Honda FOURTRAX Page 96 Owner'S Manual Download

Page: 96 / 242

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

..............................................................................................

Throttle

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Clutch System

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Reverse Lock System

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Spark Plug

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Valves

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Spark Arrester

Chassis

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Brakes

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Tyres

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Differential Oil (

only)

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Guards

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Drivetrain Boots

Electrical

...............................................................................................

Battery

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Appearance Care

102
105
114
116
118
124

130
132
133
134
137
138

TRX420FM

139
150
157
159

161

166

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Summary of Contents for FOURTRAX

Page 1: ......

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Page 3: ...Honda TRX420TM FM FOURTRAX 420 4 4 OWNER S MANUAL...

Page 4: ...in guidelines and perform all pre ride and other periodic checks detailed in this manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety inf...

Page 5: ...duction Introduction 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 r...

Page 6: ...ave provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or pos...

Page 7: ...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 8: ...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 9: ...gular maintenance what you need to know before servicing your Honda an owner maintenance schedule and instructions for specific maintenance and adjustment items How to store and transport your ATV and...

Page 10: ......

Page 11: ...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 12: ...few that we consider to be most important The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle It s a proven fact helmets significantly reduce t...

Page 13: ...you need to cross a paved or public road get off and walk your ATV across The terrain can present a variety of challenges when you ride off road Continually read the terrain for unexpected turns drop...

Page 14: ...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 15: ...arts of the vehicle If a label comes off or becomes hard to read contact your Honda dealer for replacements Your ATV comes with several labels containing important safety information Anyone who rides...

Page 16: ...Engine net power Machine mass Engine net power Machine mass 6 Safety Labels ATV Safety TRX420TM TRX420FM...

Page 17: ...7 Safety Labels ATV Safety...

Page 18: ...8 Safety Labels ATV Safety TRX420FM only...

Page 19: ...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 20: ...tton Headlight Switch Headlight Dimmer Switch Horn Button Recoil Starter Throttle Lever Reverse Selector Knob Front Brake Lever Rear Brake Pedal Parking Brake Flag Pole Bracket Trailer Hitch 2WD 4WD S...

Page 21: ...rottle lever headlight dimmer switch horn button front brake lever headlight switch rear brake lever parking brake lock lever engine stop switch 2WD 4WD select lever TRX420FM only parking brake lever...

Page 22: ...front cargo rack rear brake pedal recoil starter rear cargo rack fuel valve seat latch 12 Instruments Controls Operation Component Locations...

Page 23: ...shift lever trailer hitch flag pole bracket 13 Instruments Controls Operation Component Locations...

Page 24: ...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 Refer to the indicators...

Page 25: ...digital segments so you can make sure the liquid crystal display is functioning properly Display Check If one of these indicators does not come on when it should have your Honda dealer check for probl...

Page 26: ...ife of the engine If the high coolant temperature indicator comes on while you are riding immediately bring the vehicle to a stop turn the engine off and let it cool See page PGM FI indicator Lights w...

Page 27: ...al for engine oil change is reached page Speedometer Shows riding speed Odometer Shows accumulated mileage page Tripmeter Shows mileage per trip page Hourmeter Shows hours and tenths of hours of engin...

Page 28: ...indicator 4 speedometer 5 odometer tripmeter hourmeter 5 18 Multi function Display Indicators Displays Instruments Controls The multi function display includes the following functions 1 Gear position...

Page 29: ...for the five forward gears will be displayed on the gear position indicator when the transmission is not shifted into gear properly Before riding check that the gear position is properly displayed on...

Page 30: ...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 31: ...nition is ON To change the display from tripmeter or hourmeter to odometer press and release the hourmeter odometer tripmeter select button When selected the tripmeter shows mileage per trip while the...

Page 32: ...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 33: ...Instruments Controls The fuel gauge shows the approximate fuel supply available At F Full the fuel tank capacity including reserve is When the gauge needle enters the red band fuel will be low and you...

Page 34: ...you refuel If the fuel valve is left in the RES position you may run out of fuel with no reserve Reserve Fuel RES for extra fuel to get to a gas supply for refueling OFF for parking storing or transp...

Page 35: ...LEBAR OFF ON Key Position Function 25 Ignition Switch Controls Features Instruments Controls The ignition switch is used for starting and stopping the engine page Insert the key and turn it to the rig...

