Honda SPORTRAX 300EX Owner'S Manual Download

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207

Table of Contents

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SERVICING YOUR HONDA

. 71

Service Preparations

Bef ore You Service Your Honda

Service Procedures

(cont’d)

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The Importance of Maintenance

. 73

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Maintenance Safety

. 74

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Important Safety Precautions

. 75

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Maintenance Schedule

. 76

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Maintenance Record

. 80

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Maintenance Component Locations

. 81

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Tool Kit

. 84

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Owner’s Manual Storage

. 85

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Seat Removal

. 86

Fluids & Filters

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Fuel

. 87

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Engine oil & Filter

. 92

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Air Cleaner

. 99

Engine

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

Throttle

. 103

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Clutch System

. 105

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Reverse Lock System

. 109

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Engine Idle Speed

. 110

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Spark Plug

. 111

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Valves

. 114

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Spark Arrester

. 115

06/04/27 10:53:04 31HM3740_216

Summary of Contents for SPORTRAX 300EX

Page 1: ...n This publication includes the latest production information available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation This manual should be considered a permanent part of the ATV and should remain with the ATV when it is resold Honda Motor Co Ltd 2006 ...

Page 2: ...Noise Emission 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 vehicle is equipped with a USDA qualified spark arrester Obey local laws and regulations It conforms to US EPA and California exhaust emission regulations for ATVs ...

Page 3: ...this 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 list of topics at the beginning of each section and both an in depth table of contents and an index at the back of the book As you read this manual you will find information that is preceded by a sy...

Page 4: ...want to visit our website at www honda com California Proposition 65 Warning This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive 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 Happy riding ...

Page 5: ...have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining an ATV You must use your own good judgment You will find important safety information in a variety of forms including on t...

Page 6: ...ou 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 Precautions such as ATV Safety how to use this ATV correctly and safely This entire manual is filled with important safety information please read it carefully ...

Page 7: ... safety information you should know plus a look at the safety related labels on your ATV The importance of wearing a helmet and other protective gear how to make sure you and your ATV are ready to ride and important information about loading How to start and stop the engine shift gears and brake Also riding precautions The location and function of indicators and controls on your ATV and operating ...

Page 8: ...intenance 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 tire your engine won t start etc ID numbers technical specifications and other technical facts Information on warranties emission controls how to get Honda service manuals Sequential listing of topics ...

Page 9: ......

Page 10: ...most 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 on your ATV Important Safety Information 2 Safety Labels 5 ...

Page 11: ...re 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 no handholds footrests or seat for a second person so never carry a passenger A passenger could interfere with your ability to move around to maintain your balance and control of the ATV It s a prove...

Page 12: ... 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 ATVs take time to become familiar with how this ATV works and handles Practice in a safe area until you build your skills and get accustomed to the ATV s size and weight Because many accidents involv...

Page 13: ...make 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 So don t drink and ride and don t let your friends drink and ride either It s important to keep your ATV properly maintained and in safe riding condition Having a breakdown can be difficult especially...

Page 14: ... containing important safety information Anyone who rides the vehicle should read and understand this information before riding The labels should be considered permanent parts of the vehicle If a label comes off or becomes hard to read contact your Honda dealer for replacements ...

Page 15: ...6 Safety Labels ATV Safety USA only ...

Page 16: ...7 Safety Labels ATV Safety ...

Page 17: ...8 Safety Labels ATV Safety ...

Page 18: ...tructions for other components are presented in other sections of this manual where they will be most useful Operation Component Locations 11 Indicators 14 Reverse and Neutral Indicators 14 This section shows the location of all indicators and controls you would normally use before or while riding your ATV ...

Page 19: ...5 Choke Lever 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 Front Brake Lever 22 Rear Brake Pedal 22 Parking Brake 23 Flag Pole Bracket 24 ...

Page 20: ...engine stop switch start button ignition switch headlight switch clutch lever parking brake lever throttle lever parking brake lock lever parking brake pin fuel fill cap reverse assist lever 11 Indicators Controls Operation Component Locations ...

Page 21: ...rear brake pedal 12 Operation Component Locations Indicators Controls ...

Page 22: ...choke lever flag pole bracket seat lock lever shift lever fuel valve 13 Operation Component Locations Indicators Controls ...

Page 23: ...me on when it should have your Honda dealer check for burned out bulbs or other problems The reverse indicator and the neutral indicator are located on the handle cover The reverse indicator will light when the transmission is in reverse and the ignition switch is ON The neutral indicator will light when the transmission is in neutral and the ignition switch is ON 2 1 ...

Page 24: ...ding OFF for parking storing or transportation 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 information about fueling your ATV see page RES for extra fuel to get to a gas supply for refueling The manual fuel valve is located on the left side under the ...

Page 25: ... 1 A A B B LEFT SIDE 1 choke lever C C A fully OFF B halfway position C fully ON 16 Choke Lever Controls Features Indicators Controls The choke lever may be used when starting the engine See page 46 1 ...

Page 26: ...ignition switch 1 CENTER OF HANDLEBAR ON OFF OFF ON Function Key Position 17 Ignition Switch Controls Features Indicators Controls The ignition switch is used for starting and stopping the engine page Insert the key and turn it to the right for the ON position 46 1 ...

Page 27: ...slide the switch to either 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 If your ATV is stopped with the ignition switch ON and the engine stop switch OFF the battery will discharge Turn the ignition switch OFF to prevent battery discharge When the start button is pushed the starter motor will c...

Page 28: ...mmer 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 between the high and low beams of the headlight To operate turn the switch to HI for high beam LO for low beam 2 1 ...

