Honda FOURTRAX 420 ES/4x4 Owner'S Manual Download Page 1

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Honda TRX420TE/FE
FOURTRAX 420 ES/4

OWNER’S MANUAL

06/10/24 12:56:23 32HP4800_002

Summary of Contents for FOURTRAX 420 ES/4x4

Page 1: ...Honda TRX420TE FE FOURTRAX 420 ES 4 4 OWNER S MANUAL 06 10 24 12 56 23 32HP4800_002...

Page 2: ...nd 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 information and hel...

Page 3: ...appy 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 Happy riding 06...

Page 4: ...sibility 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 potential hazards that...

Page 5: ...nstructions 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 Precautions suc...

Page 6: ...ion 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 controls and features T...

Page 7: ...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 responsible ride...

Page 8: ...06 10 24 12 57 10 32HP4800_009...

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

Page 10: ...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 no handholds foo...

Page 11: ...s 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 until you build yo...

Page 12: ...nts 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 don t drink a...

Page 13: ...icle 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 the vehicle sho...

Page 14: ...6 Safety Labels ATV Safety TRX420TE TRX420FE 06 10 24 12 58 10 32HP4800_015...

Page 15: ...7 ATV Safety Safety Labels TRX420FE only 06 10 24 12 58 33 32HP4800_016...

Page 16: ...8 ATV Safety 06 10 24 12 58 36 32HP4800_017...

Page 17: ...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 Locations Indicat...

Page 18: ...immer 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 Features 2WD 4WD...

Page 19: ...ar 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 headlight switch 11 Ins...

Page 20: ...rear cargo rack rear brake pedal seat latch front cargo rack recoil starter fuel valve 12 Instruments Controls Operation Component Locations 06 10 24 12 59 16 32HP4800_021...

Page 21: ...trailer hitch flag pole bracket 13 Instruments Controls Operation Component Locations 06 10 24 12 59 20 32HP4800_022...

Page 22: ...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 are described on...

Page 23: ...ft 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 function display w...

Page 24: ...econds 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 5 High coolant...

Page 25: ...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 display of the...

Page 26: ...ipmeter 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 Instruments Contro...

Page 27: ...d 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 ignition switch is in...

Page 28: ...ied 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 appears for 2 seconds...

Page 29: ...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 ignition is ON...

Page 30: ...e 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 odometer or tripm...

Page 31: ...rols The fuel gauge shows the approximate fuel supply available At F Full the fuel tank capacity including reserve is When the gauge needle enters the red band fuel will be low and you should refill t...

Page 32: ...he 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 transportation ON norm...

Page 33: ...ction 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 right for the ON po...

Page 34: ...s 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 2WD 4WD select le...

Page 35: ...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 position The switc...

Page 36: ...tures 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 The headlight sw...

Page 37: ...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 06 10 24 13 01 5...

Page 38: ...s 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 throttle will automati...

Page 39: ...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 gear or press the...

Page 40: ...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 sure the gear...

Page 41: ...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 The rear b...

Page 42: ...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 used as a parkin...

Page 43: ...ts 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 required in some r...

Page 44: ...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 trailer manufact...

Page 45: ...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 No Passengers N...

Page 46: ...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 proper gear can red...

Page 47: ...s 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 your vision Ad...

Page 48: ...he 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 you have ridde...

Page 49: ...d 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 age for this ATV...

Page 50: ...rugs 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 ability to operate an...

Page 51: ...ot 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 level and add oi...

Page 52: ...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 drain tube If nec...

Page 53: ...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 positions page...

Page 54: ...ction 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 Remember be sur...

Page 55: ...r 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 or making modi...

Page 56: ...d 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 accesso...

Page 57: ...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 extend beyond the ed...

Page 58: ...ested 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 Honda dealer fo...

Page 59: ...ify 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 modifying your ligh...

Page 60: ...52 Before Riding 06 10 24 13 05 13 32HP4800_061...

Page 61: ...ervice 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 Not Perform Stun...

Page 62: ...ing 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 70 72 72 74 75...

Page 63: ...tion 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 accustomed to the...

Page 64: ...ls 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 difficulty seeing an...

Page 65: ...lity 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 accident In cho...

Page 66: ...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 always check the terr...

Page 67: ...f 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 Do Not Perform St...