Page 36: ...handlebar while machine is in motion and come to a complete stop before using the 2WD 4WD select lever The 2WD 4WD select lever is located on the left side of the fuel tank To select the drive mode sh...

Page 37: ...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 38: ...on 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 between the...

Page 39: ...RIGHT SIDE 1 recoil starter 1 29 Recoil Starter Controls Features Instruments Controls Using the Recoil Starter The recoil starter is used to start the engine when the battery is low See page 1 64...

Page 40: ...ures Instruments Controls The throttle controls engine rpm speed To increase engine rpm press the throttle lever with your thumb To reduce engine rpm release pressure on the throttle lever The throttl...

Page 41: ...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 sure...

Page 42: ...ATV To operate pull the lever For information on braking techniques see page The rear brake lever parking brake lever is used to slow or stop your ATV To operate pull the lever For information on bra...

Page 43: ...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 44: ...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 45: ...railer hitch is located on the rear axle housing To use the hitch you ll need a proper size ball as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the t...

Page 46: ...36 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: ...ection and other protective clothing You don t have any alcohol or drugs in your system For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gl...

Page 49: ...t and long pants 39 Are You Ready to Ride Before Riding Additional Riding Gear In addition to a helmet and eye protection we also recommend Sturdy off road motorcycle boots to help protect your feet a...

Page 50: ...ls learned in the course and the operating techniques described in the owner s manual 40 Rider Training Are You Ready to Ride Before Riding Developing your riding skills is an on going process Even if...

Page 51: ...cause a crash and you or your passenger could be injured or killed Never carry a passenger on this ATV 41 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended a...

Page 52: ...ume alcohol or drugs before or while operating this ATV 42 No Alcohol or Drugs Are You Ready to Ride Before Riding Alcohol drugs and ATVs don t mix Even a small amount of alcohol can impair your abili...

Page 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 tyre can be a major inconvenience If your ATV has...

Page 54: ...ive wear page Check for damage pages Check for damage or looseness pages Check the wheels to see that the axle nuts are tightened Use a wrench to make sure all accessible nuts bolts and fasteners are...

Page 55: ...l steering positions page Check these items after you get on the ATV Check that all cargo is secure Check the cable housings for wear Check the fittings for looseness Replace or tighten as needed Make...

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

Page 62: ...52 Before Riding...

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

Page 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: ...cle the terrain visibility and other operating conditions and your experience 57 Control Speed Safe Riding Precautions Basic Operation Riding Riding at excessive speed increases the chance of an accid...

Page 68: ...errain Always be alert to changing terrain conditions when operating the ATV 58 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Page 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 59 D...

Page 70: ...operating the engine in an enclosed area such as a garage Your ATV s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Before star...

Page 71: ...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 72: ...erate the recoil starter several times Follow the normal starting procedure If the engine starts then open the throttle slightly if idling is unstable If the engine does not start wait 10 seconds then...

Page 73: ...n gear Once you have started the engine release the front brake lever then apply throttle gradually Normal Engine Stop To stop the engine make sure the transmission is in neutral by checking that the...

Page 74: ...ry is low To operate the recoil starter Check that the transmission is in neutral Grasp the starter grip firmly then pull it out slowly approximately 100 mm 4 in Pull the grip up briskly and fully Aft...

Page 75: ...shift lever shifts the transmission to the next higher or lower gear in the shifting sequence The shift lever automatically returns to the horizontal position when released To upshift to a higher gear...

Page 76: ...mage the engine transmission and drivetrain Upshift to a higher gear or reduce throttle before engine rpm speed gets too high Learn the relationship between engine sound and the normal shifting points...

Page 77: ...or knob 2 rear brake lever parking brake lever 67 Basic Operation Riding Riding in Reverse If you need to ride in reverse make sure the area behind you is clear and only operate the ATV at low speed B...

Page 78: ...ATV may be equipped with a reverse speed limiter which helps the vehicle to maintain a safe speed while riding in reverse gear To shift out of reverse and into neutral raise the shift lever one strok...

Page 79: ...quickly while turning Either action may cause one or more wheels to slip and reduce your control of your ATV Applying the brakes too hard may cause the wheels to lock and slide reducing control of you...

Page 80: ...engine compression braking by downshifting with intermittent use of both brakes Continuous brake application can overheat the brakes and reduce their effectiveness Riding with your foot resting on th...

