Honda FOURTRAX 420 ES/4 4 Owner'S Manual Download | Manualshive

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0.15 mm (0.006 in)
0.23 mm (0.009 in)

137

Valve Inspection

Valves

Servicing Your Honda

Saf ety Precautions

Refer to

on page

.

Excessive clearance will cause noise. Insufficient clearance will cause
loss of power and possibly damage the valves.

Valve clearance should be:

intake:
exhaust:

For those who are mechanically proficient and have the proper tools,
instructions on adjusting valve clearances are given in the official
Honda Shop Manual. All others should have valves adjusted by your
Honda dealer.

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Summary of Contents for FOURTRAX 420 ES/4 4

Page 1: ...Honda TRX420TE FE FOURTRAX 420 ES 4 4 OWNER S MANUAL...

Page 2: ...in guidelines and perform all pre ride and other periodic checks detailed in this manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety inf...

Page 3: ...Introduction Happy riding 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 H...

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: ...d to know before servicing your Honda 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...

Page 8: ......

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

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

Page 11: ...you need to cross a paved or public road get off and walk your ATV across Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice in a safe area un...

Page 12: ...ake good judgments and ride safely Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink S...

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

Page 14: ...6 Safety Labels ATV Safety TRX420TE TRX420FE...

Page 15: ...7 ATV Safety Safety Labels TRX420FE only...

Page 16: ...8 ATV Safety...

Page 17: ...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 18: ...tch Headlight Dimmer Switch Horn Button Recoil Starter Throttle Lever Reverse Selector Knob Front Brake Lever Rear Brake Lever Rear Brake Pedal Parking Brake Flag Pole Bracket Trailer Hitch Controls F...

Page 19: ...e lock lever rear brake lever parking brake lever horn button 2WD 4WD select lever TRX420FE only ignition switch throttle lever front brake lever reverse selector knob headlight dimmer switch headligh...

Page 20: ...rear cargo rack rear brake pedal seat latch front cargo rack recoil starter fuel valve 12 Instruments Controls Operation Component Locations...

Page 21: ...trailer hitch flag pole bracket 13 Instruments Controls Operation Component Locations...

Page 22: ...Lamp Check The indicators and displays 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 ar...

Page 23: ...n until you shift out of 4WD mode If one of these indicators does not come on when it should have your Honda dealer check for problems Display Check When the ignition switch is turned ON the multi fun...

Page 24: ...ght for a few 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 1 2 3 4...

Page 25: ...nge is reached page Oil change indicator Speedometer Shows riding speed Odometer Shows accumulated mileage page Tripmeter Shows mileage per trip page Hourmeter odometer tripmeter select button Selects...

Page 26: ...ter odometer tripmeter select button 1 2 3 4 5 6 7 8 9 10 11 5 oil change indicator 6 4WD indicator TRX420FE only 7 high coolant temperature indicator 18 Multi function Display Indicators Displays Ins...

Page 27: ...on is not shifted into gear properly Before riding check that the gear position is displayed on the gear position indicator properly The gear position indicator shows the gear position when the igniti...

Page 28: ...interval specified on the maintenance schedule If the oil is changed before the oil change indicator appears be sure to reset the oil change indicator after changing the oil The indicator will appear...

Page 29: ...nition 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...

Page 30: ...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 31: ...Instruments Controls 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...

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 OFF ON Function Key Position 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 34: ...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 shift the 2...

Page 35: ...button is used for starting the engine Pushing the button in starts the engine See page The engine stop switch is used to stop the engine in an emergency To operate slide the switch to either OFF pos...

Page 36: ...on Controls Features Instruments Controls The headlight dimmer switch is used to change between the high and low beams of the headlight To operate turn the switch to HI for high beam LO for low beam T...

Page 37: ...1 RIGHT SIDE 1 recoil starter 29 Recoil Starter Controls Features Instruments Controls Using the Recoil Starter The recoil starter is used to start the engine when the battery is low See page 1 64...

Page 38: ...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 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 lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see...

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: ...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 prop...

Page 47: ...t and long pants 39 Are You Ready to Ride Before Riding An open face helmet offers some protection but a full face helmet offers more Always wear a face shield or goggles to protect your eyes and help...

Page 48: ...ls learned in the course and the operating techniques described in the owner s manual 40 Rider Training Are You Ready to Ride Before Riding Developing your riding skills is an on going process Even if...

