Honda FourTrax Rancher AT 2009 Owner'S Manual Download Page 100

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Servicing Your Honda

Service Procedures

Engine

Fluids & Filters

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Fuel

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Engine Oil & Filter

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Gear Case Oil

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Coolant

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Air Cleaner

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Throttle

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Differential Oil

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Reverse Lock System

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Spark Plug

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Valves

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Spark Arrester

Chassis

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Brakes

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Tires

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Guards

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Scraper

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Drivetrain Boots

Electrical

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Battery

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Appearance Care

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119
121
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Summary of Contents for FourTrax Rancher AT 2009

Page 1: ...ms to US EPA Noise Emission regulations but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highwa...

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

Page 3: ...ive harm If you have any questions or if you ever need special service or repairs remember that your Honda dealer knows your ATV best and is dedicated to your complete satisfaction You may also want t...

Page 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: ...ntenance schedule and instructions for specific maintenance and adjustment items How to store and transport your ATV and how to be an environmentally responsible rider What to do if you have a flat ti...

Page 8: ......

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

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

Page 11: ...off road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards Even if you have ridden o...

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: ...the vehicle If a label comes off or becomes hard to read contact your Honda dealer for replacements Your ATV comes with a hang tag and several labels containing important safety information Anyone wh...

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

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

Page 16: ...8 Safety Labels 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: ...t Switch Headlight Dimmer Switch Throttle Lever 2WD 4WD Select Lever Trailer Hitch Flag Pole Bracket Parking Brake Rear Brake Pedal Rear Brake Lever Front Brake Lever Reverse Selector Knob Gearshift S...

Page 19: ...lever parking brake lever gearshift switches headlight dimmer switch parking brake lock lever engine stop switch headlight switch front brake lever drive mode select switch 2WD 4WD select lever thrott...

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

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

Page 22: ...y 4 4WD indicator 14 Indicators Displays Instruments Controls The indicators and displays on your ATV keep you informed alert you to possible problems and make your riding safer and more enjoyable Ref...

Page 23: ...shift out of neutral When applicable the 4WD indicator comes on when you turn the ignition switch ON and remains on until you shift out of 4WD mode If one of these indicators does not come on when it...

Page 24: ...comes on at any other time reduce speed and take your vehicle to a Honda dealer as soon as possible PGM FI indicator Lights when coolant temperature is high enough to adversely affect the service life...

Page 25: ...ched page Speedometer Shows riding speed in miles per hour Odometer Shows the total miles ridden page Tripmeter Hourmeter Shows hours and tenths of hours of engine operation page Hourmeter odometer tr...

Page 26: ...icator 4 speedometer 5 odometer tripmeter hourmeter 1 5 3 18 Multi function Display Indicators Displays Instruments Controls The multi function display includes the following functions 1 Gear position...

Page 27: ...five forward gears If the gear position indicator shows or blinks turn the ignition switch to the OFF position and then turn it back to the ON position again If the gear position indicator shows rock...

Page 28: ...erval specified on the maintenance schedule Reset the indicator after each oil change To reset the indicator press and hold the hourmeter odometer tripmeter select button and turn the ignition switch...

Page 29: ...ion is ON To change the display from tripmeter or hourmeter to odometer press and release the hourmeter odometer tripmeter select button When selected the tripmeter shows mileage per trip while the ig...

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

Page 32: ...g Reserve Fuel Remember to check that the fuel valve is in the ON position each time you refuel If the fuel valve is left in the RES position you may run out of fuel with no reserve For complete infor...

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

Page 34: ...cated on the left side of the fuel tank To select the drive mode shift the 2WD 4WD select lever to the desired position Keep both hands on the handlebar while machine is in motion and come to a comple...

Page 35: ...slide the switch to the OFF position The switch must be in the RUN position to start the engine and it should normally remain in the RUN position even when the engine is OFF When the start button is...

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

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

Page 38: ...ct switch RIGHT HANDLEBAR 30 Drive Mode Select Switch Controls Features Instruments Controls Shifting Gears The drive mode select switch has two positions AUTO automatic shift mode and ESP manual shif...

Page 39: ...e gearshift switches upshift switch and downshift switch are used to select the drive D neutral N and reverse R See page and page Manual shift ESP mode These gearshift switches are used to select the...

