Honda FOURTRAX 350 4x4 2001 Owner'S Manual Download

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WIRING DIAGRAM

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Summary of Contents for FOURTRAX 350 4x4 2001

Page 1: ...rmation on safety opera tion and maintenance Anyone who operates this FOURTRAX should carefully read and understand the contents of this manual before riding the vehicle Honda provides many important...

Page 2: ...TRX 350 FM Honda FOURTRAX 350 4 4 OWNER S MANUAL 01 04 28 16 27 39 3CHN5620_002...

Page 3: ...ured to meet Honda s demanding standards This manual contains a Maintenance Schedule and information on basic maintenance procedures If you have the required skills and tools your Honda dealer can sup...

Page 4: ...Controls 33 Engine Oil 36 Additional Features 37 RIDING YOUR FOURTRAX 42 Before Riding 42 Rider Preparation 42 Vehicle Preparation 44 Safe Riding Rules 52 Riding 64 Starting the Engine 65 Shifting Ge...

Page 5: ...tch 116 Electrical System 118 Brakes 125 Wheels and Tyres 135 Seat Removal 140 Engine Guard and Skid Plates 141 Spark Arrester 142 Driveshaft Boots 144 TRANSPORTING YOUR FOURTRAX 146 CLEANING YOUR FOU...

Page 6: ...precautions SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and follow the operating procedures described Always follow this age re...

Page 7: ...t or jacket and long pants Never operate at excessive speeds Always go at a speed that is proper for the terrain visibility operating conditions and your experience Never consume alcohol or drugs befo...

Page 8: ...ual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gea...

Page 9: ...nd be very cautious in order to reduce the chance of skidding out of control Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks...

Page 10: ...you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type tyres specified in this manual Always maintain proper tyre pressure as described in this manual Neve...

Page 11: ...If a label comes off or becomes hard to read contact your Honda dealer for replacements Your FOURTRAX comes with several labels containing important safety information Anyone who rides the vehicle sh...

Page 12: ...7 Indicates a strong possibility that serious injury or death may result if instructions are not followed While reading this manual remember 01 04 28 16 28 37 3CHN5620_012...

Page 13: ...8 01 04 28 16 28 50 3CHN5620_013...

Page 14: ...9 01 04 28 16 29 07 3CHN5620_014...

Page 15: ...ht switch Engine stop switch Headlight dimmer switch Starter button Reverse selector knob Horn button Choke knob Fuel gauge Ignition switch Throttle lever Front brake lever Handlebars from rider s poi...

Page 16: ...Odometer Tripmeter Digital clock Hourmeter Minute select button Hour select button Hourmeter Digital clock select button Odometer Tripmeter select button Fig 2 2 10 11 12 16 15 14 13 Indicators and mu...

Page 17: ...lever Fuel fill cap Front brake fluid reservoir Front cargo rack Recoil starter behind the recoil starter cover Right footpeg Rear brake pedal Dipstick Headlights Fig 2 3 19 20 21 22 18 18 19 20 21 2...

Page 18: ...valve Starting primer knob Storage compartment containing Tool kit Air pressure gauge Owner s Manual Oil filler cap Gearshift pedal Left footpeg Trailer hitch Fig 2 4 29 30 31 32 33 34 35 36 29 30 31...

Page 19: ...handlebars directly in front of the seat The engine and headlight can not be operated The key can be removed The key can not be re moved The headlights can be turned on With the engine stop switch at...

Page 20: ...switch is in either OFF position the engine will not operate This switch is intended primarily as a safety or emergency control and it should normally remain in the RUN position If you stop your FOURT...

Page 21: ...oke is hard to actuate or feels like it is sticking check the cable boot To start a cold engine when air temperature is 15 35 C 5 95 F pull the choke knob up to the Fully ON position before pressing t...

Page 22: ...rn The starter button Fig is below the engine stop switch To start the engine press the starter button with the transmission in neutral the ignition switch ON and the engine stop switch at RUN 2 1 1 S...

Page 23: ...the carburetor float bowl on the left side of the FOURTRAX To start the engine when air temperature is below 15 C 5 F push the knob in two or three times before pressing the starter button 1 Starting...

Page 24: ...urn smoothly because of dirt in the assembly see your Honda dealer Grasp the starter grip firmly then pull it out slowly approxi mately 100 mm 4 in Pull the grip up briskly and fully After the engine...

