Honda SPORTRAX 250EX 2007 Owner'S Manual Download | Manualshive

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109

Other Inspections & Lubrication

Clutch System

Servicing Your Honda

Start the engine, pull the clutch lever/parking brake lever in, and shift
into gear. Make sure the engine does not stall and the ATV does not
creep. Gradually release the clutch lever/parking brake lever and open
the throttle. Your ATV should move smoothly and accelerate
gradually.

Lubricate the clutch cable with a commercially-available cable
lubricant to prevent premature wear and corrosion.

Check the clutch cable for kinks or signs of wear. If necessary, have
it replaced.

Check that the clutch lever/parking brake lever assembly is positioned
properly and the securing bolts are tight.

Check the clutch lever/parking brake lever and clutch cable for loose
connections or other damage. If the clutch cable is worn or kinked, have
it replaced by your Honda dealer.

6.

06/03/09 10:17:03 31HN6660_118

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Summary of Contents for SPORTRAX 250EX 2007

Page 1: ...ion information available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be repro...

Page 2: ...egulations 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 highways is illegal The vehicle is...

Page 3: ...so 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 list of topics...

Page 4: ...ave 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 to visit our websi...

Page 5: ...sibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that...

Page 6: ...nstructions A Few Words About Safety A Few Words About Safety Safety Headings Safety Section Instructions These signal words mean such as Important Safety Reminders or Important Safety Precautions suc...

Page 7: ...ion you should know plus a look at the safety related labels on your ATV The location and function of indicators and controls on your ATV and operating instructions for various controls and features H...

Page 8: ...le 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 tire your engine...

Page 9: ...06 03 09 10 04 34 31HN6660_009...

Page 10: ...nformation and recommendations to help you ride your ATV safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your ATV Imp...

Page 11: ...consider most important The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle Your ATV is designed for one person only There are no handholds foo...

Page 12: ...y 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 other ATVs take time...

Page 13: ...nts and ride safely Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink a...

Page 14: ...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 who rides the vehi...

Page 15: ...6 Safety Labels ATV Safety USA only 06 03 09 10 05 10 31HN6660_015...

Page 16: ...7 Safety Labels ATV Safety 06 03 09 10 05 16 31HN6660_016...

Page 17: ...8 Safety Labels ATV Safety 06 03 09 10 05 26 31HN6660_017...

Page 18: ...se before or while riding your ATV The 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...

Page 19: ...Ignition Switch 17 Start Button 18 Engine Stop Switch 18 Headlight Switch 19 Headlight Dimmer Switch 19 Throttle Lever 20 Clutch Lever Parking Brake Lever 20 Reverse Assist Lever 21 Front Brake Lever...

Page 20: ...e knob reverse assist lever front brake lever headlight switch ignition switch engine stop switch clutch lever paking brake lever parking brake pin parking brake lock lever 11 Indicators Controls Oper...

Page 21: ...rear brake pedal 12 Indicators Controls Operation Component Locations 06 03 09 10 05 43 31HN6660_021...

Page 22: ...seat lock lever flag pole bracket shift lever fuel valve 13 Indicators Controls Operation Component Locations 06 03 09 10 05 46 31HN6660_022...

Page 23: ...uld have your Honda dealer check for burned out bulbs or other problems The reverse indicator and the neutral indicator are next to the ignition switch The reverse indicator will light when the transm...

Page 24: ...el 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 information about...

Page 25: ...A A B B C C A fully ON B halfway position C fully OFF 1 choke knob 16 Choke Knob Controls Features Indicators Controls The choke knob may be used when starting the engine See page 1 47 06 03 09 10 06...

Page 26: ...R 1 ignition switch 1 ON OFF ON OFF Function Key Position 17 Ignition Switch Controls Features Indicators Controls The ignition switch is used for starting and stopping the engine page Insert the key...

Page 27: ...for starting the engine Pushing the button in starts the engine See page When the start button is pushed the starter motor will crank the engine The starter motor will operate even if the engine stop...

Page 28: ...rols Features Indicators 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 high an...

Page 29: ...pressure on the throttle lever The throttle will automatically return to the closed position engine idle when you remove your thumb The clutch lever parking brake lever is used to disengage the clutc...