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: ...the ball and properly hook up a trailer follow the trailer manufacturer s instructions For load limits and operational guidelines see page The trailer hitch is located on the rear end of the rear fra...

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

Page 46: ...38 Instruments Controls...

Page 47: ...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 48: ...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 49: ...Riding Riding pants with knee and hip pads a riding jersey with padded elbows and a chest shoulder protector Off road motorcycle gloves to help protect your hands Sturdy off road motorcycle boots to h...

Page 50: ...ice Guide for the ATV Rider Developing your riding skills is an on going process Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice riding the...

Page 51: ...cause a crash and you or your passenger could be injured or killed Never carry a passenger on this ATV 43 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended a...

Page 52: ...ume alcohol or drugs before or while operating this ATV 44 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 53: ...ATV and make sure any problem you find is corrected A pre ride inspection is a must not only for safety but because having a breakdown or even a flat tire can be a major inconvenience If your ATV has...

Page 54: ...ive wear page Check for damage pages Check for damage or looseness pages Walk around your ATV and look for anything that appears unusual such as a leak or loose cable Check for deposits in the drain t...

Page 55: ...load limits page If you are carrying cargo also check the following Make sure the headlight brakelight and taillight are working properly Check the cable housings for wear Check the fittings for loos...

Page 56: ...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 57: ...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 58: ...wing load limits apply to standard equipment only Modifying your ATV using non standard equipment or riding on terrain that is not flat and smooth could further reduce these limits The weight of added...

Page 59: ...tow another vehicle or trailer Do not tow by tying a rope or cable to the rear rack Load cargo on the rear rack as far forward as possible Make sure cargo on the front rack does not interfere with ha...

Page 60: ...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 61: ...seriously impair your ATV s handling stability and braking making it unsafe to ride We also advise you not to make any modifications or remove any equipment such as the USDA qualified spark arrester...

Page 62: ...54 Before Riding...

Page 63: ...njoy optimum performance and service life refer to Break in Guidelines page cont d Safe Riding Precautions Off road Use Only Keep Hands and Feet on Controls Control Speed Use Care on Unfamiliar or Rou...

Page 64: ...c Operation Riding Braking Riding Your ATV Making Turns Skidding or Sliding Riding Up Hills Riding Down Hills Crossing or Turning on Hills or Slopes Riding Over Obstacles Riding Through Water Parking...

Page 65: ...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 66: ...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 67: ...e terrain visibility and other operating conditions and your experience 1 footpeg 1 59 Control Speed Basic Operation Riding Safe Riding Precautions Riding at excessive speed increases the chance of an...

Page 68: ...errain Always be alert to changing terrain conditions when operating the ATV 60 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Page 69: ...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 61 D...

Page 70: ...ust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death When you stop riding in reverse and turn the ignition switch to the OFF position Aft...

Page 71: ...ing Stopping the Engine Basic Operation Riding Before starting select a level surface and lock the parking brake page Turn the fuel valve and ignition switch to ON Confirm the following The transmissi...

Page 72: ...has a fuel injected engine with an automatic choke Follow the procedure indicated below Any Air Temperature Press the start button with the throttle completely closed The engine will not start if the...

Page 73: ...on for 5 seconds Follow the normal starting procedure If the engine starts then open the throttle slightly if idling is unstable If the engine still won t start refer to page If the engine does not st...

Page 74: ...e front brake lever and pressing the start button Do not press the throttle lever while starting in gear Your ATV is equipped with a start inhibitor system that will cut off the fuel supply if the thr...

Page 75: ...cator light is on then turn the ignition switch OFF To stop the engine in an emergency use the engine stop switch To operate slide the switch to either OFF position Emergency Engine Stop If your ATV i...

Page 76: ...de Use neutral when you start the engine or if it is necessary to stop briefly with the engine idling The gear position indicator shows N Neutral N In the automatic shift AUTO mode you can select neut...

Page 77: ...n automatically shifts to keep the engine at the best speed for riding conditions The gear position indicator shows D Manual shift ESP mode In this mode you can shift gears much like a manual transmis...

Page 78: ...h the gear position indicator shows D When you select manual shift ESP mode with the drive mode select switch the gear position indicator shows the selected position To select reverse shift R use the...