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: ...a collision do not ride the vehicle until it has been inspected by your Honda dealer There may be damage or other problems you cannot see Check the following items before you get on the ATV Check the...

Page 52: ...ressure Adjust if needed Also look for signs of damage or excessive wear page Walk around your ATV and look for anything that appears unusual such as a leak or loose cable Check for deposits in the dr...

Page 53: ...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 54: ...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 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: ...he following load limits apply to standard equipment only Modifying your ATV using non standard equipment or riding on terrain that is not flat and smooth could further reduce these limits The weight...

Page 57: ...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 handlebar movement Do not allow cargo to exte...

Page 58: ...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: ...equipment or modify your ATV in any way that would change its design or operation Such changes could seriously impair your ATV s handling stability and braking making it unsafe to ride Removing or mod...

Page 60: ...52 Before Riding...

Page 61: ...erformance 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 Rough Terrain Do...

Page 62: ...c Operation Riding Braking Riding Your ATV Making Turns Skidding or Sliding Riding Down Hills Riding Up 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: ...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 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: ...g or operating the engine in an enclosed area such as a garage Your ATV s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Before...

Page 69: ...cle has a fuel injected 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 thr...

Page 70: ...rate the recoil starter several times Follow the normal starting procedure If the engine starts then open the throttle slightly if idling is unstable If the engine does not starts wait 10 seconds then...

Page 71: ...t in gear Once you have started the engine release the front brake lever then apply throttle gradually Normal Engine Stop To stop the engine make sure the transmission is in neutral by checking that t...

Page 72: ...ry is low To operate the recoil starter Check that the transmission is in neutral Grasp the starter grip firmly then pull it out slowly approximately 100 mm 4 in Pull the grip up briskly and fully Aft...

Page 73: ...cated next to the left handlebar grip upshift and downshift To upshift the transmission press the upshift switch once To downshift the transmission press the downshift switch once To select reverse us...

Page 74: ...r In an emergency a gear may be selected manually so you may move the vehicle See page The transmission cannot be downshifted from 1st gear to neutral when the ground speed is above 3 km h 2 mph To do...

Page 75: ...high Downshifting when engine speed is near its allowable maximum may over rev the engine and cause possible damage To prevent transmission damage do not coast or tow the ATV for long distances with t...

Page 76: ...lector knob 2 rear brake lever parking brake lever 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 77: ...into neutral press the upshift switch once to shift into N neutral gear To stop close the throttle and gradually apply both the front and rear brakes Do not abruptly apply the rear brake by itself Re...

Page 78: ...quickly while turning Either action may cause one or more wheels to slip and reduce your control of your ATV Applying the brakes too hard may cause the wheels to lock and slide reducing control of you...

Page 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...neutral set the parking brake and turn the engine off Then assess the situation If the ATV starts rolling backwards before you begin braking Keep your weight uphill Carefully apply the front brakes f...

Page 86: ...t 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 87: ...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 88: ...nded and braced against the handlebar then go down slowly with the throttle closed Use mainly the rear brake to control speed Avoid using either the front brake or rear brake hard or abruptly when rid...

Page 89: ...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 90: ...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 91: ...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 92: ...back and forth to allow shifting the transmission into neutral The brakelights are activated by applying the parking brake When using the parking brake be sure to turn the ignition switch OFF to avoid...

Page 93: ...ired service and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking good The I...

Page 94: ...il only Coolant Air Cleaner Throttle Clutch System Appearance Care Battery Electrical Propeller Shaft Boots Yoke Joint Boot Driveshaft Boots only Engine Guard Skid Plate Tyres Brakes Chassis Spark Arr...

Page 95: ...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 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: ...to do so 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 petrol Use only non...

Page 98: ...f performing a given task or need assistance remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genui...

Page 99: ...require more technical information and tools Consult your Honda dealer In the interest of safety we recommend these items be serviced only by your Honda dealer Service more frequently when riding in d...

Page 100: ...LAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL Every 1 000 km 600 mi 100 operating hours or 12 months R REGULAR INITIAL 150 km 100 mi 20 operating hours or 1 month R HOURS MAINT INTERVAL MAINT 92 M...

Page 101: ...M Refer to page 158 114 116 114 139 147 142 148 139 133 157 132 138 150 2000 1200 200 I I I I I I I I I I I I I C I I I I I 1000 600 100 I I I I I I I I C I I 150 100 20 I I I I I I I FREQUENCY ITEMS...

