Honda HP250 Owner'S Manual Download Page 1

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Summary of Contents for HP250

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Page 3: ...s preceded by the following words mImEI Indicates a strong possibility of severe personal injury or death if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE Gives helpful information If a problem should arise or if you have any questions about the power carrier consult an authorized Honda power carrier deale...

Page 4: ...PERATION CHECKS 11 5 OPERATION 15 l Starting the engine 15 l Operating the power carrier 18 l Stopping the engine 20 l High altitude operation 23 6 CARRYING LOADS 24 7 MAINTENANCE 28 8 TRANSPORTING STORAGE 45 9 TROUBLESHOOTING 47 10 SPECIFICATIONS 48 11 WARRANTY SERVICE 49 2 ...

Page 5: ... greater than 25 or downward slopes greater than 15 e When operating the power carrier in reverse gear and walking backward there is a greater risk of slipping or tripping Be especially careful when backing up e Know how to stop the power carrier quickly and understand the opera tion of all controls Never permit anyone to operate the power carrier without proper instruction e Gasoline is extremely...

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Page 7: ...FUEL FILLER CAP I ENGINE SWITCH FILLER CAP WRACK 5 ...

Page 8: ...THROTTLE LEVER DRIVE CLUTCH LEVERS r iJEL VALVE TRANSMISSION GUARD 6 ...

Page 9: ...ty of fuel leakage Gasoline is ex tremely flammable and is explosive under certain conditions Fuel vapor or spilled fuel may ignite Engine switch The engine switch controls the electrical circuit for the spark plug ignition system and must be turned to the ON position to enable the engine to start and run The engine will stop when the engine switch is turned to the OFF position CamQ When the power...

Page 10: ...ottle lever is moved to the START CHOKE position it also closes the choke for cold starting The choke is open when the throttle lever is in the HI NORMAL or LO position NORMAL HIGH START CHOKE Starter grip Pull the starter grip to operate the recoil starter STARTER GRI ...

Page 11: ... Drive cltitch levers Use the drive clutch levers to propel or stop the power carrier The two levers are connected and move simultaneously When the levers are held down against the handlebars this releases the brake and engages the drive the power carrier will move if the transmission is in gear When the levers are released this disengages the drive and applies the brake the power carrier will sto...

Page 12: ...you wish to tilt the bed for dumping a load With the carrier bed unlocked tilt it by lifting the engine guard To lock the carrier bed again push down firmly on the engine guard FWWQBefore operating the power carrier check that the carrier bed is locked If the carrier bed is not locked it may tilt while going downhill and ac cidentally dump the load which may cause personal injury and property or e...

Page 13: ... gasoline Avoid getting dirt dust or water in the fuel tank After refueling be sure to tighten the fuel tank cap firmly l Gasoline is extremely flammable and explosive under certain conditions Refuel in a well ventilated area with the engine stopped l Do not smoke or allow flames or sparks in the area where the power carrier is refueled or where gasoline is stored l Be careful not to spill fuel wh...

Page 14: ...containing more than 5 methanol even if it has cosolvents and corro sion inhibitors NOTE l Fuel system damage or engine performance problems resulting from the use of such fuels are not covered under Power Equipment Warranties Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete l Before purchasing fuel from an unfamiliar station try to...

Page 15: ...se Honda 4 stroke oil or an equivalent high detergent premium quality motor oil certified to meet or exceed U S automobile manufacturer s re quirements for Service Classification SE or SF Motor oils classified SE or SF will show this designation on the container SAE 1OW 40 is recommended for general all temperature use 1 ENGINE OIL FILLER CAP CAUTION UPPER LEVEL l Engine oil is a major factor affe...

Page 16: ...ollow the cleaning procedure described on page 33 3 Reinstall the air cleaner element cover and wing nut Securely tighten the wing nut CAUTION Never run engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn through the carburetor into the engine AIR CLEAN l COVER FOAM ELEMENT 14 ...

Page 17: ...tarting the engine 1 Check that the gear shift lever is in the NEUTRAL position Allow the drive clutch levers to remain in the STOP position G EAR SHIFT LEVER STOP NEUTRAL 2 Turn the fuel valve to the ON position 15 ...

Page 18: ...he START CHOKE position START CHOKE THROTTLE LE NOTE If restarting a warm engine the choke will not a warm engine with the throttle lever in the LO position be needed Restart 4 Turn the engine switch to the ON position INE SWITCH 16 ...

Page 19: ...p back against the engine Return it gently to prevent damage to the starter l Do not pull the starter grip while the engine is running as that hay damage the starter 6 Allow the engine to warm up for 2 or 3 minutes Move the throttle lever to the LO position when the engine is warm enough to idle smoothly THROTTLE LEVER 17 ...

Page 20: ...o the desired position I N El z 1 R I N NEUTRAL 1 LOW SPEED 2 HIGH SPEED R REVERSE l To avoid loss of control descend steep slopes in low I 1 gear using LO throttle position l Do not shift gears while the power carrier is moving CAUTION Always shift gears with the engine running and the drive clutch levers released 18 ...