Page 79: ...r brake lever With the throttle closed select the manual shift ESP mode and press the upshift switch once to shift into 1st gear The gear position indicator shows 1 When speed increases release the th...

Page 80: ...the transmission cannot be selected over 4th gear or 5th gear If the electric shift system malfunctions the transmission cannot be shifted by pressing the gearshift switches See your Honda dealer In...

Page 81: ...high Downshifting when engine speed is near its allowable maximum may over rev the engine and possibly cause damage To prevent transmission damage do not coast or tow the ATV for long distances with t...

Page 82: ...ear brake lever parking brake lever LEFT HANDLEBAR 74 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 83: ...ront and rear brakes Do not abruptly apply the rear brake by itself Release the rear brake lever parking brake lever Open the throttle gradually and ride slowly Do not open the throttle suddenly or ma...

Page 84: ...ke controls steer straight ahead until you regain control then reapply the brakes more gently Gradually increase braking as you feel the brakes slowing your speed The increase in engine compression fr...

Page 85: ...various riding situations see the following section Riding with your foot resting on the brake pedal or your hands on the brake levers may overheat the brakes reducing effectiveness When descending a...

Page 86: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 78 Making Turns Riding Your ATV Basic Operation Riding Learn how to tur...

Page 87: ...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 88: ...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 89: ...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 90: ...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 91: ...ft into 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 b...

Page 92: ...ot too steep and you have good footing you may be able to walk the ATV back down the hill Make sure your intended path is clear in case you lose control of the ATV Stand with your body facing downhill...

Page 93: ...scribed in this owner s manual 85 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 94: ...ms extended 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 w...

Page 95: ...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 96: ...as described in this owner s manual 88 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 97: ...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 and rear brakes Avoid gettin...

Page 98: ...le back and forth to allow shifting the transmission into neutral If rocks or other objects are available you can block the wheels as shown for additional security If the ATV begins to move either whi...

Page 99: ...for required service and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking go...

Page 100: ...Engine Oil Filter Gear Case Oil Coolant Air Cleaner Throttle Differential Oil Reverse Lock System Spark Plug Valves Spark Arrester Chassis Brakes Tires Guards Scraper Drivetrain Boots Electrical Batte...

Page 101: ...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 102: ...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 103: ...Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around gasoline Use only non flamm...

Page 104: ...dule can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual Other items involve more extensive procedures and may require special training...

Page 105: ...e more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the o...

Page 106: ...LANT COOLING SYSTEM 600 1000 100 C I I I R I I Refer to page 135 129 134 138 141 111 116 123 REGULAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL INITIAL REGULAR HOURS MAINT INTERVAL MAINT 98 Mainten...

Page 107: ...RAPER SUSPENSION SPARK ARRESTER NUTS BOLTS FASTENERS WHEELS TIRES TIE ROD AND JOINT BOOTS STEERING SHAFT HOLDER BEARINGS STEERING SYSTEM FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITIAL HOURS NOT...

Page 108: ...your ATV is properly maintained Retain detailed receipts to verify the maintenance was performed If the ATV is sold these receipts should be transferred with the ATV to the new owner Make sure whoever...

Page 109: ...rear brake lever parking brake lever front brake lever front brake fluid reservoir throttle lever fuel fill cap 101 Servicing Your Honda Maintenance Component Locations...

Page 110: ...n bolt coolant reserve tank air cleaner housing drain tube rear brake pedal rear brakelight switch engine oil filter engine oil filler cap air pressure gauge owner s manual air cleaner rear brake flui...

Page 111: ...ar case oil filler cap gear case oil drain bolt spark arrester fuse box battery main fuse PS fuse TRX420FPA only engine oil dipstick tool kit rear brake caliper gear change tool 103 Servicing Your Hon...

Page 112: ...4 Tool Kit Servicing Your Honda To open the compartment unhook the rubber strap The tool kit and the gear change tool are stored in the storage compartment below the rear cargo rack An optional larger...

Page 113: ...V provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual in the plastic document bag underside of the seat Be careful not to flood this area wh...

Page 114: ...t Insert the front prongs into the hooks on the frame and press the studs into the grommets Pull the seat latch at the rear of the seat The seat must be removed for the air cleaner engine oil engine o...