Page 30: ...on the right side of the fuel tank is used to shift into reverse To operate pull in the clutch lever parking brake lever with your ATV stopped Leaving your left hand on the clutch lever parking brake...

Page 31: ...brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see page The rear brake pedal is used to slow or stop your ATV To operate depress the peda...

Page 32: ...res Indicators Controls Parking The lock lever and parking brake pin on the clutch lever parking brake lever allows it to be used as a parking brake To operate push down and hold the parking brake pin...

Page 33: ...s Controls Flag poles are optional equipment available from your Honda dealer To mount a pole in the bracket follow the instructions that come with the flag pole kit Flag poles are required in some ri...

Page 34: ...to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride 26 Protective Apparel 26 Rider Training 28 Age Recommendation 29 No...

Page 35: ...wear an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved shirt or jacket whenever you ride Although complete protection is not possible wearing proper gear can red...

Page 36: ...helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker in any helmet you buy USA only Always wear a face shield or...

Page 37: ...er 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 ATV in a safe area to bu...

Page 38: ...d you or your passenger could be injured or killed Never carry a passenger on this ATV 29 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended age for this ATV...

Page 39: ...rugs before or while operating this ATV 30 No Alcohol or Drugs Are You Ready to Ride Before Riding Alcohol drugs and ATVs don t mix Even a small amount of alcohol can impair your ability to operate an...

Page 40: ...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 overturned or been involved in a collisio...

Page 41: ...hat could be a fire hazard or interfere with the proper operation of the vehicle Walk around your ATV and look for anything that appears unusual such as a leak or loose cable Check for deposits in the...

Page 42: ...fluid leakage page Check for smooth operation and adjust if needed page Check for proper function page Check for proper function page Check that the wheels turn properly as you steer the handlebar Mov...

Page 43: ...ATV s design and performance can also make it unsafe Also the weight of any accessories will reduce the maximum load the ATV can carry More specific information on load limits accessories and modifica...

Page 44: ...es the weight of the rider all cargo and accessories The following load limits apply to standard equipment only Modifying your ATV using non standard equipment or riding on terrain that is not flat an...

Page 45: ...making turns and other maneuvers Be sure to observe the weight limits and follow these guidelines Check that the tires are properly inflated Never ride with a passenger The ATV is not designed to car...

Page 46: ...use can cause a loss of lights or engine power page Make sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls Make sure the acce...

Page 47: ...ations or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make your ATV illegal in your area We strongly advise you not to remove any or...

Page 48: ...ns including how to start and stop your engine and how to use the throttle and brakes and what to do when you re through riding Safe Riding Precautions 41 Off Road Use Only 41 Keep Hands and Feet on C...

Page 49: ...ing Braking 55 Riding Your ATV 57 Making Turns 57 Skidding or Sliding 59 Riding Up Hills 60 Riding Down Hills 64 Crossing or Turning on Hills or Slopes 65 Riding Over Obstacles 67 Riding Through Water...

Page 50: ...beginning on page Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice in a safe area until you build your skills and get accustomed to the ATV...

Page 51: ...ls Safe Riding Precautions Basic Operation Riding Always keep both hands on the handlebars and both feet on the footpegs when riding your ATV This is important to maintain your balance and to control...

Page 52: ...visibility and other operating conditions and your experience 43 Control Speed Basic Operation Riding Safe Riding Precautions Riding at excessive speed increases the chance of an accident In choosing...

Page 53: ...alert to changing terrain conditions when operating the ATV 44 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area always check the terr...

Page 54: ...f terrain Attempting wheelies jumps and other stunts increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off 45 Do Not Perform St...

Page 55: ...ns poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death The engine stop switch is set to RUN The transmission is in neutral neutral indicator ON Confi...

Page 56: ...only when the transmission is in neutral Normal Air Temperature 10 35 C 50 95 F With the throttle slightly open press the start button If the engine is cold pull the choke knob up all the way to full...

Page 57: ...F or above Do not use the choke Immediately after the engine starts push the choke knob down to the halfway position Warm up the engine by opening and closing the throttle slightly After the engine ha...

Page 58: ...d Racing a cold engine wastes fuel and increases engine wear Follow steps under Warm up the engine by opening and closing the throttle slightly When the engine begins to run slightly rough push the ch...

