Honda SPORTRAX 250EX Owner'S Manual Download

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Servicing Your Honda

Service Procedures

Fluids & Filters

Engine

Electrical

Chassis

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Fuel

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Engine Oil

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Gear Case Oil

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Air Cleaner

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

Throttle

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Carburetor Choke Cable & Knob

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Clutch System

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Reverse Lock System

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Engine Idle Speed and Air-Fuel Mixture

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Spark Plug

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Valves

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Spark Arrester

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Brakes

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

Tyres

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Engine Guard & Skid Plates

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Battery

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Appearance Care

87
90
96
98

103
105
106
110
111
113
116
117

119
132
139

140

145

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Summary of Contents for SPORTRAX 250EX

Page 1: ...Honda TRX250EX SPORTRAX 250EX OWNER S MANUAL...

Page 2: ...in guidelines and perform all pre ride and other periodic checks detailed in this manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety inf...

Page 3: ...duction Introduction If you have any questions or if you ever need special service or repairs remember that your Honda dealer knows your ATV best and is dedicated to your complete satisfaction Happy r...

Page 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: ...d to know before servicing your Honda an owner maintenance schedule and instructions for specific maintenance and adjustment items How to store and transport your ATV and how to be an environmentally...

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: ...you need to cross a paved or public road get off and walk your ATV across Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice in a safe area un...

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

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

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

Page 16: ...8 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: ...e Knob Ignition Switch Start Button Engine Stop Switch Headlight Switch Headlight Dimmer Switch Throttle Lever Clutch Lever Parking Brake Lever Front Brake Lever Rear Brake Pedal Parking Brake Flag Po...

Page 19: ...button ignition switch throttle lever engine stop switch choke knob headlight dimmer switch parking brake pin parking brake lock lever clutch lever parking brake lever reverse assist lever 11 Indicato...

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

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

Page 22: ...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 OFF for parking storing or transportation RES for extra fuel to get to a gas supply for refueling Remember to check that the fuel valve is in the ON position each time you refuel If the fuel valve...

Page 24: ...EFT HANDLEBAR 1 A A B B 1 choke knob C C A fully ON B half way position C fully OFF 16 Choke Knob Controls Features Indicators Controls The choke knob may be used when starting the engine See page 1 4...

Page 25: ...gnition switch 1 CENTRE OF HANDLEBAR ON OFF ON OFF Key Position Function 17 Ignition Switch Controls Features Indicators Controls The ignition switch is used for starting and stopping the engine page...

Page 26: ...slide the switch to the OFF position The switch must be in the RUN position to start the engine and it should normally remain in the RUN position even when the engine is OFF When the start button is p...

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: ...o operate pull the clutch lever parking brake lever in all the way before shifting then slowly release it after shifting See page The throttle controls engine rpm speed To increase engine rpm press th...

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 Protective Apparel Rider Training Age Recommendation...

Page 34: ...ection and other protective clothing You don t have any alcohol or drugs in your system For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gl...

Page 35: ...t and long pants 27 Are You Ready to Ride Before Riding Additional Riding Gear In addition to a helmet and eye protection we also recommend Sturdy off road motorcycle boots to help protect your feet a...

Page 36: ...ls learned in the course and the operating techniques described in the owner s manual 28 Rider Training Are You Ready to Ride Before Riding Developing your riding skills is an on going process Even if...

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 Before Riding Are You Ready to Ride 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 tyre can be a major inconvenience If your ATV has overturned or been involved i...

Page 40: ...ere 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 drain tube If necessary clean the t...

Page 41: ...ever and step on the rear brake pedal to check that the controls operate normally Check for proper freeplay page Make sure there is no brake fluid leakage page Check the freeplay and adjust if needed...

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: ...o not tow another vehicle Never ride with a passenger The ATV is not designed to carry a passenger Check that the tyres are properly inflated Be sure to observe the weight limits and follow these guid...

Page 45: ...designed and tested for your ATV Because Honda cannot test all other accessories you must be personally responsible for proper selection installation and use of non Honda accessories Check with your...