Page 115: ...nda Removal Press down on the center pin to release the lock Pull the clip out of the hole Installation Push the bottom of the pin Insert the clip into the hole Lightly press down on the center pin to...

Page 116: ...pump octane number For information on the use of oxygenated fuels see page Use of lower octane gasoline can cause persistent pinging or spark knock a loud rapping noise which if severe can lead to en...

Page 117: ...fueling Procedure Fuel Servicing Your Honda Safety Precautions Fuel tank capacity including reserve Reserve capacity Refer to on page The tank should be refilled as soon as possible after switching to...

Page 118: ...bottom of the filler neck Avoid over filling the tank There should be no fuel in the filler neck If the fuel valve was set to RES turn the fuel valve ON If you replace the fuel fill cap use only a Hon...

Page 119: ...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 120: ...lter Servicing Your Honda Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label Your ATV does not need oil additives Use the re...

Page 121: ...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 122: ...t the engine in a well ventilated area and let it idle for 3 5 minutes If the air temperature is below 10 C 50 F let the engine idle for an additional 5 minutes a total of 10 minutes Stop the engine a...

Page 123: ...the oil level is near or below the lower level mark remove the right side cover Remove the oil filler cap from the front right crankcase cover and add the specified oil into the filler cap hole up to...

Page 124: ...fied for your model or a filter of equal quality With the ATV on the level ground remove the seat page right side cover page left side cover page and then remove the oil filler cap from the front righ...

Page 125: ...on 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 wrong Honda filter or a non Honda filter which is not of...

Page 126: ...ing washer Reinstall the oil drain plug and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Stop the engine wait 2 3 minutes and check the oil level...

Page 127: ...oil Honda shaft drive oil or equivalent 119 Changing Oil Oil Recommendation Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the gear case at normal operatin...

Page 128: ...ve the oil filler cap and the drain plug Install the oil filler cap Make sure the oil level is at the lower edge of the oil filler inspection hole Fill the gear case with the recommended oil Pour the...

Page 129: ...l Honda shaft drive oil or equivalent 121 Oil Recommendation Changing Oil Differential Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the differential at normal opera...

Page 130: ...move the oil filler cap and the drain plug Install the oil filler cap Make sure the oil level is at the lower edge of the oil filler inspection hole Fill the differential with the recommended oil Pour...

Page 131: ...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 132: ...o provide additional protection against freezing Check the cooling system frequently during freezing weather Refer to on page Check the engine coolant level each day before operating your ATV and add...

Page 133: ...t level to the UPPER level mark Remove the seat page Unhook the rubber strap Remove the rear fender cover and reserve tank cap Always add coolant to the reserve tank Do not attempt to add coolant by r...

Page 134: ...lacement Coolant Servicing Your Honda Safety Precautions You the Environment Improper disposal of drained fluids is harmful to the environment Refer to on page Coolant should be replaced by your Honda...

Page 135: ...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 136: ...adiator grill plate 8 radiator core 128 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 137: ...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 138: ...2 UNDER SEAT 1 retainer clips 2 air cleaner housing cover 130 Cleaning Air Cleaner Servicing Your Honda Remove the seat page Unlatch the retainer clips Remove the air cleaner housing cover 1 2 3 2 1 1...

Page 139: ...r the foam Inspect for tears or cracks in the foam or seams of the air cleaner Replace the air cleaner if it is damaged Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner wi...

Page 140: ...o the sealing surface of the air cleaner assembly Install the clamp Insert the air cleaner assembly into the air cleaner housing Fasten the screw Reassemble by reversing the disassembly sequence Insta...

Page 141: ...1 dust cover 1 2 UNDER SEAT 2 breather joint 133 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 142: ...ld 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...

Page 143: ...Safety Precautions Refer to on page After adjustment check for smooth operation of the throttle lever from fully closed to fully open in all steering positions Tighten the lock nut and reinstall the s...

Page 144: ...y open to fully closed in all steering positions If there is a problem see your Honda dealer Inspect the condition of the throttle cable from the throttle lever down to the throttle body If the cable...

Page 145: ...Check the reverse assist lever and cable for loose connections or other damage If the cable is worn or kinked have it replaced by your Honda dealer Refer to on page Return the dust cover and rubber s...

Page 146: ...on Replacement Spark Plug Servicing Your Honda Using spark plugs with an improper heat range can cause engine damage Safety Precautions Use only the recommended type of spark plug in the recommended h...