Page 81: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 71 Making Turns Basic Operation Riding Riding Your ATV Learn how to tur...

Page 82: ...so improves front wheel steering To make a turn from a full stop Apply the throttle gradually when you turn and start up at the same time Remember to shift your body forward to make sharp low speed tu...

Page 83: ...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 84: ...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 85: ...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 86: ...neutral set the parking brake and turn the engine off Then assess the situation If the ATV starts rolling backwards before you begin braking Keep your weight uphill Carefully apply the front brakes f...

Page 87: ...s so the vehicle doesn t roll backwards If the hill is not 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...

Page 88: ...wnhills shift your weight back 78 Riding Down Hills Riding Your ATV Basic Operation Riding It s usually advisable to descend hills with the ATV pointed straight downhill Avoid angles that would cause...

Page 89: ...nded and braced against the handlebar then go down slowly with the throttle closed Use mainly the rear brake to control speed Avoid using either the front brake or rear brake hard or abruptly when rid...

Page 90: ...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 91: ...as described in this owner s manual 81 Riding Over Obstacles Riding Your ATV Basic Operation Riding Before operating in a new area check for obstacles Watch out for bumps rain ruts potholes and other...

Page 92: ...y the brakes repeatedly until they dry out and operate normally Riding through water can make the brakes less effective than normal and may reduce stopping ability After leaving the water always test...

Page 93: ...le back and forth to allow shifting the transmission into neutral The brakelights are activated by applying the parking brake When using the parking brake be sure to turn the ignition switch OFF to av...

Page 94: ...84 Basic Operation Riding...

Page 95: ...c maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking good For information about replacing fuses see page cont d The I...

Page 96: ...Filter Gear Case Oil Coolant Air Cleaner Throttle Clutch System Reverse Lock System Spark Plug Valves Spark Arrester Chassis Brakes Tyres Differential Oil only Guards Drivetrain Boots Electrical Batt...

Page 97: ...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 98: ...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 99: ...to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around petrol Use only non...

Page 100: ...e Schedule 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 tra...

Page 101: ...require more technical information and tools Consult your Honda dealer In the interest of safety we recommend these items be serviced only by your Honda dealer Service more frequently when riding in d...

Page 102: ...LAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL Every 1 000 km 600 mi 100 operating hours or 12 months R INITIAL REGULAR 150 km 100 mi 20 operating hours or 1 month R HOURS MAINT INTERVAL MAINT 92 M...

Page 103: ...00 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 Refer to page 159 114 116 114 140 147 142 139 133 157 132 138 NOTE FREQUENCY ITEMS WHICHEV...

Page 104: ...to the new owner Make sure whoever performs the maintenance completes this record All scheduled maintenance including the 150 km 100 mile or 20 hours initial maintenance is considered a normal owner...

Page 105: ...front brake fluid reservoir fuel fill cap front brake lever throttle lever rear brake lever parking brake lever 95 Servicing Your Honda Maintenance Component Locations...

Page 106: ...ilter drain tube air cleaner housing rear brakelight switch coolant reserve tank differential oil drain bolt TRX420FM only differential oil filler cap TRX420FM only front brake caliper 96 Servicing Yo...

Page 107: ...ester clutch spark plug engine oil filler cap dipstick gear case oil filler cap tool kit owner s manual gear case oil drain bolt air pressure gauge main fuse fuse box battery 97 Servicing Your Honda M...

Page 108: ...he rubber strap The tools in the kit are sufficient to perform routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your Honda dealer The tool ki...

Page 109: ...V provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual in the plastic document bag underside of the seat The owner s manual and air pressure...

Page 110: ...sert the front prongs into the hooks on the frame and press the studs into the grommets The seat must be removed for the air cleaner engine oil engine oil filter clutch spark plug battery and fuse mai...

Page 111: ...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 112: ...trol pumps at service stations normally display the pump octane number For information on the use of see page Never use stale or contaminated petrol or an oil petrol mixture Avoid getting dirt dust or...

Page 113: ...l Capacity Refueling 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...

Page 114: ...terclockwise Pull the breather tube out of the handlebar cover hole Add fuel until the level reaches the bottom of the filler neck Avoid over filling the tank There should be no fuel in the filler nec...