Page 46: ...equipment or modify your ATV in any way that would change its design or operation Such changes could seriously impair your ATV s handling stability and braking making it unsafe to ride Removing or mod...

Page 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 Off Road Use Only Keep Hands and...

Page 48: ...c Operation Riding Braking Riding Your ATV Making Turns Skidding or Sliding Riding Up Hills Riding Down Hills Crossing or Turning on Hills or Slopes Riding Over Obstacles Riding Through Water Parking...

Page 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 You should never ride your ATV on public streets roads or highways even if they are not paved Drivers of street vehicles may have diffi...

Page 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: ...neutral Normal Air Temperature 10 35 C 50 95 F Pull the choke knob up all the way to fully ON position if the engine is cold cont d To restart a warm engine follow the procedure for With the throttle...

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

Page 60: ...ind As a general rule shift while moving in a straight line Close the throttle and pull the clutch lever parking brake lever in completely before shifting Improper shifting may damage the engine trans...

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 Bring the vehicle to a complete stop pull in the clutch lever parkin...

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: ...pped with disc brakes on both front wheels which are hydraulically activated by operating the brake lever A single drum brake on the rear axle housing is mechanically activated by depressing the brake...

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 For information on how to apply th...

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: ...ons for specific 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 the fuse see...

Page 80: ...l Engine Oil Gear Case Oil Air Cleaner Throttle Carburetor Choke Cable Knob Clutch System Reverse Lock System Engine Idle Speed and Air Fuel Mixture Spark Plug Valves Spark Arrester Brakes Tyres Engin...

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

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

Page 85: ...require more technical information and tools Consult your Honda dealer In the interest of safety we recommend these items be serviced only by your Honda dealer Service more frequently when riding in d...

Page 86: ...COMES FIRST INITIAL HOURS MAINT INTERVAL MAINT INITIAL 150km 100mi 20 operating hours or 1 month R REGULAR Every 1000km 600mi 100 operating hours or 12 months R 78 Maintenance Schedule Servicing Your...

Page 87: ...I I I C I I 2000 1200 200 I I I I I I I I I I C I I I I I 150 100 20 I I I I I I I Refer to page 96 120 126 122 130 119 110 139 106 117 FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITIAL HOURS NOTE...

Page 88: ...e new owner Make sure whoever performs the maintenance completes this record All scheduled maintenance including the 150 km 100 mile or 20 hours initial maintenance is considered a normal owner operat...

Page 89: ...front brake fluid reservoir choke knob fuel fill cap front brake lever throttle lever clutch lever parking brake lever 81 Servicing Your Honda Maintenance Component Locations...

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

Page 91: ...ase oil filler cap engine oil drain bolt engine oil filler cap dipstick gear case oil level check bolt spark plug owner s manual spark arrester clutch 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: ...reful not to flood this area when washing your ATV The owner s manual and spare fuse should be stored in the plastic document bag and fastened with the rubber band Your ATV provides storage for the ow...

Page 94: ...seat 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...

Page 95: ...pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of petr...

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

Page 97: ...ttom 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 Honda...

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: ...ecommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation cont d Motor oils intended for Service SE SF or SG will show this designation on the con...

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: ...If required add the specified oil into the filler cap hole up to the upper level mark on the oil filler cap dipstick Do not overfill Insert the oil filler cap dipstick without screwing it in then remo...

Page 102: ...res 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 dealer With the...

Page 103: ...n plug 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 l...

Page 104: ...gear oil SAE 80 96 Oil Recommendation Changing Oil Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the gear case at normal operating temperature to assure co...

Page 105: ...il 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 gear ca...

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 Uncover the rubber sheet from the retainer clips cont d Unlatch the retainer clips Remove the air...

Page 108: ...air cleaner Replace the air cleaner if it is damaged Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not fully absorb the oil Unscrew the clamp Remove the air cleane...

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

Page 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: ...ur Honda 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 adjustmen...

Page 115: ...utch does not work correctly the cable or clutch friction discs may be worn See your Honda dealer If the cable adjuster is threaded out near its limit or the correct freeplay cannot be obtained using...

Page 116: ...rect freeplay 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 pro...