Page 25: ...the right handgrip and it is operated by the thumb Pressing the lever opens the throttle When pressure is released spring tension automatically closes the throttle 1 A 1 Throttle lever A To open the t...

Page 26: ...Fig are above the engine stop switch next to the left handgrip Turning the headlight switch ON turns the headlight on Use the dimmer switch to select either high beam HI or low beam LO 2 Dimmer switc...

Page 27: ...dicator Fig will light The reverse indicator will light when the transmission is in reverse and the ignition switch is ON The neutral indicator will light when the transmission is in neutral and the i...

Page 28: ...23 1 Reverse indicator 2 Neutral indicator 3 Oil high temperature indicator 1 2 3 Fig 2 14 01 04 28 16 30 38 3CHN5620_028...

Page 29: ...display of the odometer or tripmeter Resets the tripmeter to zero 0 page Odometer tripmeter select button Digital clock hourmeter select button Selects display of the hourmeter or digital clock page H...

Page 30: ...sconnected When the ignition switch is turned ON the display Fig will temporarily show all the modes and digital segments so you can make sure the liquid crystal display is functioning properly 1 1 1...

Page 31: ...pmeter select button and hold it in for at least two seconds When selected the odometer Fig registers total distance traveled in kilometers while the ignition is ON To change the display from tripmete...

Page 32: ...ate service period information for initial and regular maintenance To change the display from the digital clock to the hourmeter mark press and release the hourmeter digital clock select button 1 2 1...

Page 33: ...advancing Release the button when the display reaches the desired hour To advance the minute display one unit at a time press and release the minute select button To advance the minute display automat...

Page 34: ...shifting sequence Fig The pedal automatically returns to the horizontal position when released Gearshifting sequence To upshift to a higher gear put the toe of your boot under the gearshift pedal and...

Page 35: ...Reverse Selector Knob The reverse selector knob Fig is on the rear brake lever To shift into reverse first bring the FOURTRAX to a complete stop and make sure the transmission is in neutral While push...

Page 36: ...31 Indicates a strong possibility that serious injury or death may result if instructions are not followed While reading this manual remember 01 04 28 16 31 37 3CHN5620_036...

Page 37: ...nd rear wheels For information on how to apply the brakes in various riding situations see pages The rear brake lever has a lock which allows it to be used as a parking brake To set the parking brake...

Page 38: ...0 3 43 US gal 2 86 Imp gal 3 2 0 85 US gal 0 70 Imp gal 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 ta...

Page 39: ...to tighten the fuel fill cap Fig until it clicks Insert the breather tube into the handlebar cover hole To refuel refer to page 1 1 Fuel fill cap 2 3 2 3 2 Breather tube 3 Handlebar cover hole 2 26 Fi...

Page 40: ...tor When the fuel valve is in the RES position fuel will flow from the reserve fuel supply to the carburetor Use the reserve fuel only when the main supply is gone Refill the tank as soon as possible...

Page 41: ...ging oil see pages While reading this manual remember The dipstick Fig on the right side of the front crankcase cover is used to measure the oil level The oil should be checked each day before operati...

Page 42: ...before riding The flag pole bracket Fig is on the rear cargo rack Flag poles are optional equipment available from your Honda dealer To mount a pole in the bracket follow the instructions that come wi...

Page 43: ...ou ll need a proper size ball as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the trailer manufacturer s instructions For load limits and operational...

Page 44: ...ush down on the rear end of the plastic tray The owner s manual and air pressure gauge should be stored in the plastic tray The tool kit should be stored in the storage compartment Be careful not to f...

Page 45: ...p Be careful not to flood this accessory socket when washing your FOURTRAX Do not plug in any heat generating accessory such as an automobile cigarette lighter because it can damage the socket To use...

Page 46: ...41 Indicates a strong possibility that serious injury or death may result if instructions are not followed While reading this manual remember 01 04 28 16 32 47 3CHN5620_046...

Page 47: ...safety never let children under 16 years old operate this vehicle You need to be prepared before riding This includes getting proper instruction making sure your FOURTRAX is in good operating conditi...

Page 48: ...r death can result Even though a child may be within the age group for which an ATV is recommended he or she may not have the skills abilities or judgment needed to operate the ATV safely and may be i...