Page 59: ...tion even when the engine is OFF Emergency Engine Stop Wait 10 seconds then turn the engine stop switch to RUN Repeat the starting procedure but don t use the choke If the engine still won t start ref...

Page 60: ...shift lever automatically returns to the horizontal position when released To upshift to a higher gear put the toe of your boot under the shift lever and raise it one full stroke To downshift step on...

Page 61: ...ght line Close the throttle completely before shifting Improper shifting may damage the engine transmission and drive train Upshift to a higher gear or reduce throttle before engine rpm speed gets too...

Page 62: ...e cont d If you need to ride in reverse make sure the area behind you is clear and only operate the ATV at low speed Depress and hold down the rear brake pedal Bring the vehicle to a complete stop pul...

Page 63: ...pt turns While turning the reverse assist lever depress the shift lever to reach the reverse gear below neutral Make sure that the reverse indicator comes on Slowly release the clutch lever parking br...

Page 64: ...or complete braking before entering a turn Avoid braking or closing the throttle quickly while turning Either action may cause one or more wheels to slip and reduce your control of your ATV For maxim...

Page 65: ...sion braking by downshifting with intermittent use of both brakes Continuous brake application can overheat the brakes and reduce their effectiveness Riding with your foot resting on the brake pedal o...

Page 66: ...s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 57 Making Turns Basic Operation Riding Riding Your ATV Learn how to turn your ATV pro...

Page 67: ...ll stop To make a sharp turn at low speed It helps to shift your body slightly forward on the seat and lean inside as you steer the handlebar Shifting weight forward allows the rear wheels to turn eas...

Page 68: ...Riding The terrain surface can be a major factor affecting turns Skidding during a turn is more likely to occur on slippery surfaces such as snow ice mud and loose gravel If you skid on ice you may l...

Page 69: ...bility to safely climb hills largely depends on the rider s skill and judgment Begin by practicing on smooth gentle slopes As you gain experience you ll learn the hazards and your own limitations You...

Page 70: ...ill To climb a hill take a running start in an appropriate gear and speed for the conditions Maintain a steady speed as you ascend the hill Never open the throttle suddenly or make sudden gear changes...

Page 71: ...en climbing a hill If you are about to lose all forward speed Using the front and rear brakes together bring the ATV to a stop with the vehicle pointed straight uphill Get off the ATV while you contin...

Page 72: ...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 What to do after the ATV has stalled or rolled backw...

Page 73: ...owner s manual 64 Riding Down Hills Riding Your ATV Basic Operation Riding It s usually advisable to descend hills with the ATV pointed straight downhill Avoid angles that would cause the vehicle to l...

Page 74: ...gear shift your weight back with your arms 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 fron...

Page 75: ...ean toward the uphill side On a slippery or loose surface you may also need to steer slightly uphill to maintain a straight course across the slope Avoid crossing hills that are excessively steep slip...

Page 76: ...n this owner s manual 67 Riding Over Obstacles Riding Your ATV Basic Operation Riding Before operating in a new area check for obstacles Watch out for bumps rain ruts potholes and other obstacles in t...

Page 77: ...eatedly until they dry out and operate normally Riding through water can make the brakes less effective than normal and may reduce stopping ability After leaving the water always test both the front a...

Page 78: ...gine when your ATV is stopped on a grade in gear rock the vehicle back and forth to allow shifting the transmission into neutral While holding the brakes set the parking brake Turn the ignition switch...

Page 79: ...70 Basic Operation Riding 06 03 09 10 12 20 31HN6660_079...

Page 80: ...fic 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 a fuse see page The Impor...

Page 81: ...Case Oil 96 Air Cleaner 98 Throttle 103 Carburetor Choke Cable Knob 105 Clutch System 106 Reverse Lock System 110 Engine Idle Speed 111 Spark Plug 112 Valves 115 Spark Arrester 116 Battery 137 Appeara...

Page 82: ...ditions Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair If your ATV overturns or is involved in a crash be sure your Honda dealer inspec...

Page 83: ...ese tasks with the tools provided with your ATV Other tasks that are more difficult and require special tools are best performed by professionals Removing the wheels should normally be handled only by...

Page 84: ...ctions 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 flammable solvent not...

Page 85: ...ormed 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 tools and equipm...

Page 86: ...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 official Honda Se...

