Honda SPORTRAX 250EX 2008 Page 196 Owner'S Manual Download | Manualshive

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2008 TRX250EX Service Manual

Common Service Manual

2008 TRX250EX Owner’s Manual

Publication Item No.

Description

Price Each

188

Authorized Manuals

Consumer Information

The Service Manual used by your authorized Honda dealer is
available from Helm, Inc. (USA 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 service information for various systems common to all Honda
motorcycles, motor scooters and ATVs.

These Honda manuals are written for the professional technician, but
most mechanically-capable owners should find them easy to use if
they have the proper tools and observe proper safety standards.
Special Honda tools are necessary for some procedures.

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Summary of Contents for SPORTRAX 250EX 2008

Page 1: ...sion regulations but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways is illegal The vehic...

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

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

Page 4: ...important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potent...

Page 5: ...u don t follow instructions A Few Words About Safety A Few Words About Safety Safety Headings Safety Section Instructions These signal words mean such as Important Safety Reminders or Important Safety...

Page 6: ...safety information you should know plus a look at the safety related labels on your ATV The location and function of indicators and controls on your ATV and operating instructions for various controls...

Page 7: ...ntenance schedule and instructions for specific maintenance and adjustment items How to store and transport your ATV and how to be an environmentally responsible rider What to do if you have a flat ti...

Page 8: ......

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

Page 10: ...e a few that we 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...

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

Page 12: ...ake good judgments and ride safely Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink S...

Page 13: ...the vehicle If a label comes off or becomes hard to read contact your Honda dealer for replacements Your ATV comes with a hang tag and several labels containing important safety information Anyone wh...

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

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

Page 16: ...8 Safety Labels ATV Safety...

Page 17: ...ould normally use 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 the...

Page 18: ...5 Choke Knob 16 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 Fr...

Page 19: ...t lever front brake lever ignition switch clutch lever paking brake lever parking brake lock lever headlight switch engine stop switch headlight dimmer switch parking brake pin choke knob 11 Indicator...

Page 20: ...rear brake pedal 12 Indicators Controls Operation Component Locations...

Page 21: ...seat lock lever shift lever fuel valve flag pole bracket 13 Indicators Controls Operation Component Locations...

Page 22: ...e on when it should 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...

Page 23: ...ing Reserve Fuel Remember to check that the fuel valve is in the ON position each time you refuel If the fuel valve is left in the RES position you may run out of fuel with no reserve For complete inf...

Page 24: ...EFT HANDLEBAR 1 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...

Page 25: ...TER OF HANDLEBAR 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...

Page 26: ...tarter motor will operate even if the engine stop switch is in the OFF position when the start button is pushed The engine stop switch is used to stop the engine in an emergency To operate slide the s...

Page 27: ...mer Switch Controls 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 betw...

Page 28: ...ine rpm release 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 dise...

Page 29: ...e assist lever located 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 clut...

Page 30: ...trols The front 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 d...

Page 31: ...ls 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 squeeze the clutch l...

Page 32: ...atures Indicators 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 33: ...nd adjustments 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 Recomm...

Page 34: ...that you always wear an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved shirt or jacket whenever you ride Although complete protection is not possible wearing prop...

Page 35: ...ng An open face 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...

Page 36: ...for the ATV Rider Developing your riding skills is an on going process Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice riding the ATV in a...

Page 37: ...cause a crash and 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 a...

Page 38: ...ume alcohol or drugs 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 abili...

Page 39: ...you find is corrected A pre ride inspection is a must not only for safety but because having a breakdown or even a flat tire can be a major inconvenience If your ATV has overturned or been involved i...

Page 40: ...ble nuts bolts and fasteners are tight Check for and remove any dirt vegetation or other debris that could be a fire hazard or interfere with the proper operation of the vehicle Walk around your ATV a...

Page 41: ...eft and check that there is no excessive backlash Check for proper function page Check for proper function page Check for smooth operation and adjust if needed page Squeeze the front brake lever and s...

Page 42: ...hat change this 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 accessor...

Page 43: ...can carry includes 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 tha...

Page 44: ...ting braking and 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...

Page 45: ...page A blown fuse 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 Mak...

Page 46: ...ake any modifications 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 t...

Page 47: ...iding instructions 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 Han...

Page 48: ...c Operation Riding 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 Ridin...

Page 49: ...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 accus...

Page 50: ...Feet on Controls 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...

Page 51: ...cle the terrain 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 accid...

Page 52: ...errain Always be 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 alway...