Page 102: ...to the new owner Make sure whoever performs the maintenance completes this record All scheduled maintenance including the 150 km 100 mile or 20 hours initial maintenance is considered a normal owner...

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

Page 104: ...e engine oil filter rear brakelight switch rear brake pedal differential oil filler cap TRX420FE only differential oil drain bolt TRX420FE only front brake caliper coolant reserve tank 96 Servicing Yo...

Page 105: ...ain bolt engine oil filler cap dipstick owner s manual battery gear case oil drain bolt gear case oil filler cap spark arrester tool kit air pressure gauge fuse box main fuse 97 Servicing Your Honda M...

Page 106: ...strap The gear change tool is stored underside of the seat screwdriver handle standard Phillips screwdriver The tools in the kit are sufficient to perform routine maintenance and simple repairs Any e...

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: ...e oil engine oil filter clutch spark plug battery and fuse maintenance and to remove the side covers rear fender cover and left tank side cover to access the owner s manual air pressure gauge gear cha...

Page 109: ...val Removal Press down on the center pin to release the lock Pull the clip out of the hole Push the bottom of the pin Insert the clip into the hole Lightly press down on the center pin to lock the cli...

Page 110: ...trol pumps at service stations normally display the pump octane number For information on the use of see page Never use stale or contaminated petrol or an oil petrol mixture Avoid getting dirt dust or...

Page 111: ...l Capacity Refueling 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...

Page 112: ...ottom of the filler neck Avoid over filling the tank There should be no fuel in the filler neck If the fuel valve was set to RES turn the fuel valve ON If you replace the fuel fill cap use only a genu...

Page 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: ...or SG will show this designation on the container Your ATV does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch op...

Page 115: ...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 116: ...to on page Check the engine oil level each day before operating your ATV and add if needed Park your ATV on a firm level surface Start the engine in a well ventilated area and let it idle for 3 5 min...

Page 117: ...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 118: ...l filter specified for your model or a filter of equal quality This procedure requires mechanical skill and professional tools such as a torque wrench and oil filter wrench as well as a means for disp...

Page 119: ...1 RIGHT SIDE 1 right side cover 111 Engine Oil Filter Servicing Your Honda Install a New Engine Oil Filter Unsnap and remove the right side cover Remove the seat page cont d 1 2 100 1...

Page 120: ...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 121: ...y Reinstall the oil drain plug and tighten it to the specified torque Check that the drain plug sealing washer is in good condition If necessary replace the sealing washer Reinstall the oil filler cap...

Page 122: ...gear oil SAE 80 114 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 operating temperature to assure c...

Page 123: ...h the recommended oil Park the ATV on level ground Place an oil drain pan under the oil drain plug Remove the oil filler cap and the drain plug After the oil has completely drained reinstall the drain...

Page 124: ...AE 80 116 Oil Recommendation Changing Oil Differential Oil TRX420FE only Servicing Your Honda Safety Precautions Refer to on page Change the oil with the differential at normal operating temperature t...

Page 125: ...the differential with the recommended oil Make sure the oil level is at the lower edge of the oil filler inspection hole Install the oil filler cap Park the ATV on level ground Place an oil drain pan...

Page 126: ...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 127: ...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 128: ...t level to the UPPER level mark Remove the seat page Unhook the rubber strap After adding coolant install the reserve tank cap and rear fender cover Fasten the rubber strap Install the seat Remove the...

Page 129: ...nt Replacement Coolant Servicing Your Honda Safety Precautions You the Environment Improper disposal of drained fluids is harmful to the environment Refer to on page To properly dispose of drained coo...

Page 130: ...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 131: ...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 132: ...r will allow dirt dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer can help you determine the...

Page 133: ...NDER SEAT 1 retainer clips 2 air cleaner housing cover 125 Cleaning Air Cleaner Servicing Your Honda cont d Unlatch the retainer clips Remove the air cleaner housing cover Remove the seat page 1 2 3 1...

Page 134: ...ner This can 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 we...

Page 135: ...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 Install the air cleaner housing cover with the FRONT m...

Page 136: ...1 dust cover UNDER SEAT 2 1 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 137: ...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 138: ...afety 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 sl...

Page 139: ...om fully open to fully closed in all steering positions If there is a problem see your Honda dealer Check the cables for tension or stress in all steering positions Lubricate the cables with a commerc...