Page 87: ...URS MAINT INTERVAL MAINT INITIAL 100mi 150km 20 operating hours or 1 month R REGULAR Every 600mi 1000 km 100 operating hours or 12 months R 78 Maintenance Schedule Servicing Your Honda Maintenance Pro...

Page 88: ...ON SPARK ARRESTER NUTS BOLTS FASTENERS WHEELS TIRES STEERING SHAFT HOLDER BEARINGS STEERING SYSTEM FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITIAL HOURS NOTE 1 2 R EVERY 2 YEARS MAINT INTERVAL M...

Page 89: ...e sure whoever performs the maintenance completes this record All scheduled maintenance including the 100 mile 150 km or 20 hours initial maintenance is considered a normal owner operating cost and wi...

Page 90: ...l fill cap choke knob front brake fluid reservoir clutch lever parking brake lever throttle lever front brake lever 81 Servicing Your Honda Maintenance Component Locations 06 03 09 10 13 31 31HN6660_0...

Page 91: ...r housing drain tube front brake caliper engine idle speed air pressure gauge tool kit storage compartment rear brake pedal rear brake light switch 82 Servicing Your Honda Maintenance Component Locati...

Page 92: ...iller cap dipstick gear case oil drain bolt gear case oil filler cap engine oil drain bolt spark plug owner s manual spark arrester 83 Servicing Your Honda Maintenance Component Locations 06 03 09 14...

Page 93: ...mple repairs Any extensive work requiring additional tools should be performed by your Honda dealer The tool kit includes the following items standard Phillips screwdriver screwdriver handle tool case...

Page 94: ...ATV provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual in the storage compartment under the seat The owner s manual and spare fuse should b...

Page 95: ...be removed for air cleaner battery and fuse maintenance Press down on the seat until locks Installation Slide the seat back and lift it Removal Insert the front prongs into the hooks on the frame and...

Page 96: ...ber 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 engine damage Ligh...

Page 97: ...e 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 reserve and the...

Page 98: ...ller neck Avoid over filling the tank There should be no fuel in the filler neck If the fuel valve was set to RES turn the fuel valve ON If you replace the fuel fill cap use only a genuine Honda repla...

Page 99: ...e performed more frequently than specified in the maintenance schedule Using the proper oil page and regularly checking adding and changing oil will help extend your engine s life Even the best oil we...

Page 100: ...g Your Honda Engine Oil Do not use non detergent vegetable or castor based racing oils Do not use API SH or higher oils displaying a circular API energy conserving service label on the container They...

Page 101: ...hen the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two clas...

Page 102: ...engine oil level each day before operating your ATV and add if needed Remove the oil filler cap dipstick from the front crankcase cover and wipe it clean Insert the oil filler cap dipstick without sc...

Page 103: ...procedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid page If you do not have the skills or the tools see your Honda...

Page 104: ...plug and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Check that there are no oil leaks If a torque wrench is not used for installation see your...

Page 105: ...drive oil or equivalent 96 Changing Oil Oil Recommendation Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Changing the oil with the gear case at normal operating temperature t...

Page 106: ...ace an oil drain pan under the oil drain plug Remove the oil filler cap and the drain plug After the oil has completely drained reinstall the drain plug and tighten it to the specified torque Fill the...

Page 107: ...t dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer can help you determine the correct service...

Page 108: ...ousing cover 1 3 2 99 Cleaning Air Cleaner Servicing Your Honda Remove the seat page Unlatch the four retainer clips Remove the air cleaner housing cover Uncover the rubber sheet from the retainer cli...

Page 109: ...Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not fully absorb the oil Pour clean Pro Honda Foam Filter Oil or an equivalent Canada Honda Foam Filter Oil or an eq...

Page 110: ...e to the sealing surface of the air cleaner assembly Install the clamp Insert the air cleaner assembly into the air cleaner housing Fasten the screws Install the air cleaner housing cover Latch the fo...

Page 111: ...accordance with the Maintenance Schedule Riding through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle Remove...

Page 112: ...efer to on page After adjustment check for smooth operation of the throttle lever from fully closed to fully open in all steering positions Tighten the lock nut and reinstall the sleeve Loosen the loc...