Page 147: ...rrosion or carbon fouling If the corrosion or deposits are heavy replace the plug Clean a carbon or wet fouled plug with a plug cleaner if available or a wire brush Inspect the spark plug electrodes f...

Page 148: ...ent cross threading Tighten the spark plug If the old plug is good 1 8 turn after it seats If installing a new plug tighten it twice to prevent loosening First tighten the plug NGK turn after it seats...

Page 149: ...those who are mechanically proficient and have the proper tools instructions on adjusting valve clearances are given in the official Honda Service Manual Otherwise the valves should be adjusted by you...

Page 150: ...ocess in your engine from reaching the environment The use of safety glasses is recommended for this procedure Because of the possible fire hazard check that there are no combustible materials in the...

Page 151: ...limit there is probably air in the brake system See your Honda dealer to have the air bled from the system The recommended brake fluid is Honda DOT 4 Brake Fluid or any brake fluid of equal quality an...

Page 152: ...you do add fluid have your Honda dealer check the system as soon as possible Wipe up spills immediately Avoid brake fluid contact with skin or eyes If it comes in contact with your eyes wash them out...

Page 153: ...e fluid level It should be between the UPPER and LOWER level mark If the level is at or below the LOWER level mark check the brake pads for wear page Worn brake pads should be replaced If the pads are...

Page 154: ...sage and riding conditions The pads will wear faster in wet or muddy conditions Inspect the pads visually during all regular service intervals to determine the pad wear Check the wear indicator If the...

Page 155: ...ator RIGHT REAR 2 reference mark 147 Brakes Servicing Your Honda Check the wear indicator If the wear indicator aligns with the reference mark replace both pads as a set see your Honda dealer for this...

Page 156: ...eeplay Brakes Servicing Your Honda Inspection Press down on the rear brake pedal several times Measure the distance the rear brake lever parking brake lever moves before the brake starts to take hold...

Page 157: ...adjusting nut located on the brake operating rod at the brake caliper Make sure the cutout on the adjusting nut is properly seated on the brake arm pin Adjust the freeplay of the rear brake lever par...

Page 158: ...n page Rear Brake Only Check the operation of the rear brakelight switch at the right side behind the engine from time to time The brakelight should turn on at 0 6 in 15 mm of pedal stroke Adjustment...

Page 159: ...es must be the proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tires Although the tires are designed specifically for...

Page 160: ...dling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tires make your ATV ride harshl...

Page 161: ...r tires are cold If you check air pressure when your tires are warm even if your ATV has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the reco...

Page 162: ...e system found in service stations This will minimize the possibility of tire damage from overinflation If you use a high pressure system at a service station add air in small amounts and check the pr...

Page 163: ...ur Honda Also if you hit a pothole or other hard object while riding stop as soon as you safely can and carefully inspect the tires for damage Tread Wear For best performance you should replace a tire...

Page 164: ...temporary repairs see page A tire that is repaired either temporarily or permanently will have lower speed and performance limits than a new or undamaged tire If you have a tire professionally repaire...

Page 165: ...designed to match the performance capabilities of your ATV and provide the best combination of handling braking and comfort It is best to replace all four tires however if that is not possible you mu...

Page 166: ...are cracked or damaged If the guard and plate bolts are loose tighten them securely The skid plate protects the rear final gear case The engine guard protects the frame and engine crankcase Check the...

Page 167: ...nt Driveshaft Guards Guards Servicing Your Honda Safety Precautions Refer to on page Check the front boot guards and front driveshaft guards for cracks damage or looseness Tighten any loose fasteners...

Page 168: ...ds 160 Rear Boot Guards Servicing Your Honda Guards Safety Precautions Refer to on page Check the rear boot guards for cracks damage or looseness Tighten any loose fasteners Replace the rear boot guar...

Page 169: ...The scraper wear will depend upon the severity of usage and riding conditions The scraper will wear faster in wet or muddy conditions Inspection Check the scraper on the rear upper arm for cracks dama...

Page 170: ...62 Front Driveshaft Boots Rear Driveshaft Boots Servicing Your Honda Drivetrain Boots Safety Precautions Check the rubber driveshaft boots for cuts damage or leaking grease If necessary have your Hond...