Page 115: ...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 116: ...se the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation Do not use API SH or higher oils displaying a circular API energy conserving ser...

Page 117: ...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 118: ...he engine oil level Refer to on page Check the engine oil level each day before operating your ATV and add if needed Unsnap and remove the left side cover Remove the seat page Start the engine in a we...

Page 119: ...he oil filler cap dipstick and check the oil level The oil level should be between the upper level mark and the lower level mark on the oil filler cap dipstick Reinstall the oil filler cap dipstick If...

Page 120: ...ter specified for your model or a filter of equal quality This procedure requires mechanical skill and professional tools such as a torque wrench and oil filter wrench as well as a means for disposing...

Page 121: ...1 RIGHT SIDE 1 right side cover 111 Engine Oil Filter Servicing Your Honda Install a New Engine Oil Filter Unsnap and remove the right side cover Remove the seat page cont d 1 2 100 1...

Page 122: ...manner page Check that the oil filter cover O rings are in good condition and then install a new oil filter Use only the Honda Genuine oil filter or a filter of equivalent quality specified for your...

Page 123: ...o verify proper assembly Install the seat Install the left side cover Check that there are no oil leaks Stop the engine wait 2 3 minutes and check the oil level Make sure the oil is between the upper...

Page 124: ...oil SAE 80 type 114 Oil Recommendation Changing Oil Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the gear case at normal operating temperature to assure c...

Page 125: ...il filler cap and the drain plug After the oil has completely drained reinstall the drain plug and tighten it to the specified torque Check that the drain plug sealing washer is in good condition If n...

Page 126: ...AE 80 116 Oil Recommendation Changing Oil Differential Oil TRX420FM only Servicing Your Honda Safety Precautions Refer to on page Change the oil with the differential at normal operating temperature t...

Page 127: ...n plug Remove the oil filler cap and the drain plug Pour the drained oil into a suitable container and dispose of it in an approved manner page After the oil has completely drained reinstall the drain...

Page 128: ...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 129: ...rovide additional protection against freezing Check the cooling system frequently during freezing weather Refer to on page Check the engine coolant level each day before operating your ATV and add if...

Page 130: ...t level to the UPPER level mark Remove the rear fender cover and reserve tank cap Always add coolant to the reserve tank Do not attempt to add coolant by removing the radiator cap Remove the seat page...

Page 131: ...nt Replacement Coolant Servicing Your Honda Safety Precautions You the Environment Improper disposal of drained fluids is harmful to the environment Refer to on page To properly dispose of drained coo...

Page 132: ...ter can damage the radiator core 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 f...

Page 133: ...adiator grill plate 8 radiator core 123 Coolant Servicing Your Honda Remove the radiator grill plate Wash the radiator core and radiator grill plate Install the removed parts in reverse order of remov...

Page 134: ...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 135: ...SEAT 2 1 retainer clips 2 air cleaner housing cover 1 125 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 10...

Page 136: ...e out the remaining solvent Avoid twisting or wringing the air cleaner This can tear the foam Inspect for tears or cracks in the foam or seams of the air cleaner Replace the air cleaner if it is damag...

Page 137: ...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 138: ...1 2 1 dust cover UNDER SEAT 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 2 1...

Page 139: ...be serviced in accordance with the Maintenance Schedule Riding through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the...

Page 140: ...afety Precautions Refer to on page After adjustment check for smooth operation of the throttle lever from fully closed to fully open in all steering positions Tighten the lock nut and reinstall the sl...

Page 141: ...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 142: ...riction discs may be worn See your Honda dealer or refer to official Honda Shop Manual Turn the clutch adjuster counterclockwise until you feel slight resistance Turn the adjuster 1 4 turn clockwise t...

Page 143: ...rse 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 sleeve Other Che...

Page 144: ...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 145: ...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 146: ...ent cross threading Tighten the spark plug First tighten the plug NGK turn after it seats DENSO turn after it seats Then loosen the plug Next tighten the plug again 1 8 turn after it seats If the old...

Page 147: ...cessive clearance will cause noise Insufficient clearance will cause loss of power and possibly damage the valves For those who are mechanically proficient and have the proper tools instructions on ad...

Page 148: ...ipe is cool Remove the bolt Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel Stop...

Page 149: ...ght brake lever freeplay does not feel within the normal range while riding check the brake pads for wear page Worn pads should be replaced If the pads are not worn beyond the recommended limit there...