Page 113: ...to fully closed in all steering positions If there is a problem see your Honda dealer Inspect the condition of the throttle cables from the throttle lever down to the carburetor If the cable is kinked...

Page 114: ...hoke Cable Knob Servicing Your Honda Safety Precautions Refer to on page Check the condition of the choke cable Check the operation of the choke knob If the cable is damaged or kinked have it replaced...

Page 115: ...y Precautions Refer to on page Inspection Check freeplay Freeplay If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear Clutch adjustment may be requi...

Page 116: ...correctly the cable or clutch friction discs may be worn See your Honda dealer Pull back the dust cover Loosen the lock nut and turn the clutch cable adjuster Tighten the lock nut and check the adjus...

Page 117: ...be obtained Tighten the upper lock nut and pull the dust cover back to its normal position Loosen the upper lock nut and turn the upper clutch cable adjuster all the way in to provide maximum freeplay...

Page 118: ...lerate gradually Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion Check the clutch cable for kinks or signs of wear If necessary have it...

Page 119: ...Servicing Your Honda Reverse Lock System Safety Precautions Refer to on page To adjust loosen the lock nut and turn the adjusting nut After adjustment tighten the lock nut securely Check the reverse...

Page 120: ...fuel delivery system Adjusting the idle will not compensate for a fault elsewhere Adjust idle speed by turning the throttle stop screw Idle speed in neutral Park your ATV on a firm level surface Conn...

Page 121: ...ark plugs with an improper heat range can cause engine damage Safety Precautions Use only the recommended type of spark plug in the recommended heat range Refer to on page Using a spark plug wrench pr...

Page 122: ...ly The gap should be Inspect the electrodes and center porcelain for deposits corrosion or carbon fouling If the corrosion or deposits are heavy replace the plug Clean a carbon or wet fouled plug with...

Page 123: ...n by hand to prevent 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 tu...

Page 124: ...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 adjusting valve clea...

Page 125: ...muffler The spark arrester must be serviced every 100 operating hours to maintain its efficiency Regular servicing prevents carbon build up which can diminish engine performance and also complies wit...

Page 126: ...he muffler and tighten the bolts securely Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of...

Page 127: ...o drop Mechanical Drum Rear Brake If the clutch lever parking brake lever or brake pedal freeplay does not feel within the normal range while riding check the brake shoes for wear page Worn pads shoul...

Page 128: ...ge plastic and painted surfaces Handle with care Refer to on page Do not add or replace brake fluid except in an emergency If you do add fluid have your Honda dealer check the system as soon as possib...

Page 129: ...eyes It should be above the LOWER level mark If the level is at or below the LOWER level mark check the brake pads for wear page Check for deterioration or cracks in the hoses and fittings If the hos...

Page 130: ...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 wear indicator...

Page 131: ...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 pedal should be...

Page 132: ...AR 123 Brakes Servicing Your Honda Turn the brake pedal adjusting nut located on the brake operating rod at the rear of the frame Make sure the cutout on the adjusting nut is properly seated on the br...

Page 133: ...ar without disassembly Application of the brake control causes the arrow on the brake arm to move toward a reference mark on the brake panel Apply the brake control and check the movement of the arrow...

Page 134: ...uired if the parking brake does not hold properly Adjustment Temporarily adjust the clutch lever parking brake lever freeplay to more than 3 4 in 20 mm page Turn the brake lever adjusting nut located...

Page 135: ...completed adjust the clutch freeplay to the correct specification page Push down the parking brake pin and then squeeze the clutch lever parking brake lever until firm resistance is felt Measure the...

Page 136: ...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 See page Adjustment is...

Page 137: ...afety Precautions Refer to on page Make sure the engine is off and the parking brake is set Remove the rear brake drain bolt from the bottom of the rear brake cover If any water drains the brake seals...

Page 138: ...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 off road use th...

Page 139: ...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 harshly are more prone...

Page 140: ...e recommended cold tire pressures are Always check air pressure when your 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 re...

Page 141: ...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 pressure increase...

Page 142: ...e 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 before the tread depth at the ce...

Page 143: ...A permanent repair such as an internal plug patch can be made if a tire has only a small puncture in the tread area However you may not be able to safely carry as much weight If you choose to have a t...

Page 144: ...tch 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 must replace the...