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

Page 172: ...when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your ATV or do not ride frequently we recommend that you charge the battery freque...

Page 173: ...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 174: ...emoval Make sure the ignition switch is OFF Remove the seat page Remove the rear fender cover page Release the rings and remove the rubber band Disconnect the negative terminal lead from the battery f...

Page 175: ...llowing section once every 30 days Installation Remove the battery Clean the compartment after removing the battery for storage Dry the compartment and if paint is missing re paint the area Check that...

Page 176: ...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 177: ...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 178: ...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 179: ...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 180: ...washing your ATV consider using a commercially available spray cleaner polish or quality liquid or paste wax to finish the job Use only a non abrasive polish or wax made specifically for motorcycles...

Page 181: ...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 182: ...Bureau of Land Management riding clubs and off road magazines are good sources of information Along with your ATV and riding gear you should take along some tools and supplies in case you have a prob...

Page 183: ...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 184: ...port your ATV we recommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking gas...

Page 185: ...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 186: ...ct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again We suggest you perform the following procedures to keep your ATV in top...

Page 187: ...n the cylinder perform the following Check that the fuel valve is OFF Remove the spark plug cap from the spark plug Remove the spark plug Do not connect the spark plug to the spark plug cap Pour a tab...

Page 188: ...cted from freezing temperatures and direct sunlight Slow charge the battery page once a month Cover your ATV with a porous material Avoid using plastic or similar non breathing coated materials that r...

Page 189: ...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 190: ...y increase noise they also reduce engine performance and may be illegal Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which da...

Page 191: ...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 Emergency Gear Selection Operation If You Have a F...

Page 192: ...doesn t feel right If you continue riding you could cause more damage and endanger your own safety After stopping take time to assess the situation Carefully inspect your ATV to identify the problem...

Page 193: ...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 194: ...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 195: ...itch OFF SYMPTOM POSSIBLE CAUSE WHAT TO DO out of fuel Fill the fuel tank flooded engine See page loose or unconnected spark plug cap Install the spark plug cap securely If the engine still won t star...

Page 196: ...Honda dealer detonates or pings under load If applicable switch to the recommended octane gasoline page or change your brand of gasoline If the problem persists see your Honda dealer afterfires backf...

Page 197: ...nsmission If the gear position indicator shows or blinks while riding perform the following Stop the ATV Turn the ignition switch to the OFF position After the engine stops turn the ignition switch to...

Page 198: ...the transmission is locked Use the following procedure to unlock the transmission Make sure the transmission is in neutral Apply the parking brake Turn the ignition switch to the OFF position Loosen t...

Page 199: ...stopped and the ignition switch is ON Stop the ATV Turn the ignition switch to the OFF position After the engine stops turn the ignition switch to the ON position Press both shift switches and check t...

Page 200: ...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 201: ...atically 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 hexagonal...

Page 202: ...a temporary repair As soon as possible have the tire permanently repaired by your Honda dealer Any tire that cannot be repaired should be replaced Whenever the ATV is to be operated far from service...

Page 203: ...f the temporary repair fails you can crash and be seriously injured or killed If you must ride with a temporary tire repair ride slowly and carefully until the tire is permanently repaired or replaced...

Page 204: ...face Removal Remove the wheel Remove the wheel nuts Raise the front or rear wheels off the ground and place a support block under the vehicle Loosen but do not remove the wheel nuts 95 1 1 2 3 4 5 Avo...

Page 205: ...ce the wheel rim Hand tighten the wheel nuts on the wheel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque If a torque w...

Page 206: ...t don t touch the engine or radiator system Let everything cool off first Check the radiator fan If the fan is not working turn the engine off Open the fuse box page and check the radiator fan fuse If...

Page 207: ...eck for an oil leak Check the oil level If necessary add the recommended oil page to the upper level mark If you must leave your ATV to get oil secure it as much as possible If you are able to resume...

Page 208: ...es to protect them from 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...

Page 209: ...ted Main Fuse Access To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuses Remove the seat page Pull the main fuse out If it is blown install the s...

Page 210: ...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 211: ...teering Fuse Access Turn the ignition switch OFF before checking the fuse Remove the seat page Install the seat Install the PS fuse box cover To access the PS fuse remove the PS fuse box cover If the...