Page 49: ...rake fluid leakage If necessary adjust free play pages Check condition and pressure pages Check for smooth opening and closing in all steering positions Check for proper func tion page Check for prope...

Page 50: ...CAN HAPPEN Increases the possibility of an accident HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspectio...

Page 51: ...ays maintain proper tyre pressure as described in this Owner s Manual Tyres Correct any problem before you ride If you can t correct a problem contact your Honda dealer for assistance Before riding ma...

Page 52: ...weight of the rider all accessories and all cargo The following weight limits apply to standard equipment only Modi fying your FOURTRAX using non standard equipment or riding on terrain that is not fl...

Page 53: ...ed tongue weight Make sure all cargo is secured before riding Do not allow cargo to extend beyond the edges of either the front or rear racks Allow extra room for starting stopping and turning wheneve...

Page 54: ...ceed the stated load limits for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Use extra c...

Page 55: ...plus the following Make sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls Carefully inspect the accessory to make sure it doe...

Page 56: ...rough improper installation or use of accessories All parts and accessories added to this vehicle should be genuine Honda or equivalent components designed for use on this ATV and should be installed...

Page 57: ...ong sleeved shirt or jacket and long pants An example of a properly dressed rider Modifying this FOURTRAX or removing original equipment may render the vehicle unsafe or illegal Spark arresters and mu...

Page 58: ...Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of se...

Page 59: ...carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers This FOURTRAX is designed as an operator only vehicle The long...

Page 60: ...in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV Alcohol drugs and FOURTRAX s don t mix Even a small amount of alcohol can impair your ability to...

Page 61: ...f the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Never operate the ATV on any paved surfaces including sidewalks driveways parking lots and streets Your FOURTRAX is des...

Page 62: ...or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways You should never ride your FOURTRAX on public streets roads or highways even if...

Page 63: ...ing off road also remember to always obey local off road riding laws and regulations Obtain permission to ride on private property Avoid posted areas and obey no trespassing signs 01 04 28 16 34 28 3C...

Page 64: ...y come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footpegs of your ATV during o...

Page 65: ...ARD Always go at a speed that is proper for your vehicle the terrain visibility and other operating conditions and your experience Riding at excessive speed increases the chance of an accident In choo...

Page 66: ...g an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off When riding you should keep all four wheels of your FOURTRAX on the ground Avoid wheelies jum...

Page 67: ...rning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Before r...

Page 68: ...e on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Ne...

Page 69: ...nsciousness and may lead to death HOW TO AVOID THE HAZARD Never operate the ATV engine in an enclosed area such as a garage For your initial riding practice select a safe area free of obstacles with a...

Page 70: ...urn the fuel valve and ignition switch to ON Make sure the engine stop switch is at RUN Make sure that the transmission is in neutral by checking that the neutral indicator lights 1 2 3 4 2 3 1 1 4 3...

Page 71: ...procedure for High Air Tempera ture Normal Air Temperature 10 35 C 50 95 F With the throttle closed press the starter button Pull the choke knob up all the way to fully ON position if the engine is co...

Page 72: ...rten the life of the engine High Air Temperature 35 C 95 F or above Low Air Temperature 10 C 50 F or below Do not use the choke With the throttle slightly open press the starter button Follow the proc...

Page 73: ...To clear the engine If the battery is low or dead use the recoil starter page to start the engine Turn the engine stop switch OFF Push the choke knob to the OFF position Hold the throttle fully open a...

Page 74: ...nd letting it warm up follow these proce dures With the transmission in neutral release the parking brake but continue squeezing the rear brake lever Release the rear brake lever and increase engine s...

Page 75: ...o obstacles or people in the way Release the rear brake lever Open the throttle gradually and ride slowly Do not open the throttle suddenly or make abrupt turns To stop close the throttle and graduall...

Page 76: ...sure there are no obstacles or people behind you When it is safe to proceed go slowly POTENTIAL HAZARD Applying only the rear brake abruptly when operating in reverse gear WHAT CAN HAPPEN The front w...

Page 77: ...he turn Fig Leaning helps balance the vehicle and it feels more comfortable Leaning into a turn is an impor tant technique to master in riding a FOURTRAX To make a sharp turn at low speed it helps to...