Page 145: ...tects the engine crankcase The skid plates protect the frame and rear final gear case Check the guard and plates for cracks damage or looseness at intervals shown in the Maintenance Schedule Have the...

Page 146: ...n 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 frequently see page If...

Page 147: ...fer to on page If you plan to store your ATV we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life If you do not remove the batte...

Page 148: ...ttery is located in a compartment under the seat cont d Remove the battery Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Remove the battery ho...

Page 149: ...d direct sunlight Clean the battery box after removing the battery for storage Dry the battery box and if paint is missing re paint the area Slow charge the battery see following section once every 30...

Page 150: ...e the battery We recommend using a trickle charger for home charging These units can be left connected for long periods without risking damage to the battery However do not intentionally leave the cha...

Page 151: ...sh detergents or chemical solvents that could damage the metal paint and plastic on your ATV If your ATV is still warm from recent operation give the engine and exhaust system time to cool off Park in...

Page 152: ...ne and let it idle for several minutes The engine heat will help dry moist areas As a precaution ride your ATV at a slow speed and apply the brakes several times This will help dry the brakes and rest...

Page 153: ...ner polish and wipe with a non abrasive cloth Apply a high quality chrome aluminum polish and wipe with a non abrasive cloth Dull corroded chrome or aluminum Heavy grime Oil leaks Brake dust Light roa...

Page 154: ...V consider using a commercially available spray cleaner polish or quality liquid or paste wax to finish the job Use only a non abrasive polish or wax made specifically for motorcycles or automobiles A...

Page 155: ...ode from contact with dirt mud or road salt Clean the wheels after riding through any of these substances Use a wet sponge and mild detergent Avoid stiff brushes steel wool or cleaners containing abra...

Page 156: ...o transport and store your Honda and how to be an environmentally responsible ATV owner Preparing for a Ride 148 What to Take to The Riding Area 148 What to Take on The Trail 149 Transporting Your Hon...

Page 157: ...istry of Natural Resources Canada only 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...

Page 158: ...how far you might go from your base camp or help and how experienced you or your companions are in making repairs If you decide to take some tools spare parts or other supplies on the trail be sure y...

Page 159: ...ou 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 gasoline could be a hazard Set the p...

Page 160: ...down 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 area...

Page 161: ...e storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again For more information about storage refer to the available from your Honda dealer USA only We...

Page 162: ...e This procedure requires a means for draining and disposing of drained fuel page Fill the fuel tank Make sure the fuel fill cap is properly installed cont d Drain the carburetor into an approved gaso...

Page 163: ...plug and spark plug cap With the engine stop switch in the OFF position press the start button several times to crank the engine and distribute the oil Remove the battery and charge it fully Store it...

Page 164: ...for more than two months ask your Honda dealer to drain and replace the fuel Perform a pre ride inspection page then test ride your ATV at low speeds Charge the battery page as required Install the ba...

Page 165: ...they also reduce engine performance and may be illegal Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosph...

Page 166: ...tion gives 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 158 If Your Engine Quits or Wo...

Page 167: ...right If you continue riding you could cause more damage and endanger your own safety After a stop take time to assess the situation Carefully inspect your ATV to identify the problem then consider yo...

Page 168: ...the situation and your options before deciding what to do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have permanent repairs mad...

Page 169: ...of the problem may be a simple operational oversight If you have a problem starting the engine or experience poor engine performance the following information may help you If you can t correct the pr...

Page 170: ...ral Shift into neutral blown fuse Replace with a new fuse of the same rating page battery lead loose Tighten the battery lead Charge the battery page If charging doesn t help see your Honda dealer fau...

Page 171: ...el mixture See your Honda dealer sooty exhaust rich fuel mixture See your Honda dealer detonates or pings under load If applicable switch to the recommended octane gasoline page or change your brand o...

Page 172: ...air 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 facilities or av...

Page 173: ...rm level surface Raise the front or rear wheels off the ground and place a support block under the vehicle Remove the wheel Removal Remove the wheel nuts Avoid getting grease oil or dirt on the disc o...

Page 174: ...at the tapered sides face the wheel rim Tighten the wheel nuts in a crisscross rather than a circular pattern to the specified torque If a torque wrench was not used for installation see your Honda de...

Page 175: ...low short circuit or overload If something electrical on your ATV stops working the first thing you should check for is a blown fuse Check the fuse before looking elsewhere for another possible cause...