Page 212: ...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 213: ...carefully inspect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there...

Page 214: ...e If you lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer where you purchased your Honda ATV They may have it list...

Page 215: ...especially if you use an automobile battery The greater amperage of an automobile battery when the car engine is running can damage your ATV s electrical system Bump starting is also not recommended...

Page 216: ...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 217: ...ction contains dimensions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification Specifications Break in Guidelines Emissio...

Page 218: ...tion The VIN engine serial number and key number may be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN is stamp...

Page 219: ...echnical Information The color code is helpful when ordering replacement parts You may record the color and code in the Quick Reference section at the rear of this manual The color label is attached t...

Page 220: ...cycle oil 49 4 in 1 255 mm 9 1 in 231 mm unleaded gasoline pump octane number of 86 or higher 3 51 US gal 13 3 0 69 US gal 2 6 4 2 US qt 4 0 3 8 US qt 3 6 3 6 US qt 3 4 including reserve after disasse...

Page 221: ...pecifically recommended for use in aluminum engines 1 400 100 rpm 0 039 0 043 in 1 00 1 10 mm 0 009 in 0 23 mm 1 6 US qt 1 5 0 006 in 0 15 mm or intake exhaust displacement bore stroke compression rat...

Page 222: ...M977 MAXXIS M978 4 4 psi 30 kPa front rear 1st 2nd 3rd 4th 5th reverse primary reduction secondary reduction caster final drive transmission ratio trail tire size front tire size rear tire pressure fr...

Page 223: ...RX420FPA only generator battery headlight brake tail light 4WD indicator reverse indicator neutral indicator PS Electric Power Steering indicator high coolant temperature indicator PGM FI indicator ma...

Page 224: ...t 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 47 lbf ft 64 N m 6 5 kgf m engine oil drain bolt engine oil filter cover bolts rear final gear case oil drain bolt differential oil drain bolt wheel nuts T...

Page 225: ...on Help assure your ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts ra...

Page 226: ...he U S Environmental Protection Agency EPA and the California Air Resources Board CARB require that your ATV comply with applicable exhaust emissions standards during its useful life when operated and...

Page 227: ...onoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons The exhaust emission control system inc...

Page 228: ...Rough idle Misfiring or backfiring during acceleration After burning backfiring Poor performance driveability and poor fuel economy Federal regulations prohibit removing or disabling a device or eleme...

Page 229: ...ESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part...

Page 230: ...ns cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and...

Page 231: ...toms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of...

Page 232: ...224 Technical Information...

Page 233: ...ation This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals Warranty Coverage Warranty Service Contacting Honda Your Honda Dealer The Ho...

Page 234: ...authorized Honda dealer is available from Helm Inc Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service infor...

Page 235: ...s Sales Tax Mich add 6 Calif add 7 25 Handling Charge Grand Total 3 75 227 Consumer Information Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR NOTE For Credit Card Orders Only 1 888 29...

Page 236: ...e Telephone Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Check here if your billing address is different from the shipping address shown above VISA Discover...

Page 237: ...overed It is important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage does not apply to normal wear or deterioration associated with u...

Page 238: ...you the results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the rep...

Page 239: ...d and operated That s why it s important to work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comm...

Page 240: ...ries The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the parts department...

Page 241: ...rmation The Honda Rider s Club www hrca honda com You may be eligible for a Honda Rider s Club of America HRCA membership with the purchase of your new Honda You can log on to the HRCA Clubhouse websi...

Page 242: ...resents the contents of each section of your owner s manual Important Safety Information Safety Labels Indicators Displays Operation Component Locations Multi function Display Gear Position Indicator...

Page 243: ...Ready to Ride No Alcohol or Drugs No Passengers Age Recommendation Rider Training Protective Apparel Are You Ready to Ride Trailer Hitch Flag Pole Bracket Parking Brake Rear Brake Pedal Rear Brake Lev...

Page 244: ...nfamiliar or Rough Terrain Do Not Perform Stunts Starting Stopping the Engine Preparation Starting Procedure Flooded Engine Bank Angle Sensor Ignition Cut off System Stalled Engine How to Stop the Eng...

Page 245: ...il Filter Fuel Fluids Filters Clip Removal Seat Removal Maintenance Schedule Important Safety Precautions Maintenance Safety The Importance of Maintenance Parking Differential Oil Reverse Lock System...