Page 140: ...ction discs may be worn See your Honda dealer or refer to official Honda Shop Manual Make sure the engine is cool Make sure the ignition switch is OFF Remove the seat page and left side cover page Loo...

Page 141: ...ge Turn over the dust cover Check the reverse assist lever freeplay measured at the rear brake lever end near the cable To adjust slide the rubber sleeve loosen the lock nut and turn the adjusting nut...

Page 142: ...ent Inspection Spark Plug Servicing Your Honda Using spark plugs with an improper heat range can cause engine damage Safety Precautions Use only the recommended type of spark plug in the recommended h...

Page 143: ...e Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped Inspect the electrodes and centre porcelain for deposits corrosion or carbon fouling If the corrosion or de...

Page 144: ...ent cross threading Tighten the spark plug First tighten the plug NGK turn after it seats DENSO turn after it seats Then loosen the plug Next tighten the plug again 1 8 turn after it seats If the old...

Page 145: ...se noise Insufficient clearance will cause loss of power and possibly damage the valves Valve clearance should be intake exhaust For those who are mechanically proficient and have the proper tools ins...

Page 146: ...hile momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel Stop the engine and allow the exhaust pipe to cool Remove the bolt Select a well ventilated...

Page 147: ...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 148: ...fluid can damage plastic and painted surfaces Handle with care Refer to on page Do not add or replace brake fluid except in an emergency If you do add fluid have your Honda dealer check the system as...

Page 149: ...ge Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks Wipe up spills immediately Avoid contact with skin or eyes In case of contact wash thoroughly...

Page 150: ...sage and riding conditions The pads will wear faster in wet or muddy conditions Inspect the pads visually during all regular service intervals to determine the pad wear Always inspect both pads in bot...

Page 151: ...E 1 143 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 ped...

Page 152: ...rm pin RIGHT REAR 144 Brakes Servicing Your Honda Adjustment Turn the brake pedal adjusting nut located on the brake operating rod at the rear of the frame Make sure the cutout on the adjusting nut is...

Page 153: ...er 145 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 brake...

Page 154: ...ng nut located on the brake operating rod at the rear of the frame Make sure the cutout on the adjusting nut is properly seated on the brake arm pin Check that the brake lever and brake pedal assembli...

Page 155: ...check brake wear without disassembly Application of the brake control causes the arrow on the brake arm to move toward a reference mark on the brake panel Apply the brake control and check the moveme...

Page 156: ...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 15 mm 0 6 in of pedal stroke See...

Page 157: ...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 158: ...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 tyres Although the tyres are designed specifically for...

Page 159: ...dling tread life and riding comfort Generally underinflated tyres wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tyres make your ATV ride harshl...

Page 160: ...ck air pressure when your tyres are cold If you check air pressure when your tyres are warm even if your ATV has only been ridden for a few miles the readings will be higher If you let air out of warm...

Page 161: ...e system found in service stations This will minimize the possibility of tyre damage from overinflation If you use a high pressure system at a service station add air in small amounts and check the pr...

Page 162: ...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 tyres for damage Tread Wear For best performance you should replace a tyre...

Page 163: ...temporary repairs see page A tyre that is repaired either temporarily or permanently will have lower speed and performance limits than a new or undamaged tyre If you have a tyre professionally repaire...

Page 164: ...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 tyres however if that is not possible you mu...

Page 165: ...rotects the frame and engine crankcase The skid plate protects the rear final gear case Check the guard and plate for cracks damage or looseness at intervals shown in the Maintenance Schedule Have the...

Page 166: ...eshaft boots 158 Driveshaft Boots TRX420FE only Servicing Your Honda Safety Precautions Refer to on page Check the rubber driveshaft boots for damage or leaking grease If necessary have your Honda dea...

Page 167: ...e joint boot 159 Servicing Your Honda Propeller Shaft Boots Yoke Joint Boot Safety Precautions Refer to on page Check the rubber propeller shaft boots and rubber yoke joint boot for damage or leaking...

Page 168: ...om the battery even 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 charg...

Page 169: ...tery Charging Refer to on page If you plan to store your ATV we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life If you do not...

Page 170: ...is located in a compartment under the seat Removal 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 t...

Page 171: ...temperature and direct sunlight Slow charge the battery see following section once every 30 days Installation Reinstall in the reverse order of removal Be sure to connect the positive terminal first...