Page 176: ...accidental short circuit turn the ignition switch OFF before checking or replacing the fuse To access the fuse remove the seat page Remove the fuse holder assembly Pull the old fuse out of the fuse h...

Page 177: ...spect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor dam...

Page 178: ...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 you purchased your Honda from They may have it listed in their record...

Page 179: ...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 If you can t ch...

Page 180: ...r other critical component your ATV may be unsafe to ride Carefully assess the damage and make any repairs that you can But if there is any doubt it s best to be conservative and safe The levers or pe...

Page 181: ...172 Taking Care of the Unexpected 06 03 09 10 24 38 31HN6660_181...

Page 182: ...s and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 174 Specifications 176 Break in Guidelines 180 High Altitude Carburetor Adjus...

Page 183: ...he VIN and engine serial numbers 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 stampe...

Page 184: ...ation The color label is attached to the frame under the seat Remove the seat page to check the label The color code is helpful when ordering replacement parts You may record the color and code in the...

Page 185: ...label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil USA Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil including reserve a...

Page 186: ...6 3 692 X24EPR U9 DENSO X22EPR U9 DENSO or or shaft passenger capacity bore stroke maximum weight capacity displacement spark plug standard compression ratio spark plug cold climate idle speed primary...

Page 187: ...30 kPa 0 30 kgf cm AT22 10 9 DUNLOP KT175 DUNLOP KT171 Low High front rear front rear front rear caster trail tire size front reverse indicator neutral indicator headlight generator battery minimum t...

Page 188: ...f m 9 lbf ft 12 N m 1 2 kgf m 47 lbf ft 64 N m 6 5 kgf m rear final gear case oil drain bolt wheel nuts main engine oil drain bolt Torque Specification Fuse 179 Specifications Technical Information 06...

Page 189: ...elp 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 and ra...

Page 190: ...servicing dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout it...

Page 191: ...l Information Label is attached on the right side of the frame below the front fender The U S Environmental Protection Agency EPA and the California Air Resources Board CARB require that your ATV comp...

Page 192: ...subjected to sunlight Carbon monoxide 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 exha...

Page 193: ...vehicle inspected and repaired by your Honda ATV dealer Symptoms Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burning backfiring Poor performa...

Page 194: ...prior to its sale or delivery to the ultimate purchaser or while it is in use or the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person A...

Page 195: ...The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be m...

Page 196: ...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 oxygenates menti...

Page 197: ...188 Technical Information 06 03 09 10 50 49 31HN6660_197...

Page 198: ...ontains information on your warranty and how to get an official Honda service manual Authorized Manuals 190 Warranty Coverage 193 Warranty Service 194 Contacting Honda 195 Your Honda Dealer 196 The Ho...

Page 199: ...only Canada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic se...

Page 200: ...rand Total Price Each 191 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00 PM EST By compl...

Page 201: ...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 MasterCard...

Page 202: ...th your Warranties Booklet USA only It is important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage will not be voided if you choose to...

Page 203: ...s 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 repair it is best...

Page 204: ...e any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division...

Page 205: ...only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department...

Page 206: ...ssistance for your new Honda includes roadside assistance for your transport vehicle up to one ton as long as your Honda is aboard or in tow An exclusive HRCA website complete with access to the offic...

Page 207: ...NDICATORS CONTROLS 9 The following presents the contents of each section of your owner s manual Important Safety Information 2 Safety Labels 5 Operation Component Locations 11 Indicators 14 Reverse an...

Page 208: ...ever 20 Reverse Assist Lever 21 Front Brake Lever 22 Rear Brake Pedal 22 Parking Brake 23 Flag Pole Bracket 24 Are You Ready to Ride 26 Protective Apparel 26 Rider Training 28 Age Recommendation 29 No...

Page 209: ...t Perform Stunts 45 Starting Stopping the Engine 46 Preparation 46 Starting Procedure 47 Flooded Engine 50 How to Stop the Engine 50 Shifting Gears 51 Riding in Reverse 53 Braking 55 Riding Your ATV 5...

Page 210: ...ty 74 Important Safety Precautions 75 Maintenance Schedule 76 Maintenance Record 80 Fuel 87 Engine oil 90 Gear Case Oil 96 Air Cleaner 98 Maintenance Component Locations 81 Tool Kit 84 Owner s Manual...