Page 117: ...oothly and accelerate gradually 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 d...

Page 118: ...vicing Your Honda Safety Precautions Refer to on page Check the operation of the reverse assist lever for smooth without sticking Check the reverse assist lever and cable for loose connections or othe...

Page 119: ...ng including carburetor adjustment Refer to on page Remember idle speed adjustment is not a cure all for other problems in your engine s fuel delivery system Adjusting the idle will not compensate for...

Page 120: ...d in neutral Turn the pilot screw clockwise until you hear the engine miss or decrease in speed Then turn the screw counterclockwise until the engine misses or decreases in speed again If idle speed c...

Page 121: ...nda 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 spark pl...

Page 122: ...ectrode carefully The gap should be Inspect the electrodes and centre porcelain for deposits corrosion or carbon fouling If the corrosion or deposits are heavy replace the plug Clean a carbon or wet f...

Page 123: ...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 124: ...essive 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 adj...

Page 125: ...y Precautions Refer to on page The exhaust system must be periodically purged of accumulated carbon To purge the system Select a well ventilated area free of combustible materials and make sure the ex...

Page 126: ...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 127: ...e the level to drop Worn pads should be replaced If the pads are not worn beyond the recommended limit there is probably air in the brake system See your Honda dealer to have the air bled from the sys...

Page 128: ...fluid 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...

Page 129: ...it contacts your eyes Check for deterioration or cracks in the hoses and fittings If the hoses are worn or cracked have them replaced by your Honda dealer Make sure there are no fluid leaks It should...

Page 130: ...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 131: ...IDE 123 Rear Brake Pedal Freeplay Brakes Servicing Your Honda Measure the distance the rear brake pedal moves before the brake starts to take hold Freeplay measurement at the tip of the end of the ped...

Page 132: ...3 brake arm pin 124 Brakes Servicing Your Honda Adjustment 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...

Page 133: ...4 brake arm 4 125 Brakes Servicing Your Honda Adjust the freeplay of the rear brake pedal Push the brake arm then check the clearance between the brake arm and the brake arm pin 2 4...

Page 134: ...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 135: ...old properly Adjustment Adjust the freeplay of the clutch lever parking brake lever with the front wheels pointed straight ahead cont d Temporarily adjust the clutch lever parking brake lever freeplay...

Page 136: ...Brakes Servicing Your Honda Push the brake arm then check the clearance between the brake arm and the brake arm pin Push down the parking brake pin and then squeeze the clutch lever parking brake leve...

Page 137: ...se connections or other damages If the parking brake cable is worn or kinked have it replaced by your Honda dealer Check that the clutch lever parking brake lever assembly is positioned properly and t...

Page 138: ...to on page Rear Brake Only Check the operation of the rear brakelight switch at the right side behind the engine from time to time The brakelight should turn on at 15 mm 0 6 in of pedal stroke See pag...

Page 139: ...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 140: ...es must be the proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tyres Although the tyres are designed specifically for...

Page 141: ...g tread life and riding comfort Generally underinflated tyres wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tyres make your ATV ride harshly ar...

Page 142: ...check air pressure when your tyres are warm even if your ATV has only been ridden for a few miles the readings will be higher If you let air out of warm tyres to match the recommended cold tyre pressu...

Page 143: ...ystem found in service stations This will minimize the possibility of tyre damage from overinflation If you use a high pressure system at a service station add air in small amounts and check the press...

Page 144: ...ou hit a pothole or other hard object while riding stop as soon as you safely can and carefully inspect the tyres for damage Tread Wear For best performance you should replace a tyre before the tread...

Page 145: ...temporary repairs see page A tyre that is repaired either temporarily or permanently will have lower speed and performance limits than a new or undamaged tyre If you have a tyre professionally repaire...

Page 146: ...designed to match the performance capabilities of your ATV and provide the best combination of handling braking and comfort It is best to replace all four tyres however if that is not possible you mu...

Page 147: ...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 148: ...om the battery even when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your ATV or do not ride frequently we recommend that you charg...

Page 149: ...tery Charging Refer to on page If you plan to store your ATV we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life If you do not...