Page 78: ...verturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at...

Page 79: ...us in order to reduce the chance of skidding or sliding out of control The terrain surface can be a major factor affecting turns Skidding during a turn is more likely to occur on slippery surfaces suc...

Page 80: ...ies Practice on smaller hills before attempting larger hills The FOURTRAX s ability to safely climb hills largely depends on the rider s skill and judgment Begin by practicing on smooth gentle slopes...

Page 81: ...e hill Shift weight forward when climbing hills When climbing hills you must shift weight toward the front wheels to help keep them on the ground To do this shift your body slightly forward on the sea...

Page 82: ...t forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backward Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or p...

Page 83: ...erating any brake control with four wheel drive will cause braking at both the front and rear wheels If you roll backwards down a hill don t apply either brake abruptly If the FOURTRAX starts rolling...

Page 84: ...p weight uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply either brake abruptly while rolling backwards Apply the front br...

Page 85: ...clear of the wheels Check your footing Then slowly and carefully back the FOURTRAX down the hill using the rear brake lever to control speed If you lose control of the FOURTRAX for your safety get awa...

Page 86: ...81 Indicates a strong possibility that serious injury or death may result if instructions are not followed While reading this manual remember 01 04 28 16 36 42 3CHN5620_086...

Page 87: ...ift into a lower gear shift your weight back with your arms extended and braced against the handlebars then go down slowly with the throttle closed Do not downshift abruptly while descending a hill Us...

Page 88: ...described in this Owner s Manual Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Ne...

Page 89: ...this move your body off the center of the seat and lean toward the uphill side On a slippery or loose surface you may also need to steer slightly uphill to maintain a straight course across the slope...

Page 90: ...n crossing the side of a hill Always follow proper procedures as described in this Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the AT...

Page 91: ...bstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in this Owner s Manual Watch out for bum...

Page 92: ...to travel through water up to approxi mately 250 mm 10 in deep Before crossing a stream make sure the water is not too deep or flowing too fast Choose a path where both banks have gradual slopes then...

Page 93: ...d While reading this manual remember Always choose a level place to park After bringing your FOURTRAX to a stop hold the brakes while you shift into neutral Then set the parking brake and turn the ign...

Page 94: ...I I R R I Refer to page FUEL LINE THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER AIR CLEANER HOUSING DRAIN TUBE SPARK PLUG VALVE CLEARANCE ENGINE OIL ENGINE OIL FILTER ENGINE IDLE SPEED 98 103 99 101...

Page 95: ...frequently after riding in very wet or muddy conditions Replace every 2 years Replacement requires mechanical skill 111 113 128 133 125 134 117 141 116 142 135 139 DRIVE SHAFT BOOTS REAR FINAL GEAR C...

Page 96: ...HE HAZARD Always follow the inspection and maintenance procedures and schedules described in this Owner s Manual Use only genuine Honda replacement parts or parts of equivalent quality MAINTENANCE PRE...

Page 97: ...rear cargo rack The tools in the kit are sufficient to perform routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your authorized Honda dealer...

Page 98: ...93 Indicates a strong possibility that serious injury or death may result if instructions are not followed While reading this manual remember 01 04 28 16 37 55 3CHN5620_098...

Page 99: ...tube from the handle cover hole Then turn the fuel fill cap counterclockwise After refueling be sure to tighten the fuel fill cap firmly by turning it clockwise until it clicks Insert the breather tub...

Page 100: ...careful not to spill fuel when refueling After refueling make sure the fuel fill cap is closed properly and securely If any fuel is spilled make sure the area is dry before starting the engine POTENTI...

Page 101: ...number R M 2 of 86 or higher or a research octane number of 91 or higher Petrol pumps at service stations normally display the pump octane number Using a lower octane than recommended can cause persi...

Page 102: ...than 5 methanol even if it has cosolvents and corrosion inhibitors Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the warranty Honda cannot endo...

Page 103: ...t throttle free play Slide the rubber sleeve back to expose the throttle cable adjuster Loosen the lock nut then turn the adjuster to obtain the correct free play Tighten the lock nut and reinstall th...

Page 104: ...in the Maintenance Schedule If the FOURTRAX is submerged in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine Remove the seat...

