots Except Drivetrain Boots Servicing Your Honda TRX420TM Safety Precautions Refer to on page Check the rubber driveshaft boots for cuts damage or leaking grease If necessary h...

Page 173: ...en 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 fre...

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: ...sure the ignition switch is OFF Removal Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Release the rings and remove the rubber band Remove the...

Page 176: ...moving the battery for storage Dry the compartment and if paint is missing re paint the area Slow charge the battery see following section once every 30 days Installation Check that the battery band f...

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

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: ...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 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: ...ade specifically for motorcycles or automobiles Apply the polish or wax according to the instructions on the container The exhaust pipe and muffler are stainless steel but may become stained by mud or...

Page 182: ...174 Servicing Your Honda...

Page 183: ...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 184: ...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 185: ...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 186: ...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 187: ...down straps in the areas shown Using tie down straps in any other areas can damage your ATV Suitable tie down straps are available from your dealer Ordinary rope is not recommended because it can str...

Page 188: ...any 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 con...

Page 189: ...valve is OFF Remove the spark plug cap from the spark plug Remove the spark plug Do not connect the spark plug to the spark plug cap Pour a tablespoon 15 20 cc of clean engine oil into the cylinder an...

Page 190: ...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 191: ...V has been stored for more than two months ask your 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 In...

Page 192: ...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 193: ...practical advice to help you deal with a wide range of problems Take time to read this section before you ride Also review the tips in page General Guidelines If Your Engine Quits or Won t Start If th...

Page 194: ...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 195: ...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 196: ...any 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 c...

Page 197: ...CAUSE WHAT TO DO SYMPTOM If all possible causes are negative the starter motor may be faulty See your dealer faulty starter motor low or dead battery Charge the battery page If charging doesn t help s...

Page 198: ...e gasoline page or change your brand of gasoline If the problem persists see your dealer afterfires backfires See your dealer pre ignition runs on after ignition switched OFF See your dealer SYMPTOM p...

Page 199: ...ake a temporary repair As soon as possible have the tire permanently repaired by your dealer Any tire that cannot be repaired should be replaced Whenever the ATV is to be operated far from service fac...

Page 200: ...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 201: ...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 202: ...face 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 torqu...

Page 203: ...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 204: ...for 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 ridi...

Page 205: ...t 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 another possibl...

Page 206: ...cted Main Fuse Access Pull the main fuse out If it is blown install the spare main fuse To access the main fuse remove the fuse box cover Remove the seat page To prevent an accidental short circuit tu...

Page 207: ...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 208: ...Access Turn the ignition switch OFF before checking the fuse Remove the seat page Install the PS fuse box cover To access the PS fuse remove the PS fuse box cover If the PS fuse is blown see your deal...

Page 209: ...can do without temporarily If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses t...

Page 210: ...ely 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 th...

Page 211: ...made If you lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer where you purchased your Honda ATV They may have it l...

Page 212: ...ded 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 recommend...

Page 213: ...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 214: ...206 Taking Care of the Unexpected...

Page 215: ...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 216: ...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 217: ...echnical Information The color label is attached to the frame under the seat Remove the seat page to check the label The color code is helpful when ordering replacement parts You may record the color...

Page 218: ...ergy conserving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 stroke oil or an equivalent motorcycle oil including reserve after disassembly after draining TRX420...

Page 219: ...71 5 mm BKR5E 11 NGK 1 400 100 rpm 9 9 1 0 009 in 0 23 mm 0 006 in 0 15 mm 0 039 0 043 in 1 00 1 10 mm K16PR U11 DENSO 485 lb 220 kg or intake exhaust cooling system recommendation cooling system cap...

Page 220: ...5 0 kPa Except TRX420TM TRX420TM TRX420FM TRX420FPM TRX420TM TRX420FM TRX420FPM TRX420TM TRX420FM TRX420FPM front rear caster final drive final reduction secondary reduction primary reduction reverse...

Page 221: ...PM TRX420TM TRX420FM TRX420FPM TRX420TM TRX420FM TRX420FPM TRX420TM TRX420FM TRX420FPM TRX420FPM TRX420FM YTX14 BS Except TRX420TM battery generator PS Electric Power Steering indicator 4WD indicator...

Page 222: ...kgf m 9 lbf ft 12 N m 1 2 kgf m TRX420FPM only main other engine oil drain bolt engine oil filter cover bolts rear final gear case oil drain bolt PS Electric Power Steering wheel nuts differential oi...

Page 223: ...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 224: ...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 225: ...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 226: ...gh 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 element...