Page 29: ...ess the throttle lever with your thumb To reduce engine 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 disengage the clutch whenever you shift gears To operate pull the clutch lever parking brake lever in all the way before shifting then slowly release it...

Page 30: ...sist lever on the right side positioned under the fuel tank is used to shift into reverse To operate pull in the clutch lever parking brake lever with your ATV stopped Leaving your left hand on the clutch lever parking brake lever remove your right hand from throttle and turn the reverse assist lever While turning the reverse assist lever depress the shift lever to reach the reverse gear below 1st...

Page 31: ...ntrols 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 depress the pedal For information on braking techniques see page 56 56 ...

Page 32: ...ols 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 lever parking brake lever and then lock it with the lock lever See page To release the parking brake squeeze the clutch lever parking brake lever 1 3 2 70 ...

Page 33: ...eatures 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 required in some riding areas Check local regulations before riding 1 ...

Page 34: ...and 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 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 35 Loading Guidelines 36 Accessories Modificat...

Page 35: ... 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 proper gear can reduce the chance of injury when you ride Following are suggestions to help you choose the proper gear Helmets and Eye Protection Your helmet is your most important piece of riding gear b...

Page 36: ...ing 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 a face shield or goggles to protect your eyes and help your vision Riding pants with knee and hip pads a riding jersey with padded elbows and a chest shoulder protector Off road motorcycle gloves to ...

Page 37: ...e 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 safe area to build your skills Do not ride in rough terrain until you get accustomed to the ATV s controls and feel comfortable with its size and weight We urge all riders to take a certified course...

Page 38: ... 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 age for this ATV model is 16 For safety never let children under 16 years old operate this vehicle This ATV is designed as an operator only vehicle The long seat is designed to allow the rider to chan...

Page 39: ...sume 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 ability to operate an ATV safely Likewise drugs even if prescribed by a physician can be dangerous while operating an ATV Consult your doctor to be sure it is safe to operate a vehicle after taking medica...

Page 40: ...m 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 in a collision do not ride the vehicle until it has been inspected by your Honda dealer There may be damage or other problems you cannot see Check the following items before you get on the ATV Check t...

Page 41: ...on and slack Adjust and lubricate if needed Also check the chain slider for wear and replace if needed page 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 Check for deposits in the drain tube If necessary clean the tube page and check the air cleaner case Walk around your ATV and look for anything that appe...

Page 42: ...nt brake lever and step on the rear brake pedal to check that the controls operate normally Make sure there is no brake fluid leakeage page Check for smooth operation and adjust if needed page Check the freeplay and adjust if needed page Make sure the lever operates smoothly without sticking Check for proper function page Check for proper function page Check that the wheels turn properly as you st...

Page 43: ...that 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 accessories and modifications follows How much weight you put on your ATV and how you load it are important to your safety If you decide to carry cargo you should be aware of the following information Your H...

Page 44: ... 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 that is not flat and smooth could further reduce these limits Following are the load limits for your ATV There are limits to how much weight can be carried on your ATV ...

Page 45: ...Do not tow another vehicle Never ride with a passenger The ATV is not designed to carry a passenger Check that the tires are properly inflated Be sure to observe the weight limits and follow these guidelines Carrying cargo or pulling a trailer will affect how your ATV handles and greatly reduce its ability in accelerating braking and making turns and other maneuvers As discussed on page we recomme...

Page 46: ...y 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 Make sure the accessory does not obscure any lights reduce ground clearance limit suspension travel or steering travel or interfere with operating any controls We strongly recommend that you use only ge...

Page 47: ...make 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 to remove any original 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 ...

Page 48: ...riding 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 Hands and Feet on Controls 42 Control Speed 43 Use Care on Unfamiliar or Rough Terrain 44 Do Not Perform Stunts 45 Starting Stopping the Engine 46 Preparation 47 Starting Procedure 48 Flooded Engine 51 ...

Page 49: ...ic Operation Riding Braking 56 Riding Your ATV 58 Making Turns 58 Skidding or Sliding 60 Riding Up Hills 61 Riding Down Hills 65 Crossing or Turning on Hills or Slopes 66 Riding Over Obstacles 68 Riding Through Water 69 Parking 70 ...

Page 50: ...1 and the section beginning on page Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice in a safe area until you build your skills and get accustomed to the ATV s size and weight Your ATV and its tires are designed and manufactured for off road use only not for pavement Riding on pavement can affect handling and control You should not ride y...

Page 51: ...d 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 and to control the vehicle Removing even one hand from the handlebars or one foot from the footpegs can reduce your ability to control the ATV or could cause you to lose your balance and fall off the...

Page 52: ...icle 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 accident In choosing a proper speed you need to consider the capability of your vehicle the terrain visibility and other operating conditions plus your own skills and experience ...

Page 53: ...terrain 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 always check the terrain thoroughly Don t ride fast on unfamiliar terrain or when visibility is limited It s sometimes difficult to see obstructions like hidden rocks bumps or holes in time to react ...

Page 54: ... 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 Do Not Perform Stunts Safe Riding Precautions Basic Operation Riding You should always operate your ATV in a safe and reasonable manner When riding always keep all four wheels on the ground Never ride...

Page 55: ... a garage Your ATV s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Your ATV is equipped with a gear position starter cut off system The engine cannot be started if the transmission is in a forward gear unless the clutch lever parking brake lever is pulled in The engine cannot be started if the transmission is in reverse gear...

Page 56: ...on Starting Stopping the Engine Basic Operation Riding Before starting select a level surface and lock the parking brake page Turn the fuel valve and ignition switch to ON Confirm the following The transmission is in neutral neutral indicator ON The engine stop switch is set to RUN 1 2 1 2 4 3 23 ...