Page 150: ...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 151: ...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 152: ...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 153: ...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 154: ...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 155: ...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 156: ...Apply the polish or wax according to the instructions on the container Refer to on page Aluminum may corrode from contact with dirt mud or road salt Clean the wheels after riding through any of these...

Page 157: ...and store your Honda and how to be an environmentally responsible ATV owner Preparation for Storage Removal from Storage You the Environment Preparing for a Ride What to Take to the Riding Area What...

Page 158: ...iculties you might encounter see which begins on page We recommend that you always take water food a first aid kit and your owner s manual Other items you should consider loading on your truck or trai...

Page 159: ...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 160: ...recommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking petrol could be a ha...

Page 161: ...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 162: ...ct your ATV and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again We suggest you perform the following procedures to...

Page 163: ...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 164: ...stall 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 it...

Page 165: ...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 166: ...ly 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 d...

Page 167: ...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 If Your Engine...

Page 168: ...owly ride back to your base where you can make a permanent repair or get help When a problem is more serious or you don t have the tools supplies experience or time to deal with it you need to choose...

Page 169: ...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 170: ...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 171: ...ion not in neutral Shift into neutral blown fuse Replace with a new fuse of the same rating page battery lead loose Charge the battery page If charging doesn t help see your Honda dealer Tighten the b...

Page 172: ...xhaust rich fuel mixture See your Honda dealer detonates or pings under load If applicable switch to the recommended octane petrol page or change your brand of petrol If the problem persists see your...

Page 173: ...a temporary repair As soon as possible have the tyre permanently repaired by your Honda dealer Any tyre that cannot be repaired should be replaced Whenever the ATV is to be operated far from service...

Page 174: ...V 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 1 1 2 3 4 75 Avoid getting grease oil...

Page 175: ...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 176: ...where for another possible cause of the problem Replace a blown fuse and check component operation The fuse is located in the battery compartment All of the electrical circuits on your ATV have a fuse...

Page 177: ...em Install the fuse holder assembly and seat To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuses To access the fuse remove the seat page Remove t...

Page 178: ...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 179: ...all the dealer where you purchased your Honda ATV They may have it listed in their records If they don t transport your ATV to them or the nearest Honda dealer The dealer will probably have to remove...

Page 180: ...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 181: ...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 182: ...174 Taking Care of the Unexpected...

Page 183: ...cities and other technical data plus information on government requirements and how to break in your ATV Serial Numbers Colour Label Code Vehicle Identification Specifications Break in Guidelines High...

Page 184: ...Technical Information The VIN engine serial number and key number may be required when ordering replacement parts Record the numbers here for your reference The VIN is stamped on the front of the fra...

Page 185: ...dentification Technical Information The colour code is helpful when ordering replacement parts Record the colour and code here for your reference COLOUR CODE The colour label is attached to the frame...

Page 186: ...qt 1 7 Imp qt 1 6 1 7 US qt 1 4 Imp qt API Service Classification SE SF or SG Honda 4 stroke oil or an equivalent including reserve after disassembly after draining overall length overall width overal...

Page 187: ...444 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 idl...

Page 188: ...lbf ft 12 N m 1 2 kgf m 9 lbf ft 64 N m 6 5 kgf m 47 lbf ft front rear Low High caster trail tyre size front tyre pressure front rear cold tyre size rear battery generator headlight brake tail light n...

Page 189: ...on Help assure your ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 25 km 15 miles During this period avoid full throttle starts ra...

Page 190: ...ficial Honda Shop Manual available from your Honda dealer All others should have this carburetor modification performed by a Honda dealer Sustained riding at lower altitudes with the lean high altitud...

Page 191: ...use petrol containing more than 5 methanol even if it has cosolvents and corrosion inhibitors Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the...

Page 192: ...peration Component Locations Indicators Controls Features Fuel Valve Choke Knob Ignition Switch Start Button Engine Stop Switch Headlight Switch Headlight Dimmer Switch Throttle Lever Clutch Lever Par...