Page 105: ...cleaner assembly from the air cleaner housing Unscrew the clamp Remove the air cleaner from the air cleaner body Gently wash the air cleaner in clean non flammable high flash point solvent such as ke...

Page 106: ...over Soak the air cleaner in clean gear oil SAE 80 SAE 90 or an equivalent until saturated then squeeze out the excess oil Reassemble by reversing the disassembly sequence If the dust cover Fig is dir...

Page 107: ...ing through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle Remove the drain tube by removing the clip Drain t...

Page 108: ...Knob Check the condition of the choke cable Fig and the operation of the choke knob If the cable is damaged or kinked have it replaced by your Honda dealer 2 1 Choke cable 2 1 2 Choke knob 4 8 Fig 4 8...

Page 109: ...again Center the pilot screw exactly between the two extreme positions Usually the correct setting between extremes of rich and lean will be found at turns open from a fully closed position If idle sp...

Page 110: ...high altitude richness For those who are mechanically proficient and have the necessary tools installation and adjustment procedures are given in the official Honda Service Manual available from your...

Page 111: ...ficiently may give an inaccurate low oil level reading Stop the engine After a few minutes remove the dipstick Fig from the front crankcase cover and wipe it clean Insert the dipstick without screwing...

Page 112: ...ation Use only high detergent premium quality motor oil certified to meet API Service Classification SE SF or SG Motor oils intended for Service SE SF or SG will show this designation on the container...

Page 113: ...he oil from the crankcase while the engine is still warm This will ensure complete and rapid draining To change the oil and oil filter With the FOURTRAX on level ground remove the oil filler cap from...

Page 114: ...model Using the wrong Honda filter or a non Honda filter which is not of equivalent quality may cause engine damage Install the filter with the rubber seal facing out away from the engine You will see...

Page 115: ...proximately Reinstall the oil filler cap Start the engine and let it idle for 5 minutes Stop the engine and after a few minutes check the oil level Make sure the oil is between the upper and lower lev...

Page 116: ...g Torque Change the oil in the rear final gear case when specified by the Main tenance Schedule Change the oil with the final gear case warm and the FOURTRAX on level ground to assure complete and rap...

Page 117: ...aches the lower edge of the inspection hole Change the oil in the differential when specified by the Maintenance schedule Change the oil with the differential warm and the FOURTRAX on level ground to...

Page 118: ...113 1 2 3 1 Oil filler cap 2 Oil drain plug 3 Lower edge of inspection hole Fig 4 15 01 04 28 16 40 28 3CHN5620_118...

Page 119: ...e eroded If the electrodes and insulator tip appear unusually fouled or burned we suggest that you contact your authorized Honda dealer Discard the spark plug if there is apparent wear or if the insul...

Page 120: ...l cause loss of power and possibly damage the valves For those who are mechanically proficient and have the proper tools instructions on adjusting valve clearances are given in the official Honda Serv...

Page 121: ...terclockwise until you feel slight resistance Then turn the adjuster 1 4 turn clockwise and tighten the lock nut to hold the adjuster in this position After adjustment start the engine and test ride t...

Page 122: ...eck 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 To adjust the free play Slide the rubber sleeve back t...

Page 123: ...rtment under the seat The battery is sealed so it is not necessary to check the electrolyte level or add distilled water If the battery seems weak see your authorized Honda dealer for information on r...

Page 124: ...ll bolts and other fasteners are secure Make sure the ignition switch is OFF Remove the seat page To remove the rear fender lid remove the clips Fig Release the rings and remove the rubber band After...

Page 125: ...120 5 3 4 6 3 Battery 4 Rubber band 5 Negative terminal lead 6 Positive terminal lead Fig 4 20 01 04 28 16 41 25 3CHN5620_125...

Page 126: ...load in the electrical system See your authorized Honda dealer for repair 15 A 2 10 A 2 The specified sub fuses are 30 A To replace the main fuse Make sure the ignition switch is OFF As illustrated in...

Page 127: ...age Remove the rear fender lid page Remove the fuse box cover page Pull the old fuse out of the clips Push a new fuse into the clips and install the fuse box cover Install the rear fender lid Install...

Page 128: ...pecified in this Owner s Manual Do not pry the clips open to get a fuse out as a loose fuse could cause damage to the electrical system or start a fire Remove the seat page Remove the rear fender lid...