Page 57: ...esulting in hard starting With the throttle slightly open press the start button Pressing the electric start button for more than 5 seconds at a time may cause the starter to overheat and damage the starter Release the start button for approximately 10 seconds before pressing it again Pull the choke lever up all the way to fully ON if the engine is cold To restart a warm engine follow the procedur...

Page 58: ... push the choke lever down to the halfway position Warm up the engine by opening and closing the throttle slightly After the engine has warmed up push the choke lever down all the way to fully OFF If idling is unstable open the throttle slightly Warm up the engine by opening and closing the throttle slightly If idling is unstable open the throttle slightly With the throttle slightly open press the...

Page 59: ...d engine wastes fuel and increases engine wear For temperature below 15 C 5 F operate the starter button after opening and closing the throttle lever several times Follow steps under Warm up the engine by opening and closing the throttle slightly About a half minute after the engine starts push the choke lever down to the halfway position After the engine has warmed up push the choke lever down al...

Page 60: ...y OFF position To stop the engine make sure the transmission is in neutral by checking that the neutral indicator lights and turn the ignition switch OFF If your ATV is stopped with the engine stop switch OFF and the ignition switch ON the battery will discharge To stop the engine in an emergency use the engine stop switch To operate move the switch to either OFF position Leave the engine stop swi...

Page 61: ...ars 1 2 3 4 and 5 To shift the transmission pull in the clutch lever then operate the shift lever as follows To upshift to a higher gear put the toe of your boot under the shift lever and raise it one full stroke To downshift step on the shift lever and depress it one full stroke After starting the engine and letting it warm up follow these procedures With the transmission in neutral depress and h...

Page 62: ...ommended Shift Points To prevent transmission damage do not coast or tow the ATV for long distances with the engine off Avoid downshifting to help slow your ATV when engine rpm is high Downshifting when engine speed is near its allowable maximum may over rev the engine and cause possible damage Downshift to a lower gear before you feel the engine laboring lugging at low rpm Upshift to a higher gea...

Page 63: ...c Operation Riding 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 Leaving your left hand on the clutch lever parking brake lever remove your right hand from the throttle and place it on the reverse assist lever Turn the reverse assist lever clockwise Be sure there are no obstacles or people in t...

Page 64: ...e throttle suddenly or make abrupt turns Slowly release the clutch lever parking brake lever and open the throttle gradually to begin reverse operation To stop pull in the clutch lever parking brake lever close the throttle and gradually apply both the front and rear brakes Do not abruptly apply the rear brake by itself While turning the reverse assist lever depress the shift lever to reach the re...

Page 65: ...hen possible reduce 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 your ATV Applying the brakes too hard may cause the wheels to lock and slide reducing control of your ATV If this happens release the brake controls steer straight ahead until you regain c...

Page 66: ...rmittent use of both brakes Continuous brake application can overheat the brakes and reduce their effectiveness For information on how to apply the brakes in various riding situations see the following section Riding with your foot resting on the brake pedal or your hand on the brake lever may overheat the brakes reducing effectiveness To prevent stalling the engine pull the clutch lever parking b...

Page 67: ... in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 58 Making Turns Riding Your ATV Basic Operation Riding Learn how to turn your ATV properly Practice the techniques outlined in this section on level ground and at low speeds until you are confident in making turns ...

Page 68: ...erating 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 wheels to turn easier and it also improves front wheel steering To make a turn on level ground Steer the handlebar and lean your body toward the inside of the turn Leaning helps balance the vehicle and...

Page 69: ...V 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 on ice you may lose all directional control To avoid skidding on slippery terrain keep your speed low and ride with caution If your ATV skids sideways during a turn steer in the direction of the skid...

Page 70: ...ding 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 limitations You may then proceed to ride on more difficult terrain However you must be able to decide which hills or hazards might cause the ATV to overturn Avoid excessively steep hills When climbing...

Page 71: ...u 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 sudden gear changes The ATV could flip over backward Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill ...

Page 72: ...olls 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 while you continue holding the brakes Shift into neutral set the parking brake and turn the engine off Then assess the situation If the ATV starts rolling backwards before you begin braking If the AT...

Page 73: ...ot 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 or rolled backwards Stand with your body facing downhill beside the vehicle so you can reach the front brake lever with your left hand Be sure your legs are clear of the wheels Check your footing Slo...

Page 74: ...escribed in this owner s manual 65 Riding Down Hills Riding Your ATV Basic Operation Riding It s usually advisable to descend hills with the ATV pointed straight downhill Avoid angles that would cause the vehicle to lean sharply to one side As you approach a downhill stop and survey the terrain below Never ride past the limit of your visibility Never go down a hill at high speed ...

Page 75: ...ift 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 either the front brake or rear brake hard or abruptly when riding down hills Remember braking effectiveness is reduced on any hill with a loose surface Riding on hills or slopes is different from ri...

Page 76: ...of 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 excessively steep slippery or rough Do not make turns on any slopes until you have first mastered the techniques for making turns on level terrain Compared to riding on level ground you may need to shift m...

Page 77: ...s as described in this owner s manual 68 Riding Over Obstacles Riding Your ATV Basic Operation Riding Before operating in a new area check for obstacles Watch out for bumps rain ruts potholes and other obstacles in the terrain When you approach any obstacle reduce your speed and be prepared to stop Never try to ride over large obstacles such as large rocks or fallen logs ...

Page 78: ... and operate normally Riding through water can make the brakes less effective than normal and may reduce stopping ability After leaving the water always test both the front and rear brakes Avoid getting the spark plug or air cleaner wet as this would cause the engine to stop Watch out for submerged obstacles and slippery rocks Proceed through the water at a slow steady speed Choose a path where bo...