Page 246: ...moval from Storage You the Environment General Guidelines If Your Engine Quits or Won t Start If You Lose Your Key If You Crash If a Fuse Blows If You Have a Flat Tire Emergency Gear Selection Operati...

Page 247: ...OF CONTENTS 234 INDEX 240 QUICK REFERENCE Vehicle Identification Specifications Break in Guidelines Emission Control Systems Oxygenated Fuels Your Honda Dealer Contacting Honda Warranty Service Warran...

Page 248: ...rain tube 134 air pressure gauge 105 tire 152 American Honda contacting 231 apparel protective 40 appearance care 169 authorized manuals 226 bank angle sensor ignition cut off system 65 battery 164 br...

Page 249: ...7 20 21 22 capacity fuel 109 care appearance 169 cargo loading and operational guidelines 51 weight limit 50 cleaning appearance care 169 climbing hills 81 clip 107 color label 211 compartment owner s...

Page 250: ...r 210 oil 111 pinging 108 starting 62 stop switch 27 stopping 67 won t start 186 environment 182 exhaust system cleaning 46 purging 142 differential oil 121 dimmer switch headlight 28 dipstick 114 dis...

Page 251: ...rds 159 front driveshaft boots 162 front driveshaft guards 159 fuel fill cap 109 gauge 23 oxygenated 222 recommendation 108 refueling 109 reserve fuel supply 109 tank capacity 109 valve 24 fuses 200 g...

Page 252: ...233 hourmeter 17 18 22 hourmeter odometer tripmeter select button 14 17 20 21 22 Honda service manual 226 identification vehicle 210 ignition switch 25 indicators gear position indicator 17 18 19 high...

Page 253: ...4WD select 26 limit weight 50 load limits 50 loading guidelines 51 lubrication differential oil 121 engine oil 111 gear case oil 119 maintenance component locations 101 importance 93 precautions 95 r...

Page 254: ...53 multi function display 18 neutral indicator 14 16 noise emission control system 221 numbers serial 210 obstacles riding over 88 odometer 17 18 21 oil differential 121 engine 111 gear case 119 oper...

Page 255: ...unexpected 183 propeller shaft boots yoke joint boot 163 protective apparel 40 PS Electric Power Steering 37 rear boot guards 160 rear final gear case oil 119 rear driveshaft boots 162 removal seat 1...

Page 256: ...g for 174 over obstacles 88 safety 2 safety precautions 57 through water 89 safety important precautions 95 labels 5 riding precautions 57 schedule maintenance 96 scraper 161 seat removal 106 select l...

Page 257: ...ug 138 specifications 212 speedometer 17 18 stalling on a hill 83 start button 27 starting engine 62 troubleshooting 186 stop switch engine 27 stopping engine 67 storage ATV 178 owner s manual 105 swi...

Page 258: ...157 repairing 156 thread conditions 154 155 tool kit 104 trailer hitch 36 trailer towing operational guidelines 51 weight limits 50 training rider 42 transporting your ATV 176 tripmeter 17 18 21 troub...

Page 259: ...W V valve fuel 24 valve clearance 141 vehicle identification no VIN 210 warning labels 5 warranty coverage 229 extended 229 service 230 washing your ATV 170 water riding through 89 weight limit 50 wh...

Page 260: ...252 Memo...

Page 261: ...tant notes The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequen...

Page 262: ...Quick Reference Quick Reference Engine No VIN Ignition Key No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr...

Page 263: ...guards nuts bolts underbody exhaust system air cleaner housing drain tube leaks loose parts cables lights throttle brakes reverse assist lever switches steering Fuel Capacity unleaded gasoline pump oc...

Page 264: ...other Front Rear Front Rear standard PS Electric Power Steering TRX420FPA only MAXXIS M977 MAXXIS M978 Quick Reference Quick Reference Tires Tire Pressure cold Spark Plugs Coolant ethylene glycol anti...

Page 265: ...ges START button RUN engine stop switch OFF engine stop switch ON headlight switch OFF headlight switch HI headlight dimmer switch LO headlight dimmer switch lock lever parking brake reverse selector...

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Honda FourTrax Rancher AT 2009, Owner'S Manual

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