Page 53: ...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 45 D...

Page 54: ...exhaust contains 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 ind...

Page 55: ...tor will operate 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...

Page 56: ...erature 35 C 95 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 Aft...

Page 57: ...engine by opening and closing the throttle slightly When the engine begins to run slightly rough push the choke knob down to the halfway position Continue warming up the engine until it runs smoothly...

Page 58: ...n in the RUN position 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 stil...

Page 59: ...g sequence The 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 dow...

Page 60: ...Close the throttle and pull the clutch lever parking brake lever in completely before shifting Improper shifting may damage the engine transmission and drive train Ride in the highest gear that lets t...

Page 61: ...iding in Reverse 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 co...

Page 62: ...ly or make abrupt 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 l...

Page 63: ...duce your speed 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 you...

Page 64: ...e 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 t...

Page 65: ...in this owner 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 tur...

Page 66: ...rating from a full stop To make a sharp turn at low speed It helps to shift your body slightly forward on the seat and lean inside as you steer the handlebar Shifting weight forward allows the rear wh...

Page 67: ...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 68: ...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 69: ...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 70: ...lls backwards when 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...

Page 71: ...t too steep and you have good footing you may be able to walk the ATV back down the hill Make sure your intended path is clear in case you lose control of the ATV What to do after the ATV has stalled...

Page 72: ...scribed in this 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...

Page 73: ...ft into a lower 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...

Page 74: ...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 75: ...as described in 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...

Page 76: ...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 77: ...to start the engine 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...

Page 78: ...70 Basic Operation Riding...

Page 79: ...pecific 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 For i...

Page 80: ...90 Gear Case Oil 96 Air Cleaner 98 Engine Electrical Chassis Throttle 103 Carburetor Choke Cable Knob 105 Clutch System 106 Reverse Lock System 110 Engine Idle Speed 111 Spark Plug 112 Valves 115 Spa...

Page 81: ...crash be sure your Honda dealer inspects all major parts even if you are able to make some repairs A well maintained ATV is essential for safe economical and trouble free riding It will also help red...

Page 82: ...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 83: ...Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around gasoline Use only non flamm...

Page 84: ...dule can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual Other items involve more extensive procedures and may require special training...

Page 85: ...e more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the o...

Page 86: ...IRST INITIAL HOURS 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...

Page 87: ...0 1000 100 I I I I I I I C I I 1200 2000 200 I I I I I I I I I I C I I I I I Refer to page 96 118 124 121 127 118 110 135 106 116 FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITIAL HOURS NOTE 1 2 R...

Page 88: ...e new owner Make 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 operat...

Page 89: ...fuel 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...

Page 90: ...air cleaner housing drain tube front brake caliper rear brake pedal rear brake light switch throttle stop screw engine idle speed fuse air pressure gauge tool kit 82 Servicing Your Honda Maintenance...

Page 91: ...engine oil filler cap dipstick gear case oil filler cap engine oil drain bolt spark plug owner s manual spark arrester gear case oil level check bolt 83 Servicing Your Honda Maintenance Component Loc...

Page 92: ...rubber band to fasten the tool kit securely tool case spark plug wrench air pressure gauge screwdriver handle standard Phillips screwdriver The tools in the kit are sufficient to perform routine maint...

Page 93: ...wner s manual and spare fuse should be stored in the plastic document bag and fastened with the rubber band Be careful not to flood this area when washing your ATV Your ATV provides storage for the ow...

Page 94: ...until locks Installation Slide the seat back and lift it Removal Insert the front prongs into the hooks on the frame and press the studs into the grommets on the frame Pull the seat lock lever at the...

Page 95: ...pump octane number For information on the use of oxygenated fuels see page Use of lower octane gasoline can cause persistent pinging or spark knock a loud rapping noise which if severe can lead to en...

Page 96: ...ueling Procedure Fuel Servicing Your Honda Safety Precautions Fuel tank capacity including reserve Reserve capacity Refer to on page The tank should be refilled as soon as possible after switching to...

Page 97: ...ottom of the filler neck Avoid over filling the tank There should be no fuel in the filler neck If the fuel valve was set to RES turn the fuel valve ON If you replace the fuel fill cap use only a Hond...

Page 98: ...changes should be 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...

Page 99: ...Your Honda Engine Oil Do not use non detergent vegetable or castor based racing oils Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API se...

Page 100: ...t 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 The...