Page 79: ... 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 ignition switch OFF and release the brakes If the ATV begins to move either while sitting on it or after you dismount find a better parking location If rocks or other objects are available you can bl...

Page 80: ...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 a fuse see page The Importance of Maintenance 73 Maintenance Safety 74 Important Safety Precautions 75 Maintenance Schedule 76 Maintenance Record 80 USA Only For information about the exhaust emission and noise r...

Page 81: ...uel 87 Engine Oil Filter 92 Air Cleaner 99 Engine Throttle 103 Clutch System 105 Reverse Lock System 109 Engine Idle Speed 110 Spark Plug 111 Valves 114 Spark Arrester 115 Chassis Suspension 116 Brakes 119 Tires 128 Engine Guard Skid Plates 135 Drive Chain 136 Battery 143 Appearance Care 148 ...

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

Page 83: ...erform 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 handled only by a Honda technician or other qualified mechanic Instructions are included in this manual only to assist in emergency service Some of the most important safety precautions follow Howev...

Page 84: ...o 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 flammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Remember that your Honda dealer knows your ATV best and is fully equipped to maintain and r...

Page 85: ...edule 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 tools and equipment We recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools and equipment Procedures for such items in this ...

Page 86: ...rmation and tools Consult your Honda dealer Should be serviced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the official Honda Service Manual page In the interest of safety we recommend these items be serviced only by your Honda dealer Replace every 2 years Replacement requires mechanical skill Refer to the official Honda service ma...

Page 87: ...EGULAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL HOURS MAINT INTERVAL MAINT INITIAL 100mi 150km 20 operating hours or 1 month R REGULAR Every 600mi 1000km 100 operating hours or 12 months R 78 Maintenance Schedule Servicing Your Honda Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary C clean A adjust L lubricate R replace Should be serviced by your Honda deale...

Page 88: ...S STEERING SYSTEM Refer to page 136 142 138 119 122 123 125 119 127 109 135 105 108 116 118 115 WHICHEVER COMES FIRST REGULAR INITIAL FREQUENCY ITEMS HOURS NOTE 1 2 NOTE 3 NOTE 1 2 MAINT INTERVAL MAINT I L EVERY 300mi 500km or 50 operating hours 79 Servicing Your Honda Maintenance Schedule In the interest of safety we recommend these items be serviced only by your Honda dealer Should be serviced b...

Page 89: ...he 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 operating cost and will be charged for by your dealer Use the space under Notes to record anything you want to remind yourself about or mention to your dealer 100 150 or 20 600 1 000 or 100 1 200 2 000 or ...

Page 90: ...front brake fluid reservoir front brake lever throttle lever clutch lever parking brake lever fuel fill cap 81 Servicing Your Honda Maintenance Component Locations ...

Page 91: ...ion spring pre load adjuster rear brakelight switch front brake caliper engine oil drain bolt engine oil filter rear brake pedal rear brake fluid reservoir engine oil filler cap dipstick 82 Servicing Your Honda Maintenance Component Locations ...

Page 92: ...e gauge tool kit owner s manual engine idle speed drive chain rear brake caliper spark plug choke lever rear suspension spring pre load adjuster air cleaner housing drain tube 83 Servicing Your Honda Maintenance Component Locations ...

Page 93: ...ubber band 84 Tool Kit Servicing Your Honda The tool kit is stored on the underside of the seat page fastened with a rubber band An optional larger tool kit may be available Check with your Honda dealer s parts department 2 86 3 1 ...

Page 94: ...ood this area when washing your ATV or through water The owner s manual should be stored in the plastic document bag and fastened with the rubber band Your ATV provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual in the plastic document bag on the underside of the seat 1 2 4 3 2 ...

Page 95: ...on the seat until it locks Insert the front prongs into the hooks on the frame and press the studs into the grommets on the frame Installation Slide the seat back and lift it Pull the seat lock lever up behind the seat Removal The seat must be removed for air cleaner and fuse maintenance and access to the tool kit and owner s manual 1 2 1 2 2 75 1 3 4 5 ...

Page 96: ...nging 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 gasoline If pinging or spark knock persists consult your Honda dealer Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank Your engine is des...

Page 97: ...uel 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 switching to reserve and the fuel valve should be returned to the ON position after refueling to avoid running out of fuel with no reserve 75 ...

Page 98: ... out of the handlebar cover hole Add fuel until the level reaches the bottom of the filler neck Avoid over filling the tank There should be no fuel in the filler neck If the fuel valve was set to RES turn the fuel valve ON After refueling turn the fuel fill cap clockwise Align the arrow on the fuel tank cap with the reference mark on the fuel tank cover Insert the breather tube into the handlebar ...

Page 99: ...strainer screen Wash the screen in non flammable high flash point solvent such as kerosene not gasoline The fuel strainer is in the fuel valve The strainer has a fine mesh screen which prevents dirt from entering the carburetor passages Dirt which accumulates in the screen must be removed periodically or the fuel flow will eventually be restricted 1 2 3 4 1 2 3 1 75 ...

Page 100: ...r cap 2 O ring 3 strainer screen 2 1 3 91 Fuel Servicing Your Honda Reassemble by reversing the disassembly sequence Check to be sure the O ring is in place Turn the fuel valve ON and check for leaks Correct if necessary 5 6 7 ...

Page 101: ... life Even the best oil wears out Changing oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine and transmission Change the engine oil as specified in the maintenance schedule on page When running in very dusty conditions oil changes should be performed ...

Page 102: ...lter Servicing Your Honda Your ATV does not need oil additives Use the recommended 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 service label Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation Do not use API SH or highe...