Page 227: ...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 228: ...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 229: ...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 230: ...222 Technical Information...

Page 231: ...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 232: ...e from your Honda dealer or 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 information for vari...

Page 233: ...r you should have the proper tools and service information and be mechanically qualified Failures that occur due directly to improper maintenance are not covered TRX Limited Warranty Emission Control...

Page 234: ...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 235: ...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 236: ...nform you about competition and other riding events in your area You ll also find that your dealer is a source of information about the Honda Rider s Club of America The parts department offers Honda...

Page 237: ...Honda Rider s Club www hrca honda com The Honda Rider s Club of America HRCA sponsors local riding chapters at Authorized Honda Dealerships across the country You can log on to the HRCA Clubhouse web...

Page 238: ...essories 50 age recommendation 41 air cleaner dust cover 129 filter 125 housing drain tube 130 air pressure gauge 99 tire 155 American Honda contacting 227 apparel protective 38 appearance care 170 au...

Page 239: ...52 brakes cables 151 draining water from 153 fluid 143 front brake lever 31 pad wear 146 parking 32 rear brake lever 31 rear brake lever freeplay 149 rear brake pedal 31 rear brake pedal freeplay 147...

Page 240: ...49 weight limit 48 cleaning appearance care 170 climbing hills 74 clip 101 clutch system 133 color label 209 compartment owner s manual 99 tool kit 98 component fails 205 consumer information 223 cont...

Page 241: ...09 display check 15 display multi function 18 drivetrain boots 163 electric power steering PS 35 emission control systems 216 engine flooded 62 guard 161 number 208 oil 105 pinging 102 starting 60 sto...

Page 242: ...20TM 162 front driveshaft boots Except TRX420TM 164 front driveshaft guards Except TRX420TM 162 fuel fill cap 103 gauge 23 oxygenated 220 recommendation 102 refueling 103 reserve fuel supply 103 tank...

Page 243: ...17 18 22 hourmeter odometer tripmeter select button 13 17 20 21 22 Honda service manual 224 identification vehicle 208 ignition switch 25 indicators gear position indicator 17 18 19 high coolant temp...

Page 244: ...03 number 203 kit tool 98 labels safety 5 lamp check 14 lever 2WD 4WD select Except TRX420TM 26 limit weight 48 load limits 48 loading guidelines 49 lubrication differential oil Except TRX420TM 117 en...

Page 245: ...237 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 246: ...16 noise emission control system 219 numbers serial 208 obstacles riding over 81 odometer 17 18 21 oil differential Except TRX420TM 117 engine 105 gear case 114 operation component locations 10 owner...

Page 247: ...nger no carrying 41 pavement no riding on 55 pinging engine 102 plug spark 135 pre ride inspection 43 problems unexpected 185 propeller shaft boots yoke joint boot 163 protective apparel 38 PS Electri...

Page 248: ...st cable 134 assist lever 134 gear shifting into 67 indicator 13 16 riding in 67 selector knob 30 rider training 40 Rider s Club Honda 229 riding basic operations 53 clothing 38 precautions 55 prepari...

Page 249: ...tions 55 schedule maintenance 90 seat removal 100 select lever 2WD 4WD Except TRX420TM 26 serial numbers 208 service customer 227 manuals 224 warranty 226 shifting gears 65 skid plate 161 skidding or...

Page 250: ...ton 27 starting engine 60 troubleshooting 188 stop switch engine 27 stopping engine 64 storage ATV 180 owner s manual 99 suspension adjustment Except TRX420TM 140 spring pre load Except TRX420TM 141 s...

Page 251: ...ng 160 repairing 159 tread conditions 157 158 tool kit 98 trailer hitch 34 trailer towing operational guidelines 49 weight limits 48 training rider 40 transporting your ATV 178 tripmeter 17 18 21 trou...

Page 252: ...el 24 valve clearance 138 vehicle identification no VIN 208 warning labels 5 warranty coverage 225 extended 225 service 226 washing your ATV 171 water draining from brakes 153 riding through 82 weight...

Page 253: ...245 Memo...

Page 254: ...246 Memo...

Page 255: ...247 Memo...

Page 256: ...248 Memo...

Page 257: ...249 Memo...

Page 258: ...250 Memo...

Page 259: ...251 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 Fuel Capacity unleaded gasoline pump oc...

Page 263: ...30 A or Front Rear standard Front Rear main other PS Electric Power Steering TRX420FPM only TRX420TM TRX420FM TRX420FPM Quick Reference Quick Reference Tires Tire Pressure cold Spark Plugs Coolant et...

Page 264: ...F 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 HI headl...

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