Page 101: ...mark on the oil filler cap dipstick Do not overfill Insert the oil filler cap dipstick without screwing it in then remove the oil filler cap dipstick and check the oil level The oil level should be b...

Page 102: ...echanical 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 dealer With the ATV...

Page 103: ...g and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Stop the engine and check the oil level Make sure the oil is between the upper and lower level...

Page 104: ...oil Honda shaft drive oil or equivalent 96 Changing Oil Oil Recommendation Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the gear case at normal operating...

Page 105: ...ain pan under the oil drain plug Remove the oil filler cap and the drain plug Remove the oil level check bolt Make sure the oil level reaches the oil level check hole Fill the gear case with the recom...

Page 106: ...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 107: ...ps 3 air cleaner housing cover 1 3 2 99 Cleaning Air Cleaner Servicing Your Honda Remove the seat page Unlatch the retainer clips Remove the air cleaner housing cover Uncover the rubber sheet from the...

Page 108: ...if it is damaged 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 Fil...

Page 109: ...hin coat of grease 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 c...

Page 110: ...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 111: ...y 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 sleeve...

Page 112: ...from fully open 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...

Page 113: ...05 Carburetor Choke 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 h...

Page 114: ...nda Safety 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...

Page 115: ...the correct freeplay cannot be obtained using the cable adjuster a major adjustment must be made Loosen the lock nut and turn in the cable adjuster completely Tighten the lock nut and pull on the dus...

Page 116: ...reeplay cannot 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 m...

Page 117: ...oothly 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 ne...

Page 118: ...verse Lock System Safety Precautions Refer to on page Check the reverse assist lever and cable for loose connections or other damage If the cable is worn or kinked have it replaced by your Honda deale...

Page 119: ...problems in your engine s 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...

Page 120: ...r Honda Using spark plugs with an improper heat range can cause engine damage Safety Precautions Use only the recommended type of spark plug in the recommended heat range Refer to on page Using a spar...

Page 121: ...ode carefully 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 foule...

Page 122: ...the spark plug in 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...

Page 123: ...ssive 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 adju...

Page 124: ...gasket from the 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 al...

Page 125: ...the gasket in the 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...

Page 126: ...ause the level to 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...

Page 127: ...uid can damage 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 so...

Page 128: ...it contacts your eyes With the ATV in an upright position check the fluid level 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 p...

Page 129: ...sage and riding conditions The pads will wear faster in wet or muddy conditions Inspect the pads visually during all regular service intervals to determine the pad wear Check the wear indicator If the...

Page 130: ...T SIDE 122 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...

Page 131: ...h the front wheels pointed straight ahead 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...

Page 132: ...check brake wear without disassembly Application of the brake control causes the arrow on the brake arm to move toward a reference mark on the brake panel Replace the brake shoe if the arrow aligns w...

Page 133: ...utch lever parking brake lever freeplay to more than 3 4 in 20 mm page Turn the brake lever adjusting nut located on the brake operating rod at the rear of the frame Make sure the cutout on the adjust...

Page 134: ...e adjustment is 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 fe...

Page 135: ...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 0 6 in 15 mm of pedal stroke See pag...

Page 136: ...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 cover If any water drains...

Page 137: ...es must be the proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tires Although the tires are designed specifically for...

Page 138: ...make your ATV ride harshly are more prone to damage from surface hazards and wear unevenly Always check air pressure when your tires are cold If you check air pressure when your tires are warm even i...

Page 139: ...ystem found in service stations This will minimize the possibility of tire damage from overinflation If you use a high pressure system at a service station add air in small amounts and check the press...

Page 140: ...ou hit a pothole or other hard object while riding stop as soon as you safely can and carefully inspect the tires for damage Tread Wear For best performance you should replace a tire before the tread...

Page 141: ...ur Honda dealer 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 ch...

Page 142: ...designed to match the performance capabilities of your ATV and provide the best combination of handling braking and comfort It is best to replace all four tires however if that is not possible you mu...

Page 143: ...ngine guard protects 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 Sch...

Page 144: ...when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your ATV or do not ride frequently we recommend that you charge the battery freque...

Page 145: ...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 remo...

Page 146: ...g Your Honda The battery is located in a compartment under the seat Remove the battery Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Remove th...

Page 147: ...temperature and 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 sectio...

Page 148: ...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 149: ...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 150: ...s Start the engine and let it idle for several minutes The engine heat will help dry moist areas As a precaution ride your ATV at a slow speed and apply the brakes several times This will help dry the...