Page 103: ... chart may be used when the average temperature in your riding area is within the indicated range The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is labeled on the oil container For example the following label shows the MA classification JASO T 903 standard ...

Page 104: ...a well ventilated area and let it idle for 3 5 minutes Stop the engine and wait 2 3 minutes Remove the oil filler cap dipstick from the right crankcase cover and wipe it clean 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 between the upper level mark and the lower level mark on the oil filler cap di...

Page 105: ...ements Use a new genuine Honda oil filter specified for your model or a filter of equal quality This procedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid page If you do not have the skills or the tools see your Honda dealer With the ATV on the level ground remove the oil filler cap dipstick from the right crankcase...

Page 106: ...e oil filter Check that the oil filter cover O rings are in good condition and then install a new oil filter Use only the Honda genuine oil filter or a filter of equivalent quality specified for your model Using the wrong Honda filter or a non Honda filter which is not of equivalent quality may cause engine damage cont d Reposition the spring to the engine crankcase and install a new oil filter wi...

Page 107: ...dition If necessary replace the sealing washer Reinstall the oil drain plug and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Check that there are no oil leaks If a torque wrench is not used for installation see your Honda dealer as soon as possible to verify proper assembly Reinstall the oil filler cap dipstick Start the engine and let it idle ...

Page 108: ...r 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 correct service interval for your riding conditions Your ATV s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of...

Page 109: ...g Unscrew the clamp Remove the air cleaner from the air cleaner body Gently wash the air cleaner in clean non flammable high flash point solvent such as kerosene not gasoline After cleaning gently squeeze out the remaining solvent Avoid twisting or wringing the air cleaner This can tear the foam Inspect for tears or cracks in the foam or seams of the air cleaner Replace the air cleaner if it is da...

Page 110: ...aner Use both hands to evenly spread the oil into the air cleaner Gently squeeze out any excess oil To keep your hands dry place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner Install the air cleaner on the air cleaner body Apply a thin coat of grease to the sealing surface of the air cleaner assembly Install the remaining parts in the reverse order of removal...

Page 111: ...uld 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 vehicle Remove the drain tube by removing the clip under the air cleaner housing Drain the deposits Reinstall the drain tube securing it with the clip 1 2 3 1 2 3 ...

Page 112: ...ty Precautions Refer to on page Adjustment Check freeplay at the throttle lever Freeplay Inspection Slide the rubber sleeve back to expose the throttle cable adjuster Loosen the lock nut Turn the adjuster to obtain the correct freeplay Tighten the lock nut and reinstall the sleeve After adjustment check for smooth operation of the throttle lever from fully closed to fully open in all steering posi...

Page 113: ... 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 cable is kinked or chafed have it replaced Check the cables for tension or stress in all steering positions Lubricate the cables with a commercially available cable lubricant to prevent premature we...

Page 114: ...our 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 adjustment may be required if the ATV tends to creep or if the clutch slips when shifting into gear causing acceleration to lag behind engine speed 75 ...

Page 115: ...e upper clutch cable adjuster Upper Adjustment Pull back the dust cover Loosen the upper lock nut Turn the upper clutch cable adjuster to obtain the specified freeplay Tighten the lock nut and check the freeplay again Pull on the dust cover If proper adjustment cannot be obtained or the clutch does not work correctly the cable or clutch friction discs may be worn See your Honda dealer 1 2 4 2 3 4 ...

Page 116: ...eplay 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 maximum freeplay Hold the lower adjusting nut and loosen the lower lock nut at the lower end of the cable Turn the lower adjusting nut to obtain the specified freeplay Hold the lower adjusting nut and ti...

Page 117: ...moothly and accelerate gradually Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion Check the clutch cable for kinks or signs of wear If necessary have it replaced Check that the clutch lever parking brake lever assembly is positioned properly and the securing bolts are tight Check the clutch lever parking brake lever and clutch cable f...

Page 118: ...her Inspection Reverse Lock System Servicing Your Honda Safety Precautions Refer to on page To adjust loosen the lock nut and turn the adjusting nut After adjustment tighten the lock nut securely Check the reverse assist lever freeplay 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 dealer 1 2 75 3 1 2 ...

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 a firm level surface Connect a tachometer to the engine Shift into neutral Start the engine If the engine is cold start it and warm it up with ten minutes of stop and go riding Stop the engine The eng...

Page 120: ... Spark Plug Servicing Your Honda Using spark plugs with an improper heat range can cause engine damage Safety Precautions Use only the recommended type of spark plug in the recommended heat range Refer to on page Clean any dirt from around the spark plug base Using a spark plug wrench provided in the tool kit remove the spark plug Disconnect the spark plug cap Take care to avoid damaging the spark...

Page 121: ...de electrode carefully The gap should be Inspect the electrode and center porcelain for deposits corrosion or carbon fouling If the corrosion or deposits are heavy replace the plug Clean a carbon or wet fouled plug with a plug cleaner if available or a wire brush Inspect the spark plug electrodes for wear The center electrode should have a flat tip and sharp edges and the side electrode should not...

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 the plug NGK turn after it seats DENSO turn after it seats Then loosen the plug Next tighten the plug again 1 8 turn after it seats Reinstall the spark plug cap Take care to avoid pinching any cables...

Page 123: ...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 adjusting valve clearances are given in the official Honda Service Manual All others should have valves adjusted by your Honda dealer 75 ...

Page 124: ...d check that there are no combustible materials in the area before purging the spark arrester The exhaust system must be periodically purged of accumulated carbon Select a well ventilated area free of combustible materials and make sure the exhaust pipe is cool Remove the bolts gasket and spark arrester lid Start the engine and rev it up approximately twenty times while momentarily creating exhaus...