Page 68: ...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 starting selec...

Page 69: ...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 throttle is fully...

Page 70: ...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 follow steps a...

Page 71: ...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 the neutral indi...

Page 72: ...rate 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 After the engine st...

Page 73: ...he 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 use the reverse s...

Page 74: ...y 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 downshift press th...

Page 75: ...ng 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 the engine off R...

Page 76: ...ear 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 speed Bring the ve...

Page 77: ...ress 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 Release the rear...

Page 78: ...rning 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 ATV If this ha...

Page 79: ...ion 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 the brake pedal or...

Page 80: ...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 turn your ATV prop...

Page 81: ...ll 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 wheels to turn eas...

Page 82: ...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 on ice you may l...

Page 83: ...bility 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 limitations You...

Page 84: ...ill 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 sudden gear changes...

Page 85: ...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 first then carefu...

Page 86: ...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 beside the vehic...

Page 87: ...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 the vehicle to l...

Page 88: ...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 riding down hills...

Page 89: ...ean 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 excessively steep slip...

Page 90: ...n 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 obstacles in t...

Page 91: ...eatedly 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 both the front a...

Page 92: ...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 discharging th...

Page 93: ...d 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 Importance of Ma...

Page 94: ...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 Arrester Valves Spa...

Page 95: ...ion 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 ATV this section...

Page 96: ...ese 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 handled only by...

Page 97: ...e 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 flammable solve...

Page 98: ...iven 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 genuine Honda parts o...

Page 99: ...hnical 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 dusty areas sand...

Page 100: ...NCY 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 Maintenance Sched...

Page 101: ...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 WHICHEVER COMES...

Page 102: ...er 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 operating cost...

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 06 10 24 13 12 49 32HP4800_104...

Page 104: ...lter 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 Your Honda Mainte...

Page 105: ...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 Maintenance Comp...

Page 106: ...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 extensive work re...

Page 107: ...ge 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 gauge should be...

Page 108: ...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 change tool coolant...

Page 109: ...s 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 clip Installation 1...

Page 110: ...ervice 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 water in the f...

Page 111: ...eling 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 r...

Page 112: ...ler 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 genuine Honda replac...

Page 113: ...st oil wears out Changing oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause seri...

Page 114: ...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 operation Do not u...

Page 115: ...ed 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...

Page 116: ...ck 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 minutes Stop the e...

Page 117: ...p 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 required add th...

Page 118: ...ied 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 disposing of the dr...

Page 119: ...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 06 10 24 13 15 21 32HP4...

Page 120: ...eck 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 model Using the...

Page 121: ...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 dipstick Start...

Page 122: ...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 complete and rapi...

Page 123: ...d 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 plug and tighte...

Page 124: ...commendation 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 to assure complet...

Page 125: ...l 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 under the oil d...

Page 126: ...Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines Check the antifreeze containe...

Page 127: ...l 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 needed Make sure...

Page 128: ...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 rear fender co...

Page 129: ...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 coolant refer to p...

Page 130: ...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 dealer if the air...

Page 131: ...late 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 removal 4 5 6 8 7 06...

Page 132: ...t 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 correct service...

Page 133: ...iner 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 2 100 06 10 24...

Page 134: ...ar 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 w...

Page 135: ...rface 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 mark facing forwa...

Page 136: ...r 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 06 10 24 13 18 03 3...

Page 137: ...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 vehicle Remove...

Page 138: ...ns 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 sleeve Loosen the...

Page 139: ...o 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 commercially available...

Page 140: ...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 Loosen the lock nut...

Page 141: ...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 After adjustmen...

Page 142: ...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 range Refer...

Page 143: ...park 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 deposits are heav...

Page 144: ...ding 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 plug is good 1...

Page 145: ...icient 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 ad...

Page 146: ...y 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 area free of co...

Page 147: ...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 is probably air...

Page 148: ...ge 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 soon as possib...

Page 149: ...ads 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 and call a doct...

Page 150: ...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 both the right and...

Page 151: ...ake 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 pedal should be If...

Page 152: ...AR 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 properly seate...

Page 153: ...ke 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 starts to take...

Page 154: ...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 assemblies are position...

Page 155: ...ar 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 movement of the arrow...

Page 156: ...ar 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 Adjustment...

Page 157: ...afety 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 the brake seals...