Page 129: ...124 Indicates a strong possibility that serious injury or death may result if instructions are not followed While reading this manual remember 01 04 28 16 41 50 3CHN5620_129...

Page 130: ...d leaks The brake fluid level should be checked frequently and the brake shoe linings should be inspected periodically To check lever free play and shoe lining clearance Measure the distance the brake...

Page 131: ...free play and the brake shoe lining thicknesses are within the recommended limits reinstall the inspection hole plugs seating them into the inspection holes as shown in Fig If the brake lever free pl...

Page 132: ...does not drag Line up the inspection hole with the second adjuster and repeat steps 3 through 5 Reinstall the inspection hole plug seating it into the inspection hole as shown in Fig Follow steps 3 t...

Page 133: ...revent accidental spilling If the fluid level approaches the lower level mark the brake system should be inspected by your authorized Honda dealer A low fluid level may indicate fluid leakage Brake fa...

Page 134: ...th the skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed Make sure there are no fluid leaks Check the condition of brake hoses and fittings If the...

Page 135: ...e rear brake pedal and the rear brake lever You should also periodically check the brake shoes for wear To check and adjust brake pedal free play Measure the distance the rear brake pedal moves before...

Page 136: ...ocated on the brake operating rod at the rear of the frame Make sure the cut out on the adjusting nut is properly seated on the brake arm pin 3 2 1 3 1 Brake pedal adjusting nut 2 Brake lever adjustin...

Page 137: ...e play measured at the tip of the brake lever Fig should be 15 20 mm 0 6 0 8 in To adjust the free play turn the brake lever adjusting nut Fig located on the brake operating rod at the rear of the fra...

Page 138: ...e the brake shoes must be replaced See your authorized Honda dealer for this service Check the condition of the brake cables If there are kinks or signs of wear that could cause sticking or failure ha...

Page 139: ...hole plug Fig from the front brakes and the drain bolt Fig from the bottom of the rear brake cover If any water drains the brake seals must be replaced by your Honda dealer as soon as possible 1 1 1 R...

Page 140: ...o remove a wheel from your FOURTRAX follow these procedures When reinstalling a wheel tighten the wheel nuts in a crisscross rather than a circular pattern Wheel nuts torque Be sure the tapered side o...

Page 141: ...ated to the pressure recommended in Fig This FOURTRAX is equipped with low pressure tubeless tyres Although the tyres are designed specifically for off road use they are not immune to punctures Always...

Page 142: ...or this vehicle Always maintain proper tyre pressure as described in this Owner s Manual TYRE SIZE TYRE BRAND FRONT REAR RECOMMENDED PRESSURE MAXIMUM PRESSURE MINIMUM PRESSURE RECOMMENDED PRESSURE Tyr...

Page 143: ...roove depth Fig in the center of the tyre or check the wear indicator The minimum tread depth is 4 mm 0 16 in When the tread depth is less than recommended the tyre should be replaced 3 2 1 1 Groove d...

Page 144: ...ovides a plug an installation tool tyre cement and an instruction sheet Follow the instructions provided with the repair kit to make a temporary repair As soon as possible have the tyre permanently re...

Page 145: ...e prongs into the hooks on the frame and press the studs into the grommets on the battery holder Press the seat down until it locks Check that the seat is locked securely by lifting up on the rear of...

Page 146: ...are loose tighten them securely The engine guard Fig protects the engine crankcase The skid plates protect the frame and rear final gear case Check the guard and plates for cracks damage or looseness...

Page 147: ...and make sure the exhaust pipe is cool Remove the bolt Fig Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the...

Page 148: ...leading to death Could start a fire HOW TO AVOID THE HAZARD When purging the exhaust system Always wear eye protection and make sure no one stands behind the vehicle Always let the exhaust system cool...

Page 149: ...DRIVESHAFT BOOTS Check the rubber driveshaft boots for damage or leaking grease If necessary have your authorized Honda dealer replace them 1 1 1 Drive shaft boots Fig 4 40 01 04 28 16 44 08 3CHN5620_...

Page 150: ...145 Indicates a strong possibility that serious injury or death may result if instructions are not followed While reading this manual remember 01 04 28 16 44 11 3CHN5620_150...