Page 125: ... load whenever you change your normal load by adding or subtracting accessories or when the road or riding conditions change The way you ride your ATV and the type of ride you want to experience can also influence your suspension needs Lower spring pre load provides a softer ride and is usually preferred for light loads and smooth roads Higher spring pre load provides a firmer ride and is recommen...

Page 126: ...panner 3 2 5 117 Suspension Spring Pre Load Suspension Servicing Your Honda Safety Precautions Refer to on page The spring pre load adjuster has 5 positions for different load or riding conditions Use the pin spanner to adjust the shock spring pre load cont d 1 2 75 ...

Page 127: ...e that both shock absorbers are adjusted to the same position Position 1 standard position Positions 2 to 5 for when the ATV is more heavily loaded Also increase spring pre load for stiffer suspension Position 1 for a light load and smooth road conditions Position 2 standard position Positions 3 to 5 for when the ATV is more heavily loaded Also increase spring pre load for stiffer suspension Front...

Page 128: ...will also cause the level to drop The hydraulic braking systems on your ATV dissipate the heat generated by the friction of the brake pads on the brake discs as the wheels are slowed If the brake lever or brake pedal freeplay does not feel within the normal range while riding check the brake pads for wear page Worn pads should be replaced If the pads are not worn beyond the recommended limit there...

Page 129: ...our inspection indicates a low fluid level have your Honda dealer add the recommended fluid Do not add or replace brake fluid except in an emergency If you do add fluid have your Honda dealer check the system as soon as possible Wipe up spills immediately Avoid contact with skin or eyes In case of contact wash thoroughly and call a doctor immediately if it contacts your eyes Front Brake Fluid Leve...

Page 130: ...uld be replaced If the pads are not worn have your brake system inspected for leaks With the ATV in an upright position check the fluid level It should be between the UPPER and LOWER level mark If the level is at or below the LOWER level mark check the brake pads for wear page Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks With the ATV in an ...

Page 131: ...r Inspections Brakes Servicing Your Honda 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 ...

Page 132: ... usage and riding conditions The pads will wear faster in wet or muddy conditions Inspect the pads visually during all regular service intervals to determine the pad wear Always inspect both pads in both the right and left front brake calipers Front brake pads Rear brake pads If the wear indicator aligns with the edge of the reference mark both pads must be replaced see your Honda dealer for this ...

Page 133: ...vicing Your Honda Make sure there are no fluid leaks The rear brake pedal pivot must be inspected according to the Maintenance Schedule See your Honda dealer for this service Check for deterioration or cracks in the hoses and fittings ...

Page 134: ...page Rear Brake Only Check the operation of the rear brakelight switch on the right side near the crankcase from time to time The brakelight should turn on at 0 6 in 15 mm of pedal stroke Adjustment is done by turning the adjusting nut Turn the nut in direction if the switch operates too late and in direction if the switch operates too soon 75 1 A B 2 ...

Page 135: ...parking brake does not hold properly Loosen the lock nut on the parking brake cable and screw in the adjuster completely Temporarily adjust the clutch lever parking brake lever freeplay to more than 1 3 16 in 30 mm page Pull back the dust cover Loosen the lock nut on the parking brake arm and turn the adjusting bolt clockwise until you feel resistance Then turn the adjusting bolt 1 8 counterclockw...

Page 136: ...prevent premature wear and corrosion Push down the parking brake pin and then squeeze the clutch lever parking brake lever until firm resistance is felt Measure the distance the clutch lever parking brake lever has moved the distance should be Check the clutch lever parking brake lever and parking brake cable for loose connections or other damages If the parking brake cable is worn or kinked have ...

Page 137: ...res 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 off road use they are not immune to punctures Always select your riding area with care The following pages give detailed information on how and when to check your air pressure how to inspect your tir...

Page 138: ...dling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tires make your ATV ride harshly are more prone to damage from surface hazards and wear unevenly Make sure the valve stem caps are secure If necessary install a new cap 75 ...

Page 139: ...ng Your Honda Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your ATV has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold tire pressures the tires will be underinflated Be sure to check tire pressure at the riding site since changes in altitude can affect air p...

Page 140: ...re system 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 pressure increase frequently to prevent possible tire damage from overinflation Refer to on page Whenever you check the tire pressures you should also look for Bumps or bulges in the side of the tire o...

Page 141: ...so if you 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 depth at the center reaches the following limits To check the condition of a tire tread measure the groove depth in the center of the tire or check the wear indicator 1 2 ...

Page 142: ...our 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 choose to have a tire repaired be sure the repair work is performed by a professional A temporary repair can sometimes be made in an emergency situation However since a temporary repair may not hold yo...

Page 143: ...ere 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 must replace the tires in pairs front or rear with tires of the same size and type as the originals Never replace just one tire When you replace a tire remember Have the tire replaced by your Honda d...

Page 144: ...engine crankcase Have the engine guard and skid plates replaced if they are cracked or damaged If the guard and plate bolts are loose tighten them securely The skid plates protect the frame lower arm the drive components and the rear brake Check the guard and plates for cracks damage or looseness at intervals shown in the Maintenance Schedule 1 2 75 ...

Page 145: ...aintenance can cause premature wear or damage to the drive chain or sprockets The drive chain should be checked adjusted and lubricated as part of the pre ride inspection page Under severe usage or when the ATV is ridden in unusually dusty or muddy areas more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF and check that your transmission is in neutral ...

Page 146: ...d and binding Lubricating the chain will often eliminate binding and kinking Inspect the drive chain for damaged rollers loose pins dry or rusted links kinked or binding links excessive wear damaged or missing O rings Replace the drive chain page if it has damaged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page if it appears dry or shows signs of rust Lubricate any ...