Page 172: ...arging may damage the battery We recommend using a trickle charger for home charging These units can be left connected for long periods without risking damage to the battery However do not intentional...

Page 173: ...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 174: ...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 175: ...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 176: ...After 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 motorc...

Page 177: ...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 178: ...k to other riders who know the area Along with your ATV and riding gear you should take along some tools and supplies in case you have a problem For some of the difficulties you might encounter see wh...

Page 179: ...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 180: ...sport 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 pe...

Page 181: ...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 182: ...ct your ATV and correct 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...

Page 183: ...valve is OFF To prevent rusting in the cylinder perform the following 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 ta...

Page 184: ...cted from freezing temperatures and direct sunlight Slow charge the battery page once a month Wash and dry your ATV Wax all painted surfaces Inflate the tyres to their recommended pressures page Store...

Page 185: ...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 186: ...t only 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 whi...

Page 187: ...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 188: ...t doesn t feel right If you continue riding you could cause more damage and endanger your own safety After a stop take time to assess the situation Carefully inspect your ATV to identify the problem t...

Page 189: ...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 190: ...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 191: ...connected spark plug cap If all possible causes are negative the starter motor may be faulty See your Honda dealer faulty starter motor Charge the battery page If charging doesn t help see your Honda...

Page 192: ...petrol page or change your brand of petrol If the problem persists see your Honda dealer detonates or pings under load afterfires backfires pre ignition runs on after ignition switched OFF See your H...

Page 193: ...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 both switches are...

Page 194: ...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 195: ...tomatically and the shift switches will not operate To reactivate the system turn the ignition switch to the OFF position then turn it back to the ON position With the ATV unoccupied align the hexagon...

Page 196: ...a temporary repair As soon as possible have the tyre permanently repaired by your Honda dealer Any tyre that cannot be repaired should be replaced Whenever the ATV is to be operated far from service...

Page 197: ...V on a firm level surface Raise the front or rear wheels off the ground and place a support block under the vehicle Remove the wheel Removal Remove the wheel nuts 1 1 2 3 4 89 Avoid getting grease oil...

Page 198: ...heel nuts so that the tapered sides face the wheel rim Tighten the wheel nuts in a crisscross rather than a circular pattern to the specified torque If a torque wrench was not used for installation se...

Page 199: ...on 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 th...

Page 200: ...is low or empty don t ride without adding coolant page After adding coolant turn the engine on and check the high coolant temperature indicator If the indicator doesn t turn off do not ride The engine...

Page 201: ...damage caused by excess current flow short circuit or overload If something electrical on your ATV stops working the first thing you should check for is a blown fuse Check all the fuses before looking...

Page 202: ...n 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 fu...

Page 203: ...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 204: ...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 205: ...ly carefully inspect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If the...

Page 206: ...ey and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer you purchased your Honda from They may have it listed in their records If th...

Page 207: ...easily Go to step 5 If the transmission is not in neutral the vehicle will not move Use the gear change tool to shift to neutral so you will be able to start the engine Refer to page Apply the parkin...

Page 208: ...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 209: ...on This section contains dimensions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification Specifications Break in Guidelin...

Page 210: ...nical Information The VIN is stamped on the front of the frame The engine number is stamped on the upper side of the rear crankcase ENGINE NO The VIN and engine serial numbers and key number may be re...

Page 211: ...entification Technical Information The colour code is helpful when ordering replacement parts Record the colour and code here for your reference COLOUR CODE The colour label is attached to the frame u...

Page 212: ...alent High quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines 1 5 1 6 US qt 1 3 Imp qt including reserve after disassemb...

Page 213: ...in 1 400 100 min rpm 0 15 mm 0 006 in 0 23 mm 0 009 in rider all cargo and accessories or spark plug standard compression ratio bore stroke displacement passenger capacity maximum weight capacity spa...

Page 214: ...rimary reduction secondary reduction final reduction final drive 1st 2nd 3rd 4th 5th transmission ratio caster trail tyre size front tyre size rear tyre pressure front rear cold Noise level ISO 5131 V...

Page 215: ...8 lbf ft battery generator headlight reverse indicator neutral indicator brake tail light high coolant temperature indicator other shift motor main PGM FI indicator 4WD indicator wheel nuts differenti...

Page 216: ...on Help assure your ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 25 km 15 miles During this period avoid full throttle starts ra...

Page 217: ...use petrol containing more 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...