Page 151: ...wheels and follow these procedures Points to secure FOURTRAX with tie downs Set the parking brake and place the transmission in gear Turn the fuel valve OFF Secure the vehicle with tie downs in the ar...

Page 152: ...ious page Place a suitable container under the carburetor drain tube Turn the drain screw counterclockwise and drain the fuel from the carburetor After draining the carburetor turn the drain screw clo...

Page 153: ...off Do not smoke or allow flames or sparks in the area where fuel is handled If any fuel is spilled make sure the area is dry before starting the engine POTENTIAL HAZARD Prolonged contact of fuel with...

Page 154: ...chemical solvents that could damage the metal paint and plastic on your FOURTRAX If your FOURTRAX is still warm from recent operation give the engine and exhaust system time to cool off Park in a shad...

Page 155: ...ions may be necessary to restore normal braking performance Start the engine and let it run for several minutes Dry the FOURTRAX The inside of the headlight lens may be clouded immediately after washi...

Page 156: ...pairs may be forgotten by the time you remove the vehicle from storage In addition extended storage requires that you take the following steps to reduce the effects of deterioration from non use of th...

Page 157: ...careful not to spill fuel when refueling After refueling make sure the fuel fill cap is closed properly and securely If any fuel is spilled make sure the area is dry before starting the engine POTENTI...

Page 158: ...ch of children slow charge the battery once a month Wash and dry the FOURTRAX and wax all painted surfaces Inflate the tyres to their recommended pressures Place the FOURTRAX on blocks to raise all fo...

Page 159: ...d Spark plug standard Spark plug gap Valve clearance 8 8 1 1 400 100 rpm DPR7EA 9 NGK X22EPR U9 DENSO 4 0 AT24 8 12 AT24 9 11 Caster angle Trail length Tire size Front Rear 1 983 mm 78 1 in 1 143 mm 4...

Page 160: ...rse gear ratio Noise level ISO 5131 Vibration on seat EN 1032 ISO 5008 Vibration on handlegrip EN 1033 EN 709 Sub fuse Main fuse Head light Low High Taillight Neutral indicator Reverse indicator Oil h...

Page 161: ...156 WIRING DIAGRAM 01 04 28 16 45 45 3CHN5620_161...

Page 162: ...here for your reference KEY NO FRAME NO ENGINE NO COLOR The color label is attached to the frame below the seat page The frame serial number is stamped on the front of the frame The engine serial num...

Page 163: ...le speed adjustment 104 Cargo carrying Loading and operational guidelines 48 Weight limit 47 Choke Cable 103 Knob 16 103 Battery 118 Brakes Brake cables 133 Brake fluid 128 Front brakes Adjustment 125...

Page 164: ...oots 144 Engine Idle speed adjustment 104 Break in procedures ii Flooded engine 68 Starting the engine 65 Engine guard and skid plates 141 Engine oil Changing oil 108 Checking oil level and adding oil...

Page 165: ...ons 96 Fuel tank capacity 94 Fuel valve 35 High altitude fuel mixture adjustment 104 Refueling 94 Reserve fuel supply 35 Fuses Location 121 Replacement main fuse 121 Replacement sub fuses 122 Headligh...

Page 166: ...Weight limits 47 Lubrication see Engine oil Gear case oil and differential oil Maintenance Precautions 92 Schedule 89 Modifications 52 Multi function display 24 Neutral indicator 22 Obstacles riding...

Page 167: ...lation 140 Serial numbers and color label 157 Shifting gears 29 69 Skid plates 141 Skidding 74 Socket accessory 40 Spark arrester 142 Spark knock 96 Spark plug 114 Specifications 154 Stalling on a hil...

Page 168: ...ing diagram 156 Throttle Cable 98 Lever 20 98 Tool kit 93 Trailer hitch 38 Trailer towing Operational guidelines 48 Weight limits 47 Transporting procedures 146 Tripmeter 26 Turning On level ground 72...

Page 169: ...New Zealand Tel 09 274 4939 HONDA SUISSE S A Route des Mouli res 10 CH 1214 VERNIER GENEVE SUISSE Tel 22 41 22 00 KELLOX AS Nygardsveien 67 Nordby N 1401 SKI NORWAY Tel 09 945000 8h 16h MONTESA HONDA...

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