Page 147: ...en a span of pins from pin center to pin center If the distance exceeds the service limit the chain is worn out and should be replaced Service limit Check the drive chain slider for wear When the depth of the grooves in the slider reaches in mm remove material to lower the height of the center ridge between the grooves to less than in mm Replace the slider when the depth of the grooves reaches the...

Page 148: ...roller 4 139 Drive Chain Servicing Your Honda Use of a new chain with worn sprockets will cause rapid chain wear Inspect the front and rear sprocket teeth for excessive wear or damage If necessary have your Honda dealer replace a worn sprocket Check the chain roller for wear and replace if necessary 6 7 4 ...

Page 149: ... to on page If a torque wrench is not used for installation see your Honda dealer as soon as possible to verify proper assembly To adjust slack use an Allen wrench to loosen the rear axle holder fixing bolts Turn the adjuster to decrease or increase chain slack Retighten the rear axle holder fixing bolts Rear axle holder fixing bolts torque 1 2 3 3 2 B A 75 1 ...

Page 150: ...ur Honda Safety Precautions Refer to on page Lubricate every 30 days of riding or sooner if chain appears dry Lubricate only with SAE 80 or 90 gear oil Commercial chain lubricants may contain solvents which could damage the rubber O rings 75 ...

Page 151: ...team cleaning high pressure washers and certain solvents Clean the side surfaces of the chain with a dry cloth Use a high flashpoint solvent such as kerosene not gasoline Do not brush the rubber O rings Brushing will damage them Use of a solvent may also damage the O rings Inspect the drive chain for possible wear or damage Replace the drive chain if it has damaged rollers loose fitting links dama...

Page 152: ... 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 frequently see page If you do not expect to ride your ATV for at least two weeks we recommend you remove the battery or at least disconnect the battery cables negative cable first If you plan to store your...

Page 153: ...ttery 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 remove the battery we recommend disconnecting the battery cables negative cable first You will get the best storage results from removing the battery and slow trickle charging it every 30 days see pa...

Page 154: ... Remove the battery Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Remove the seat page Make sure the ignition switch is OFF Removal The battery is located in a compartment under the left side rear fender cont d Remove the battery holder by removing the mount bolt 1 2 3 4 5 4 3 5 1 86 2 ...

Page 155: ...g 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 section once every 30 days Installation Reinstall in the reverse order of removal Be sure to connect the positive terminal first then the negative terminal Check all bolts and other fasteners are secure 6 ...

Page 156: ...harging 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 intentionally leave the charger connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat an ATV battery a...

Page 157: ...ucts 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 cool off Park in a shady area Washing your ATV in bright sunlight may cause the finish to fade because water droplets intensify the sun s brightness Spotting is also more likely because surface w...

Page 158: ...After washing rinse your ATV thoroughly with plenty of clean water to remove any residue Detergent residue can corrode alloy parts Dry your ATV with a chamois or a soft towel Leaving water on the surface to air dry can cause dulling and water spots As you dry inspect for chips and scratches Start the engine and let it idle for several minutes The engine heat will help dry moist areas As a precauti...

Page 159: ...pply 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 Brake dust Light road grimes Dust and fingerprint smudges ATV condition Recommended Cleaning 150 Spray Cleaning Your ATV Appearance Care Servicing Your Honda Safety Precautions Refer to on page Avoid usi...

Page 160: ...ding through any of these substances Use a wet sponge and mild detergent Avoid stiff brushes steel wool or cleaners containing abrasives or chemical compounds After washing rinse with plenty of water and dry with a clean cloth Then apply a mild commercially available spray cleaner polish or wax For stained or dull looking wheels use a quality chrome aluminum polish to restore the finish 75 ...

Page 161: ...ly for motorcycles or automobiles Apply the polish or wax according to the instructions on the container If a surface on your ATV is chipped or scratched your Honda dealer has touch up paint to match your ATV s color Be sure to use your ATV s color code page when you buy touch up paint If the frame has a chip that exposes the metal first apply primer to prevent corrosion and then apply the touch u...

Page 162: ...t and store your Honda and how to be an environmentally responsible ATV owner Preparing for a Ride 154 What to Take to the Riding Area 154 What to Take on the Trail 155 Transporting Your Honda 156 Storing Your Honda 158 Preparation for Storage 159 Removal from Storage 161 You the Environment 162 ...

Page 163: ... 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 supplies in case you have a problem For some of the difficulties 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 it...

Page 164: ...u 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 trail be sure you can carry them safely and know how to use them Also be sure to follow the loading guidelines and weight limit page 35 ...

Page 165: ...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 gasoline could be a hazard Follow these procedures Set the parking brake and place the transmission in gear Turn the fuel valve OFF 1 2 ...

Page 166: ...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 in any other areas can damage your ATV Rock the vehicle back and forth to make sure the tie down straps are tight and the vehicle is secure 3 4 ...

Page 167: ...ny 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 dealer USA only We suggest you perform the following procedures to keep your ATV in top condition These storage procedures will reduce the deterioration that can occur during storage ...

Page 168: ...er to on page This procedure requires a means for draining and disposing of drained fuel page Change the engine oil and filter page Fill the fuel tank Make sure the fuel fill cap is properly installed cont d Drain the carburetor into an approved gasoline container and dispose of it in an approved manner page If storage will last longer than one month carburetor draining is important to assure prop...

Page 169: ... the spark plug Do not connect the spark plug to the spark plug cap Pour a tablespoon 15 20 cc of clean engine oil into cylinder and cover the spark plug hole with a piece of cloth Reinstall the spark plug and spark plug cap Remove the battery and charge it fully Store it in an area protected from freezing temperatures and direct sunlight Slow charge the battery page once a month Wash and dry your...