Page 150: ...upright position check the fluid level If your inspection indicates a low fluid level have your Honda dealer add the recommended fluid Do not add or replace brake fluid except in an emergency If you d...

Page 151: ...pads should be replaced If the pads are not worn have your brake system inspected for leaks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings If the hoses...

Page 152: ...sage and riding conditions The pads will wear faster in wet or muddy conditions Inspect the pads visually during all regular service intervals to determine the pad wear Always inspect both pads in bot...

Page 153: ...IDE 143 Rear Brake Pedal Freeplay Brakes Servicing Your Honda Measure the distance the rear brake pedal moves before the brake starts to take hold Freeplay measurement at the tip of the end of the ped...

Page 154: ...urn the brake pedal adjusting nut located on the brake operating rod at the rear of the frame Make sure the cutout on the adjusting nut is properly seated on the brake arm pin Adjust the freeplay of t...

Page 155: ...er 145 Rear Brake Lever Freeplay Brakes Servicing Your Honda If necessary adjust to the specified range Inspection Measure the distance the rear brake lever parking brake lever moves before the brake...

Page 156: ...ith the front wheels pointed straight ahead Turn the brake lever adjusting nut located on the brake operating rod at the rear of the frame Make sure the cutout on the adjusting nut is properly seated...

Page 157: ...ontrol and check the movement of the arrow on the brake arm The rear brake is equipped with an external brake wear indicator that lets you check brake wear without disassembly Application of the brake...

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

Page 159: ...ng Your Honda Safety Precautions Refer to on page Make sure the engine is OFF and the parking brake is set Remove the rear brake drain bolt from the bottom of the rear brake panel If any water drains...

Page 160: ...es must be the proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tyres Although the tyres are designed specifically for...

Page 161: ...dling tread life and riding comfort Generally underinflated tyres wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tyres make your ATV ride harshl...

Page 162: ...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 the recommended cold tyre pressures t...

Page 163: ...e system found in service stations This will minimize the possibility of tyre damage from overinflation If you use a high pressure system at a service station add air in small amounts and check the pr...

Page 164: ...ur Honda Also if you hit a pothole or other hard object while riding stop as soon as you safely can and carefully inspect the tyres for damage Tread Wear For best performance you should replace a tyre...

Page 165: ...slowly preferably without any cargo and have the tyre replaced or permanently repaired as soon as possible For more information on temporary repairs see page A permanent repair such as an internal pl...

Page 166: ...designed to match the performance capabilities of your ATV and provide the best combination of handling braking and comfort It is best to replace all four tyres however if that is not possible you mu...

Page 167: ...late replaced if they are cracked or damaged If the guard and plate bolts are loose tighten them securely The skid plate protects the rear final gear case Check the guard and plate for cracks damage o...

Page 168: ...veshaft Guards TRX420FM only Guards Servicing Your Honda Safety Precautions Check the front boot guards and front driveshaft guards for cracks damage or looseness Tighten any loose fasteners Replace t...

Page 169: ...oot 159 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 damage or...

Page 170: ...oots 160 Driveshaft Boots TRX420FM only Servicing Your Honda Drivetrain Boots Safety Precautions Check the rubber driveshaft boots for damage or leaking grease If necessary have your Honda dealer repl...

Page 171: ...ccessories use current from the battery even when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your ATV or do not ride frequently we...

Page 172: ...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 173: ...located in a compartment under the seat Removal Make sure the ignition switch is OFF Remove the seat page Remove the rear fender cover page Release the rings and remove the rubber band Disconnect the...

Page 174: ...ery see following section once every 30 days Installation Clean the compartment after removing the battery for storage Dry the compartment and if paint is missing re paint the area Check that the batt...

Page 175: ...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 176: ...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 177: ...fter washing rinse your ATV thoroughly with plenty of clean water to remove any residue Detergent residue can corrode alloy parts Dry your ATV with a chamois or a soft towel Leaving water on the surfa...

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

Page 180: ...170 Servicing Your Honda...

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: ...iculties you might encounter see which begins on page We recommend that you always take water food a first aid kit and your owner s manual Other items you should consider loading on your truck or trai...

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: ...parking brake and place the transmission in gear Follow these procedures When you transport your ATV we recommend that you carry the vehicle in its normal operating position on all four wheels Do not...