Page 211: ...r a Ride 148 What to Take to The Riding Area 148 What to Take on The Trail 149 Transporting Your Honda 150 Storing Your Honda 152 You the Environment 156 General Guidelines 158 If Your Engine Quits or...

Page 212: ...E Vehicle Identification 174 Specifications 176 Break in Guidelines 180 High Altitude Carburetor Adjustment 181 Emission Control Systems 182 Oxygenated Fuels 186 Authorized Manuals 190 Warranty Covera...

Page 213: ...102 air pressure gauge 84 tire 130 altitude high 181 American Honda contacting 195 apparel protective 26 appearance care 142 authorized manuals 190 Battery 137 Brakes cables 126 draining water from 1...

Page 214: ...shoe wear 124 braking 55 break in guidelines 180 capacity fuel 88 carburetor altitude adjustment 181 care appearance 142 choke cable 105 knob 105 cleaning appearance care 142 climbing hills 60 clutch...

Page 215: ...dex Index D component fails 171 consumer information 189 crash if you 168 crossing or turning on hills or slops 65 customer service 195 dimmer switch headlight 19 dipstick 93 06 03 09 10 52 45 31HN666...

Page 216: ...e flooded 50 guard 136 idle speed 111 number 174 oil 90 pinging 87 starting 47 stop switch 18 stopping 50 won t start 160 environment 156 exhaust system cleaning 32 purging 116 flag pole bracket 24 fl...

Page 217: ...ting 51 headlight dimmer switch 19 headlight switch 19 high altitude carburetor adjustment 181 fuel fill cap 88 high altitude fuel mixture adjustment 181 oxygenated 186 recommendation 87 refueling 88...

Page 218: ...ping on hills 62 Honda contacting 195 Rider s Club 197 dealer 196 Honda service manual 190 identification vehicle 174 idle speed engine 111 ignition switch 17 indicators neutral indicator 14 reverse i...

Page 219: ...fety 5 limit weight 35 load limits 35 loading guidelines 36 lubrication engine oil 90 gear case oil 96 maintenance importance 73 component locations 81 precautions 75 record 80 safety 74 schedule 76 0...

Page 220: ...ations 38 neutral indicator 14 noise emission control systems 185 numbers serial 174 obstacles riding over 67 oil engine 90 gear case 96 operating controls 15 operation component locations 11 owner s...

Page 221: ...ar shifting into 51 indicator 14 riding in 53 rider training 28 Rider s Club Honda 197 parking 69 passenger no carrying 29 pavement no riding on 3 pinging engine 87 plug spark 112 pre ride inspection...

Page 222: ...reparing for 31 over obstacles 67 safety 2 safety precautions 41 through water 68 safety important precautions 75 labels 6 riding precautions 41 schedule maintenance 76 seat removal 86 serial numbers...

Page 223: ...117 spark knock 87 spark plug 112 specifications 176 stalling on a hill 62 start button 18 starting engine 46 troubleshooting 160 stop switch engine 18 stopping engine 50 storage ATV 152 owner s manua...

Page 224: ...34 specifications 135 thread conditions 133 tool kit 84 training rider 28 transporting your ATV 150 trouble unexpected 157 troubleshooting starting 161 turning on level ground 58 on hills or slopes 65...

Page 225: ...x Index W warning labels 6 warranty coverage 193 extended 193 service 194 washing your ATV 143 water riding through 68 draining from brakes 128 weight limit 35 wheel removal 164 06 03 09 10 53 34 31HN...

Page 226: ...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 Frequent causes of cos...

Page 227: ...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 06 03 09 10 53 45 31HN6660_227...

Page 228: ...nuts bolts underbody exhaust system air cleaner housing drain tube leaks loose parts cables throttle brakes switches steering unleaded gasoline pump octane number 86 or higher Maximum Weight Capacity...

Page 229: ...5 0 psi 34 kPa 0 34 kgf cm 2 9 psi 20 kPa 0 20 kgf cm 4 4 psi 30 kPa 0 30 kgf cm AT22 10 9 DUNLOP KT175 DUNLOP KT171 15 A Front Rear maximum tire pressure minimum tire pressure or or standard Front R...

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