Page 21: ...engine stalls on a slope release the drive clutch levers im mediately to stop the power carrier and avoid loss of control 4 Use the steering clutch levers to steer the power carrier Pull up the right lever to steer right Pull up the left lever to steer left STEERING CLUTCH LEVERS LEFT TURN mm The turning action is abrupt Be sure that loads are properly secured Exercise special care when steering o...

Page 22: ...Stopping the engine 1 Release the drive clutch levers to disengage the drive and apply the brake STOP DRIVE CLUTCk LEVERS 2 Move the gear shift lever to the NEUTRAL position NEUTRAL I 20 ...

Page 23: ...3 Move the throttle lever to the LO position THROTTLE LEVER 4 Turn the engine switch to either OFF position ENGINE SWITCH 21 ...

Page 24: ...5 Turn the fuel valve to the OFF position 22 ...

Page 25: ... than 6 000 feet above sea level ask your authorized Honda power carrier dealer to perform these carburetor modifications Even with suitable carburetor jetting engine horsepower will decrease approximately 3 5 for each 1 000 feet increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modifica tion is made CAUTION Operation of the power carrier at an al...

Page 26: ...ad to the tie down hooks with strong ropes or straps l Before operating the power carrier check that the carrier bed is iodked l When operating the power carrier on ground that is soft or uneven reduce speed and exercise extra care l Use low 1 gear and LO throttle positjon when descending steep slopes Never descend slopes in reverse gear l Exercise extra care when starting stopping or changing the...

Page 27: ... pull both side rails out an equal amount then tighten the lock bolts securely SIDE RAIL Extend up to 130 mm 5 in 130 mm 5 in Return the side rails fully to the inner position for normal use CAUTION l Extend the side rails for use with lightweight loads only A heavy load extended on the sides of the power carrier will increase the hazard of overturning l Extend left and right side rails an equal a...

Page 28: ...the engine guard 2 After dumping the load push down firmly on the engine guard to lock the carrier bed in the normal position iam Before operating the power carrier check that the carrier bed is locked If the carrier bed is not locked it may tilt while going downhill and ac cidentally dump the load which may cause personal injury and property or equipment damage 26 ...

Page 29: ...s greater than 25 or downward slopes greater than 15 Observe the following safe loading and operating limits 200 kg 441 lb For operation on level ground Maximum load 200 kg 441 lb Maximum load height 900 mm 35 4 in For operation on slopes Maximum load 150 kg 330 lb Maximum load height 600 mm 23 6 in Maximum slope 25 upward l 5 downward 27 ...

Page 30: ...nt quality may damage the engine Pre operation checks Pre operation inspection and maintenance work should be conducted to assure proper operation and maximum service life Do not neglect this work Cleaning of parts Check that dirt and debris have not collected on the muffler carburetor control parts and tracks Tightening of parts Check for looseness and play Engine oil Check for low oil level or l...

Page 31: ...ervice life TEM Perform at every indicated month or operat Air cleaner NOTE 1 I Service more frequently when used in dusty areas 21 These items should be serviced by an authorized Honda dealer unless the owner has the proper tools and is mechanically proficient See the Honda Shop Manual 29 ...

Page 32: ...the carrier are necessary for performing some periodic maintenance simple adjustments and repairs Always keep the tool kit with the carrier TOOL BAG WRENCH 14 x 19 WRENCH 10 x 12 SPARK PLUG WRENCH HANDLE 0 SPARK PLUG WRENCH OIL FUNNEL 30 ...

Page 33: ...fter replenishment tighten the cap securely Oil capacity 0 4 P 0 43 US qt ENGINE OIL FILLER CAP BOLT FUNNEL 0 4 e CAUTION Used motor oil may cause skin cancer if repeatedly left in con tact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handli...

Page 34: ...plug PLUG WRENCH 4 Visually inspect t there is apparent wear or if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 5 Measure the plug gap with a feeler gauge The gap should be 0 6 0 7 mm 0 024 m 0 028 in Correct as necessary by carefully bending the side electrode PLUG GAP SIDE 0 6 m 0 7 mm ELEC 0 024 0 026 in TRODE CAUTION l The spark plug must be ...

Page 35: ...thout the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn through the carburetor into the engine 1 Remove the wing nut and the air cleaner cover Remove the element Carefully check foam element for holes or tears and replace if damaged 2 Foam element Clean in warm soapy water rinse and allow to dry thor oughly Or clean in high flash point solvent and al...

Page 36: ...dle of the tracks B 12mm 0 31 0 47 in Track adjustment 1 Tip up the carrier Loosen the two lock nuts until there is space between the nuts and the frame 2 Tighten the inner lock nut by hand until it begins to contact the frame surface 3 While holding the inner lock nut with the 14 x 19 mm wrench use the plug wrench to tighten the outer lock nut as shown NOTE Use the two 19 mm wrenches furnished wi...

Page 37: ...ir applied position DRIVE Next measure the same clearance again with the levers at their released posi tion STOP The clearance in the released position should be 1 to 2 mm 0 04 0 08 in more than in the applied position 2 To adjust loosen the lock nuts and while repeatedly applying and releasing the drive clutch levers adjust so the change in clearance Of the cable holder to the clutch arm is lm2 m...