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 your ATV and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again We suggest you perform the following procedures to...

Page 187: ...alve is OFF To prevent rusting in the cylinder perform the following Remove the spark plug cap from the spark plug Remove the spark plug Do not connect the spark plug to the spark plug cap Pour a tabl...

Page 188: ...cted from freezing temperatures and direct sunlight Slow charge the battery page once a month Wash and dry your ATV Wax all painted surfaces Inflate the tyres to their recommended pressures page Store...

Page 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: ...t only increase noise they also reduce engine performance and may be illegal Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs whi...

Page 191: ...practical advice to help you deal with a wide range of problems Take time to read this section before you ride Also review the tips in page General Guidelines If Your Engine Quits or Won t Start If Yo...

Page 192: ...or and you have the tools supplies and skills to make a permanent repair you may be able to fix it on the trail and continue riding Or you may be able to make a temporary repair that allows you to slo...

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: ...l POSSIBLE CAUSE SYMPTOM If all possible causes are negative the starter motor may be faulty See your Honda dealer faulty starter motor Charge the battery page If charging doesn t help see your Honda...

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

Page 197: ...a temporary repair As soon as possible have the tyre permanently repaired by your Honda dealer Any tyre that cannot be repaired should be replaced Whenever the ATV is to be operated far from service...

Page 198: ...evel surface Avoid getting grease oil or dirt on the front brake disc or pad surfaces when removing and installing each wheel Any contamination can cause poor brake performance or rapid pad wear after...

Page 199: ...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 200: ...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 201: ...the engine on and check the high coolant temperature indicator If the indicator doesn t turn off do not ride The engine needs repair Transport your ATV to a Honda dealer page If the temperature drops...

Page 202: ...ed by excess current flow short circuit or overload If something electrical on your ATV stops working the first thing you should check for is a blown fuse Check all the fuses before looking elsewhere...

Page 203: ...Main Fuse Access Pull the main fuse out If it is blown install the spare main fuse To access the main fuse remove the fuse box cover Remove the seat page To prevent an accidental short circuit turn t...

Page 204: ...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 205: ...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 206: ...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 207: ...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 listed in their records If...

Page 208: ...ry is low or dead as long as the engine is running If the engine is not running it may be started using the recoil starter Jump starting is not recommended especially if you use an automobile battery...

Page 209: ...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 210: ...200 Taking Care of the Unexpected...

Page 211: ...on This section contains dimensions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification Specifications Break in Guidelin...

Page 212: ...chnical Information The engine number is stamped on the upper side of the rear crankcase The VIN engine serial number and key number may be required when ordering replacement parts Record the numbers...

Page 213: ...entification Technical Information The colour label is attached to the frame under the seat Remove the seat page to check the label The colour code is helpful when ordering replacement parts Record th...

Page 214: ...commended for use in aluminum engines API Service Classification SE SF or SG Honda 4 stroke oil or an equivalent 2 8 3 0 US qt 2 5 Imp qt 2 7 2 9 US qt 2 4 Imp qt including reserve after disassembly a...

Page 215: ...es 1 00 1 10 mm 0 039 0 043 in 1 400 100 min rpm 0 15 mm 0 006 in 0 23 mm 0 009 in or NO ADJUSTMENT spark plug standard compression ratio bore stroke displacement maximum weight capacity passenger cap...

Page 216: ...duction secondary reduction final reduction 1st 2nd 3rd 4th 5th reverse final drive caster trail tyre size front tyre size rear tyre pressure front rear cold transmission ratio rear TRX420TM TRX420FM...

Page 217: ...m 47 lbf ft battery generator headlight brake tail light neutral indicator reverse indicator high coolant temperature indicator PGM FI indicator 4WD indicator main other engine oil drain bolt engine...

Page 218: ...on Help assure your ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 25 km 15 miles During this period avoid full throttle starts ra...

Page 219: ...use petrol containing more than 5 methanol even if it has cosolvents and corrosion inhibitors Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the...

Page 220: ...resents the contents of each section of your owner s manual Important Safety Information Safety Labels Operation Component Locations Indicators Displays Multi function Display Gear Position Indicator...

Page 221: ...erse Selector Knob Front Brake Lever Rear Brake Pedal Parking Brake Flag Pole Bracket Trailer Hitch Are You Ready to Ride Protective Apparel Rider Training Age Recommendation No Passengers No Alcohol...