Page 151: ...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 152: ...according to the instructions on the container If the frame has a chip that exposes the metal first apply primer to prevent corrosion and then apply the touch up paint Several thin layers of touch up...

Page 153: ...and store your Honda and how to be an environmentally responsible ATV owner Preparing for a Ride 146 What to Take to The Riding Area 146 What to Take on The Trail 147 Transporting Your Honda 148 Stor...

Page 154: ...USA only the Ministry 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 supp...

Page 155: ...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 156: ...ecommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking gasoline could be a h...

Page 157: ...vehicle with tie 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 i...

Page 158: ...y problem before 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 dea...

Page 159: ...Refer to on page 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...

Page 160: ...nstall the spark 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 i...

Page 161: ...has 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 require...

Page 162: ...y increase noise they also reduce engine performance and may be illegal Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which da...

Page 163: ...o wrong This section 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 156 If Your En...

Page 164: ...t doesn t feel 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 t...

Page 165: ...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 166: ...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 167: ...ion not in neutral 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 H...

Page 168: ...See your Honda dealer detonates or pings under load If applicable switch to the recommended octane gasoline page or change your brand of gasoline If the problem persists see your Honda dealer afterfi...

Page 169: ...a temporary repair As soon as possible have the tire permanently repaired by your Honda dealer Any tire that cannot be repaired should be replaced Whenever the ATV is to be operated far from service...

Page 170: ...our ATV on a firm 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 dir...

Page 171: ...heel nuts so that 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 se...

Page 172: ...where for another possible cause of the problem Replace a blown fuse and check component operation The fuse is located in the battery compartment A spare fuse is located in the owner s manual storage...

Page 173: ...em To prevent an 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 o...

Page 174: ...ly 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 the...

Page 175: ...e If you lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer where you purchased your Honda ATV They may have it list...

Page 176: ...especially if you use an automobile battery The greater amperage of an automobile battery when the car engine is running can damage your ATV s electrical system Bump starting is also not recommended...

Page 177: ...throttle cable or 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...

Page 178: ...170 Taking Care of the Unexpected...

Page 179: ...sions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 172 Specifications 174 Break in Guidelines 178 High Altitude C...

Page 180: ...ical Information The VIN engine serial number and key number may be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The...

Page 181: ...echnical Information 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...

Page 182: ...rving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 stroke oil USA Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil including reserve afte...

Page 183: ...44 1 933 2 846 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...

Page 184: ...2 V 8 Ah 0 123 kW 5 000 rpm 12 V 39 39 W LED 12 V 3 0 W 12 V 3 4 W Low High front rear caster trail tire size front tire pressure front rear cold tire size rear battery generator headlight brake tail...

Page 185: ...t 25 N m 2 5 kgf 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 177 Specifications Technical...

Page 186: ...on Help assure your ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts ra...

Page 187: ...eters have your 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 standar...

Page 188: ...l Information Label is attached on the right side of the frame below the front fender The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Environment Canada EC requ...

Page 189: ...emical smog when 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 hydro...

Page 190: ...mptoms have the 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 backfirin...

Page 191: ...of noise control 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...

Page 192: ...tal Protection Agency EPA California Air Resources Board CARB and Environment Canada EC The fuel tank fuel hoses and fuel vapor charge hoses used on this vehicle incorporate fuel permeation control te...

Page 193: ...ed on the pump 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 e...

Page 194: ...toms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of...

Page 195: ...This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 188 Warranty Coverage 191 Warranty Service 192 Contacting Honda 193 Your Honda De...

Page 196: ...om Helm Inc USA 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 operati...

Page 197: ...Add 8 25 5 00 Grand Total Price Each 189 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...

Page 198: ...time Telephone Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Check here if your billing address is different from the shipping address shown above VISA Disco...

Page 199: ...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 perform your own maintenance Howeve...

Page 200: ...you the results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the rep...

Page 201: ...o work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Mot...

Page 202: ...products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the...

Page 203: ...Club USA only Consumer Information www hrca honda com You may be eligible for a Honda Rider s Club of America HRCA membership with the purchase of your new Honda You can log on to the HRCA Clubhouse w...

Page 204: ...5 Operation Component Locations 11 Indicators 14 Reverse and Neutral Indicators 14 Controls Features 15 Fuel Valve 15 Choke Knob 16 Ignition Switch 17 Start Button 18 Engine Stop Switch 18 Headlight...

Page 205: ...tective Apparel 26 Rider Training 28 Age Recommendation 29 No Passengers 29 No Alcohol or Drugs 30 Is Your ATV Ready to Ride 31 Pre ride Inspection 31 Load Limits Guidelines 34 Loading 34 Load Limits...