Page 158: ...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 off road use th...

Page 159: ...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 harshly are more prone...

Page 160: ...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 tyres to match...

Page 161: ...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 pressure increase...

Page 162: ...f 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 before the tre...

Page 163: ...rs 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 repaired at a non Hond...

Page 164: ...ch 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 must replace the t...

Page 165: ...e 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 engine guard an...

Page 166: ...8 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 dealer replace the...

Page 167: ...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 grease If necess...

Page 168: ...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 charge the battery f...

Page 169: ...fer 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 remove the batte...

Page 170: ...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 the negative ter...

Page 171: ...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 then the negativ...

Page 172: ...e 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 intentionally leave the cha...

Page 173: ...sh 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 cool off Park in...

Page 174: ...ne 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 brakes and rest...

Page 175: ...ner 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 Brake dust Light roa...

Page 176: ...our ATV consider using a commercially available spray cleaner polish or quality liquid or paste wax to finish the job Use only a non abrasive polish or wax made specifically for motorcycles or automob...

Page 177: ...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 Preparation for...

Page 178: ...s 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 which begins on pa...

Page 179: ...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 trail be sure y...

Page 180: ...e 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 petrol could be a...

Page 181: ...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 can damage your A...

Page 182: ...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 keep your ATV i...

Page 183: ...o 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 tablespoon 15 20...

Page 184: ...ing 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 your ATV in an...

Page 185: ...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 Install the ba...

Page 186: ...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 damage the a...

Page 187: ...roblems 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 Emergency Gear Selectio...

Page 188: ...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 then consider yo...

Page 189: ...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 permanent repairs mad...

Page 190: ...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 t correct the pr...

Page 191: ...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 dealer low or de...

Page 192: ...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 Honda dealer hig...

Page 193: ...h 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 not functionin...

Page 194: ...f 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 start the engine...

Page 195: ...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 hexagonal hole of the g...

Page 196: ...air 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 facilities or av...

Page 197: ...el 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 or dirt on the...

Page 198: ...at 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 see your Honda de...

Page 199: ...ngine 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 the fuse is blown...

Page 200: ...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 needs repair T...

Page 201: ...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 elsewhere for a...

Page 202: ...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 fuse box cover Pul...

Page 203: ...em 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 have a replace...

Page 204: ...mporarily 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 were installed...

Page 205: ...spect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor dam...

Page 206: ...rrying 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 they don t transpo...

Page 207: ...tep 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 parking brake Turn th...

Page 208: ...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 slowing or stopping...

Page 209: ...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 Petrol Conta...

Page 210: ...n 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 required when orde...

Page 211: ...chnical 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 under the seat R...

Page 212: ...ty 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 disassembly after drainin...

Page 213: ...in 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 spark plug gap val...

Page 214: ...n 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 Vibration on sea...

Page 215: ...generator headlight reverse indicator neutral indicator brake tail light high coolant temperature indicator other shift motor main PGM FI indicator 4WD indicator wheel nuts differential oil drain plu...

Page 216: ...our 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 rapid acceleration...

Page 217: ...aining 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 warranty Honda...

Page 218: ...ents of each section of your owner s manual Important Safety Information Safety Labels Operation Component Locations Indicators Displays Multi function Display Gear Position Indicator Oil Change Indic...

Page 219: ...itch 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 Parking Brake Flag Po...

Page 220: ...opping 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 Riding in Revers...

Page 221: ...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 Differential Oil only...

Page 222: ...oring 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 Gear Selection...

Page 223: ...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 06 10 24 13 32 2...

Page 224: ...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 recommendation 41 air...

Page 225: ...e 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 24 compartment...

Page 226: ...tick 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 won t start 182...

Page 227: ...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 fuses 193 06 10 2...

Page 228: ...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 hourmeter 22 hour...

Page 229: ...2 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 reverse indicator 1...

Page 230: ...d 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 94 safety 88 sc...

Page 231: ...al 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 storage 99 06 10...

Page 232: ...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 102 plug spark 1...

Page 233: ...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 sliding 74 spark...

Page 234: ...ne 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 upshift 31 65 06...

Page 235: ...g 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 unexpected 179 t...

Page 236: ...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 189 06 10 24 13...

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Honda FOURTRAX 420 ES/4x4, Owner'S Manual

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