Page 222: ...nts Starting Stopping the Engine Preparation Starting Procedure Flooded Engine Bank Angle Sensor Ignition Cut off System Stalled Engine Using the Recoil Starter Shifting Gears Riding in Reverse Brakin...

Page 223: ...Precautions Maintenance Schedule Maintenance Record Maintenance Component Locations Tool Kit Owner s Manual Storage Fluids Filters Clip Removal Seat Removal Fuel Engine Oil Filter Gear Case Oil Coolan...

Page 224: ...Trail Transporting Your Honda Storing Your Honda Preparation for Storage Removal from Storage You the Environment General Guidelines If Your Engine Quits or Won t Start If You Have a Flat Tyre If the...

Page 225: ...f Contents MANUFACTURER AND AUTHORISED REPRESENTATIVE FOR EU MARKET TABLE OF CONTENTS INDEX TECHNICAL INFORMATION 228 210 226 201 Vehicle Identification Break in Guidelines Specifications Petrol Conta...

Page 226: ...parel protective 38 appearance care 166 bank angle sensor ignition cut off system 62 battery 161 brakelight switch adjustment 148 brakes cables 147 draining water from 149 fluid 139 front brake lever...

Page 227: ...l 103 care appearance 166 cargo loading and operational guidelines 49 weight limit 48 cleaning appearance care 166 climbing hills 74 clips 101 clutch system 132 colour label 203 compartment owner s ma...

Page 228: ...8 dipstick 109 display check 15 display multi function 18 driveshaft boots TRX420FM only 160 drivetrain boots 162 engine flooded 62 guard 157 number 202 oil 105 pinging 102 starting 60 stop switch 27...

Page 229: ...209 gear case oil 114 gear shifting 65 guards 158 final gear case oil 114 flag pole bracket 34 flat tyre 187 flooded engine 62 fuel fill cap 103 gauge 23 recommendation 102 refueling 103 reserve fuel...

Page 230: ...n 28 hourmeter 17 18 22 hourmeter odometer tripmeter select button 14 17 20 21 22 identification vehicle 202 ignition switch 25 indicators gear position indicator 17 18 19 high coolant temperature ind...

Page 231: ...only 26 limit weight 48 load limits 48 loading guidelines 49 lubrication differential oil TRX420FM only 116 engine oil 105 gear case oil 114 maintenance component locations 95 importance 87 precautio...

Page 232: ...difications 51 multi function display 18 obstacles riding over 81 odometer 17 18 21 oil differential TRX420FM only 116 engine 105 gear case 114 operation component locations 11 owner s manual storage...

Page 233: ...senger no carrying 41 pavement no riding on 55 petrol 102 petrol containing alcohol 209 pinging engine 102 plug spark 134 pre ride inspection 43 problems unexpected 181 propeller shaft boots yoke join...

Page 234: ...eat 100 reverse assist cable 133 assist lever 133 gear shifting into 67 indicator 14 16 riding in 67 selector knob 31 rider training 40 riding basic operations 53 clothing 38 over obstacles 81 precaut...

Page 235: ...cautions 55 schedule maintenance 90 seat removal 100 select lever 2WD 4WD 26 serial numbers 202 shifting gears 65 skid plate 157 skidding or sliding 73 spark arrester 138 spark knock 102 spark plug 13...

Page 236: ...226 Index Index starting engine 60 troubleshooting 184 stop switch engine 27 stopping engine 63 storage ATV 176 owner s manual 99 switch engine stop 27 headlight 28 headlight dimmer 28 ignition 25...

Page 237: ...155 replacing 156 tread conditions 153 154 tool kit 98 trailer hitch 35 trailer towing operational guidelines 49 weight limits 48 training rider 40 transporting your ATV 174 tripmeter 17 18 21 troubl...

Page 238: ...Index Index W V valve fuel 24 valve clearance 137 vehicle identification no VIN 202 warning labels 5 washing your ATV 168 water draining from brakes 149 riding through 82 weight limit 48 wheel removal...

Page 239: ...lst Belgium Honda of South Carolina Mfg Inc 1111 Honda way Timmonsville South Carolina 29161 U S A Authorised Representative for EU Market Manufacturer 229 Manufacturer and Authorised Representative f...

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Honda FOURTRAX, Owner'S Manual

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