Page 218: ...resents the contents of each section of your owner s manual Important Safety Information Safety Labels Operation Component Locations Indicators Displays Multi function Display Gear Position Indicator...

Page 219: ...Engine Stop Switch Headlight Switch Headlight Dimmer Switch Horn Button Recoil Starter Throttle Lever Gearshift Switch Reverse Selector Knob Front Brake Lever Rear Brake Lever Rear Brake Pedal Parkin...

Page 220: ...nts Starting Stopping the Engine Preparation Starting Procedure Flooded Engine Bank Angle Sensor Ignition Cut off System Stalled Engine How to Stop the Engine Using the Recoil Starter Shifting Gears R...

Page 221: ...ions Maintenance Schedule Maintenance Record Maintenance Component Locations Tool Kit Owner s Manual Storage Fluids Filters Engine Seat Removal Clip Removal Fuel Engine Oil Filter Gear Case Oil Differ...

Page 222: ...ng Your Honda Storing Your Honda Preparation for Storage Removal from Storage You the Environment General Guidelines If Your Engine Quits or Won t Start If the Shift Switches Do Not Function Emergency...

Page 223: ...215 TECHNICAL INFORMATION 201 TABLE OF CONTENTS 210 INDEX 216 Table of Contents Table of Contents Vehicle Identification Specifications Break in Guidelines Petrol Containing Alcohol 202 204 208 209...

Page 224: ...m 149 fluid 139 front brake lever 33 pad wear 142 parking 34 rear brake lever 33 rear brake lever freeplay 145 rear brake pedal 33 rear brake pedal freeplay 143 shoe wear 147 accessories 50 age recomm...

Page 225: ...ty fuel 103 care appearance 165 cargo loading and operational guidelines 49 weight limit 48 cleaning appearance care 165 climbing hills 75 clip 101 clutch system 132 colour label 203 controls features...

Page 226: ...adlight 28 dipstick 109 display check 15 display multi function 18 driveshaft boots TRX420FE only 158 engine flooded 62 guard 157 number 202 oil 105 pinging 102 starting 60 stop switch 27 stopping 63...

Page 227: ...x Index F final gear case oil 114 flag pole bracket 35 flat tyre 188 flooded engine 62 fuel fill cap 103 gauge 23 recommendation 102 refueling 103 reserve fuel supply 103 tank capacity 103 valve 24 fu...

Page 228: ...gear shifting 65 gearshift switch 65 headlight dimmer switch 28 headlight switch 28 hills crossing or turning on slopes 80 riding down hills 79 riding up hills 75 stopping on hills 77 horn button 28 h...

Page 229: ...tion vehicle 202 ignition switch 25 indicators gear position indicator 18 19 high coolant temperature indicator 14 16 191 neutral indicator 14 16 oil change indicator 18 20 PGM FI indicator 14 16 reve...

Page 230: ...t weight 48 load limits 48 loading guidelines 49 lubrication differential oil TRX420FE only 116 engine oil 105 gear case oil 114 maintenance component locations 95 importance 87 precautions 89 record...

Page 231: ...Index N O neutral indicator 14 16 numbers serial 202 obstacles riding over 82 odometer 21 oil differential TRX420FE only 116 engine 105 gear case 114 operation component locations 11 owner s manual s...

Page 232: ...r shifting into 68 indicator 14 16 riding in 68 selector knob 32 rider training 40 parking 84 passenger no carrying 41 pavement no riding on 55 petrol 102 petrol containing alcohol 209 pinging engine...

Page 233: ...ons 55 through water 83 cont d safety important precautions 89 labels 5 riding precautions 55 schedule maintenance 90 seat removal 100 serial numbers 202 shifting gears 65 skid plate 157 skidding or s...

Page 234: ...ex starting engine 60 troubleshooting 182 stop switch engine 27 stopping engine 63 storage ATV 174 owner s manual 99 switch downshift 31 65 engine stop 27 headlight 28 headlight dimmer 28 ignition 25...

Page 235: ...ing 156 repairing 155 thread conditions 153 154 tool kit 98 trailer hitch 36 trailer towing operational guidelines 49 weight limits 48 training rider 40 transporting your ATV 172 tripmeter 21 trouble...

Page 236: ...Index Index W V valve fuel 24 valve clearance 137 vehicle identification no VIN 202 warning labels 5 washing your ATV 166 water riding through 83 draining from brakes 149 weight limit 48 wheel removal...

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