Page 193: ...tive Apparel Rider Training Age Recommendation No Passengers No Alcohol or Drugs Is Your ATV Ready to Ride Pre ride Inspection Load Limits Guidelines Loading Load Limits Loading Guidelines Accessories...

Page 194: ...ot Perform Stunts Preparation Starting Procedure Flooded Engine How to Stop the Engine Shifting Gears Riding in Reverse Braking Riding Your ATV Making Turns Skidding or Sliding Riding Up Hills Riding...

Page 195: ...fety Important Safety Precautions Maintenance Schedule Maintenance Record Maintenance Component Locations Tool Kit Owner s Manual Storage Seat Removal Fuel Engine Oil Gear Case Oil Air Cleaner Throttl...

Page 196: ...ding Area What to Take on the Trail Transporting Your Honda Storing Your Honda You the Environment General Guidelines If Your Engine Quits or Won t Start If You Have a Flat Tyre If a Fuse Blows If You...

Page 197: ...TECHNICAL INFORMATION 175 TABLE OF CONTENTS 184 INDEX 190 Vehicle Identification Petrol Containing Alcohol High Altitude Carburetor Adjustment Break in Guidelines Specifications Serial Numbers Colour...

Page 198: ...190 Index Index A accessories 37 age recommendation 29 air cleaner filter 98 housing drain tube 102 air pressure gauge 84 tyre 133 altitude high 182 apparel protective 26 appearance care 145...

Page 199: ...Brakes cable 129 draining water from 131 fluid 120 front brake lever 22 front brake pads 122 parking 69 rear brake pedal 22 rear brake pedal freeplay 123 shoe lining clearance 126 shoe wear 126 braki...

Page 200: ...3 capacity fuel 88 carburetor altitude adjustment 182 care appearance 145 choke cable 105 knob 47 cleaning appearance care 140 climbing hills 60 clutch system 106 colour label 177 component fails 173...

Page 201: ...193 Index Index E engine flooded 50 guard 139 idle speed 111 number 176 oil 90 pinging 87 starting 46 stop switch 18 stopping 50 won t start 162 environment 158 exhaust system cleaning 117 purging 117...

Page 202: ...4 gear case oil 96 gear shifting 51 flag pole bracket 24 flat tyre 165 flooded engine 50 fuel fill cap 88 high altitude fuel mixture adjustment 182 recommendation 87 refueling 88 reserve fuel supply 1...

Page 203: ...tment 182 hills crossing or turning on hills or slopes 65 riding down hills 64 riding up hills 60 stopping on hills 62 key lost 171 number 171 kit tool 84 identification vehicle 176 idle speed engine...

Page 204: ...5 limit weight 35 load limits 35 loading guidelines 36 lubrication engine oil 90 gear case oil 96 maintenance component locations 81 importance 73 precautions 75 record 80 safety 74 schedule 76 maximu...

Page 205: ...ration component locations 11 owner s manual storage 85 neutral indicator 14 numbers serial 176 parking 69 passenger no carrying 29 pavement no riding on 41 petrol 87 petrol containing alcohol 183 pin...

Page 206: ...se assist cable 110 assist lever 21 gear shifting into 51 indicator 14 riding in 53 rider training 28 riding basic operations 39 clothing 26 precautions 41 preparing for 31 over obstacles 67 safety 2...

Page 207: ...rtant precautions 75 labels 5 riding precautions 41 schedule maintenance 76 seat removal 86 serial numbers 176 shifting gears 51 skid plates 139 skidding or sliding 59 spark arrester 117 spark knock 8...

Page 208: ...g on a hill 62 start button 18 starting engine 46 troubleshooting 162 stop switch engine 18 stopping engine 50 storage ATV 154 battery 141 owner s manual 85 switch engine stop 18 headlight 19 headligh...

Page 209: ...ottle lever 20 103 stop screw 111 tyres air pressure 133 flat 165 replacing 138 repairing 137 specifications 138 tread conditions 136 tool kit 84 training rider 28 transporting your ATV 152 trouble un...

Page 210: ...202 Index Index W warning labels 5 water riding through 68 draining from brakes 131 weight limit 35 wheel removal 166...

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Honda SPORTRAX 250EX, Owner'S Manual

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