Page 206: ...Terrain 44 Do Not 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 R...

Page 207: ...Maintenance Safety 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...

Page 208: ...our Honda 148 Storing Your Honda 150 151 153 You the Environment 154 General Guidelines 156 If Your Engine Quits or Won t Start 158 If You Have a Flat Tire 161 If a Fuse Blows 164 If You Crash 166 If...

Page 209: ...QUICK REFERENCE Vehicle Identification 172 Specifications 174 Break in Guidelines 178 High Altitude Carburetor Adjustment 179 Emission Control Systems 180 Oxygenated Fuels 185 Authorized Manuals 188...

Page 210: ...using drain tube 102 air pressure gauge 84 tire 130 altitude high 179 American Honda contacting 193 apparel protective 26 appearance care 141 authorized manuals 188 Battery 136 Brakes cables 126 drain...

Page 211: ...ak in guidelines 178 capacity fuel 88 carburetor altitude adjustment 179 care appearance 141 choke cable 105 knob 47 cleaning appearance care 141 climbing hills 60 clutch system 106 color label 173 co...

Page 212: ...eadlight 19 dipstick 93 emission control systems 180 engine flooded 50 guard 135 idle speed 111 number 172 oil 90 pinging 87 starting 46 stop switch 18 stopping 50 won t start 158 environment 154 exha...

Page 213: ...flag pole bracket 24 flat tire 161 flooded engine 50 fuel fill cap 88 high altitude fuel mixture adjustment 179 oxygenated 185 recommendation 87 refueling 88 reserve fuel supply 15 tank capacity 88 v...

Page 214: ...de carburetor adjustment 179 hills crossing or turning on slops 65 riding down hills 64 riding up hills 60 stopping on hills 62 Honda contacting 193 Rider s Club 195 dealer 194 Honda service manual 18...

Page 215: ...207 Index Index I K key lost 167 number 167 kit tool 84 identification vehicle 172 idle speed engine 111 ignition switch 17 indicators neutral indicator 14 reverse indicator 14 inspection pre ride 31...

Page 216: ...ight 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 manual service 1...

Page 217: ...acles riding over 67 oil engine 90 gear case 96 operating controls 15 operation component locations 11 owner s manual storage 85 oxygenated fuels 185 neutral indicator 14 noise emission control system...

Page 218: ...no riding on 3 pinging engine 87 plug spark 112 pre ride inspection 31 problems unexpected 155 protective apparel 26 removal seat 86 reverse assist cable 110 assist lever 21 gear shifting into 51 ind...

Page 219: ...riding precautions 41 schedule maintenance 76 seat removal 86 serial numbers 172 service customer 193 manuals 188 warranty 192 riding basic operations 39 clothing 26 precautions 41 preparing for 31 o...

Page 220: ...r 116 spark knock 87 spark plug 112 specifications 174 stalling on a hill 62 start button 18 starting engine 46 troubleshooting 158 stop switch engine 18 stopping engine 50 storage ATV 150 battery 137...

Page 221: ...ottle lever 20 103 stop screw 111 tires air pressure 130 flat 161 replacing 134 repairing 133 specifications 134 tread conditions 132 tool kit 84 training rider 28 transporting your ATV 148 trouble un...

Page 222: ...214 Index Index W warning labels 5 warranty coverage 191 extended 191 service 192 washing your ATV 142 water riding through 68 draining from brakes 128 weight limit 35 wheel removal 162...

Page 223: ...tant notes The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequen...

Page 224: ...Quick Reference Quick Reference Engine No VIN Ignition Key No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr...

Page 225: ...e oil fuel tires driveshaft boots nuts bolts underbody exhaust system air cleaner housing drain tube leaks loose parts cables throttle brakes switches steering unleaded gasoline pump octane number 86...

Page 226: ...30 kPa 0 30 kgf cm AT22 10 9 DUNLOP KT175 DUNLOP KT171 DPR8EA 9 NGK X24EPR U9 DENSO DPR7EA 9 NGK X22EPR U9 DENSO 15 A Front Rear or or standard main cold climate Front Rear Quick Reference Quick Refer...

Page 227: ...s section SYMBOL COMPONENT SEE PAGE ON ignition switch OFF ignition switch START button OFF engine stop switch RUN engine stop switch ON headlight switch OFF headlight switch HI headlight dimmer switc...

Page 228: ......

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