Page 38: ...lder when the drive clutch levers are at their released STOP position 2 To adjust loosen the lock nuts with the levers still at the stop position and set the distance to the prescribed value 3 After adjustment tighten the lock nuts DRIVE CLUTCH STOP LEVERS SPRING HOLDER BRAKE SPRING 0 55 0 63 in BRAKE CABLE 36 ...

Page 39: ...y adjusted Brake shoe wear is OK if you cannot see the A mark through the brake arm hole when the drive clutch lever is in its released position STOP However if you can see any part of the A mark the brake has worn past its service limit contact your authorized Honda dealer BRAKE ARM BRAKE ARM HOLE 37 ...

Page 40: ...t which each lever can be pulled Closest to the handle grip 2 With each steering clutch lever fully gripped check whether the clearance between the projection on the lever and the handle grip is 20 25 mm 0 78 0 98 in 3 To adjust loosen the lock nut with the lever gripped and turn the adjust nut to get the prescribed clearance 4 After the adjustment tighten the lock nut 20 25 mm 0 78 0 98 in STEERi...

Page 41: ...k whether the play at the end of the carrier bed release lever is 10 m 15 mm 0 39 0 55 in 2 To adjust loosen the lock n and turn the adjust bolt to set the pre scribed distance 3 After adjustment tighten the lock nut 10 10 39 15 mm 0 55 LOCK itlUT I ADJUST BOLT 39 ...

Page 42: ...up to the lower edge of the check bolt hole If it is low engine oil classification see 13 page CHECK BOLT Checking the clutch oil Remove the check bolt and check that the oil is up to the lower edge of the check bolt hole If it is low engine oil classification see 13 page BOLT 40 ...

Page 43: ...Remove the two 6 mm nuts and two 6 mm screws ancj 6 mm bolt remove the muffler protectors muffler and gasket 2 Remove the spark arrester from the muffler CAUTION Be careful not to damage the spark arrester screen 3 Check for carbon deposits around the exhaust port and the spark ar rester and clean if necessary 4 Install the spark arrester in the muffler 5 Install gasket muffler muffler protectors ...

Page 44: ...n Grease the points noted below at least once a year or after any time you have washed the carrier Recommended grease SAE multipurpose grease ARRIER B J RELEASE SECTION DRIVE CLUTCH JOINT SECTIoN JOINT SECTION 42 ...

Page 45: ...ier to a flat surface and support on wood blocks in two locations so the wheels are off the ground Dump the carrier CAUTION A carrier with a disengaged track will fall over if the carrier is dumped unless first secured with wood blocks 4 Loosen the track tension lock nuts and tighten up the inner nut as far as it will go This is done in order to facilitate the mounting of the track 5 Remove the sp...

Page 46: ...BOLT 9 Remove the wooden blocks and make sure the power carrier is level Then adjust the track tautness See p 34 CAUTION l Special care should be exercised when mounting the tracks l Do not tip the carrier onto its side oil and gasoline may spill out Tip it only enough to ease track installation l After following the above temporary procedure have the power carrier inspected by your authorized Hon...

Page 47: ...engine level to prevent fuel spillage Spilled fuel or fuel vapor may ignite 1 Remove the fuel line from the fuel valve and drain the gasoline from the tank into a suitable container FUEL LINE Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or sparks in the area I 2 To drain the gasoline from the carburetor first set the fuel valve to ON loosen...

Page 48: ...d Lubricate the points noted on page 42 NOTE If the carrier will be stored for more than three months remove the spark plug pour one tablespoon of clean engine oil into the plug hole and reinstall the spark plug securely 7 Pull the starter grip until you feel slight resistance I 8 Place a cover over the power carrier or store it in a well ventilated en closed location CAUTION When storing the powe...

Page 49: ... the spark plug b Install the spark plug in the plug cap c Turn the engine switch on d Grounding the side electrode to any engine ground pull the recoil starter to see if sparks jump across the gap If any fuel is spilled make sure the area is dry before testing the spark plug or starting the engine Spilled fuel or fuel vapor may ignite l Have you followed the starting method as described on page 1...

Page 50: ...ME Overall length Overall width Overall heiaht Dry weight Fully supplied weight No of gears Traveling speed Level Maximum ground load Sloping ground Clutch oil capacity Transmission oil capacity Track width x length 1600 mm 63 0 in 610 mm 24 0 in 1040 mm 40 9 in 119 kg 262 4 lb 122 kg 269 0 lb 2 forward gears 1 reverse gear 1 4 km 0 9 mile h in 1st gear 3 5 km h 2 2 mile h in 2nd gear 1 3 km h 0 8...

Page 51: ...wer Equipment Customer Relations Department of American Honda Motor Co Inc American Honda Motor Co Inc Power Equipment Customer Relations Department P 0 Box 50 Gardena California 90247 0805 Telephone 213 604 2400 We will need the following information in order to assist you Your name address and telephone number Product model and serial number Date of purchase Dealer name and address Nature of the...

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Honda HP250, Owner'S Manual

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