Page 170: ...strict air flow and allow heat and moisture to accumulate Refer to on page Uncover and clean your ATV If your ATV has been stored for more than four months change the engine oil page If your ATV has been stored for more than two months ask your Honda dealer to drain and replace the fuel Charge the battery page as required Install the battery Perform a pre ride inspection page then test ride your A...

Page 171: ...ly increase noise they also reduce engine performance and may be illegal It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxi...

Page 172: ...go 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 164 If Your Engine Quits or Won t Start 166 If You Have a Flat Tire 169 If a Fuse Blows 172 If You Crash 174 If You Lose Your Key 175 If the Battery Is Low or Dead 176 If a Component Fails 177 154 ...

Page 173: ...st 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 then consider your options before you decide what to do If a problem is relatively minor and you have the tools supplies and skills to make a permanent repair you may be able to fix it on the trail an...

Page 174: ...e 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 permanent repairs made as soon as possible Do not continue riding if you are hurt or your ATV is not in safe riding condition Additional recommendations for specific problems follow ...

Page 175: ...y 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 t correct the problem see your Honda dealer If your ATV won t start listen as you press the start button If you don t hear the starter motor turning refer to the symptom If you can hear the starter m...

Page 176: ...gative the starter motor may be faulty See your Honda dealer SYMPTOM POSSIBLE CAUSE out of fuel flooded engine loose or unconnected spark plug cap loose battery cables weak battery WHAT TO DO Fill the fuel tank See page Install the spark plug cap securely If the engine still won t start see your Honda dealer Tighten the battery terminal bolts Charge the battery page If charging doesn t help see yo...

Page 177: ... See your Honda dealer See your Honda dealer If applicable switch to the recommended octane gasoline page or change your brand of gasoline If the problem persists see your Honda dealer detonates or pings under load See your Honda dealer See your Honda dealer sooty exhaust rich fuel mixture blubbers rich fuel mixture pre ignition runs on after ignition switched OFF afterfires backfires 110 187 87 E...

Page 178: ...e 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 facilities or available transportation we recommend that you carry a tire pump and a repair kit with the vehicle If the leak is more serious or a temporary repair doesn t hold the tire must be replac...

Page 179: ...al Park your 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 Remove the wheel nuts Avoid getting grease oil or dirt on the disc or pad surfaces when removing and installing each wheel Any contamination can cause poor brake performance or rapid pad wear after reassembly 1 1 2 3 4 75 ...

Page 180: ...wheel nuts so that the tapered sides face the wheel rim If a torque wrench was not used for installation see your Honda dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capability Tighten the wheel nuts in a crisscross rather than a circular pattern to the specified torque 1 2 3 2 ...

Page 181: ...y excess current flow short circuit or overload Recommended Fuses If something electrical on your ATV stops working the first thing you should check for is a blown fuse Check the fuse before looking elsewhere for another possible cause of the problem Replace a blown fuse and check component operation The fuse is located near the air cleaner case cover behind the seat 1 ...

Page 182: ...he Unexpected Install the seat Replace the old fuse To replace the fuse To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuse Remove the fuse case cover Reinstall the fuse case cover To access the fuse remove the seat page 1 2 3 4 5 6 1 3 86 ...

Page 183: ...ely carefully inspect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor damage or you are unsure about possible damage but decide to try riding the ATV back to your base ride slowly and cautiously Sometimes crash damage is hidden or not immediately apparent W...

Page 184: ...made 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 you purchased your Honda from 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 the ignition switch assembly to find the key number so they can make a ke...

Page 185: ...d 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 If you can t charge the battery or it appears unable to hold a charge contact your Honda dealer ...

Page 186: ...the damage is and what tools and supplies you have with you If any component of the brake system is damaged you may be able to ride carefully back to your base using the other brake components for slowing or stopping If you damage a 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 ...

Page 187: ...178 Taking Care of the Unexpected ...

Page 188: ...nsions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 180 Specifications 182 Break in Guidelines 186 High Altitude Carburetor Adjustment 187 Emission Control Systems 188 Oxygenated Fuels 192 ...

Page 189: ...mation The VIN and engine serial numbers and key number may be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN is stamped on the front of the frame The engine number is stamped on the right side of the crankcase 2 1 ...

Page 190: ... Technical 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 and code in the Quick Reference section at the rear of this manual 1 86 ...

Page 191: ...serving 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 after disassembly after draining overall length overall width overall height wheelbase ground clearance fuel recommendation fuel tank capacity fuel tank reserve engine oil capacity engine oil recommenda...

Page 192: ...3 2 923 5 415 X24ESR U DENSO X22ESR U DENSO X27ESR U DENSO or or or chain or passenger capacity bore stroke maximum weight capacity displacement spark plug standard compression ratio spark plug cold climate spark plug high speed riding idle speed spark plug gap valve clearance cold primary reduction 5th 4th 3rd 2nd 1st reverse gear ratio final reduction final drive Capacities Engine Specifications...

Page 193: ... kgf cm 4 4 psi 30 kPa 0 30 kgf cm AT 22 10 9 OHTSU P V 102 OHTSU P V 702 Front Front Front Rear Rear Rear caster trail tire size front reverse indicator neutral indicator brake tail light headlight generator battery minimum tire pressure front rear cold maximum tire pressure front rear cold tire pressure front rear cold tire size rear Chassis Suspension Lights Electrical 184 Specifications Techni...

Page 194: ...8 lbf ft 24 N m 2 4 kgf m 7 lbf ft 10 N m 1 0 kgf m 47 lbf ft 64 N m 6 5 kgf m main engine oil drain bolt engine oil filter bolt wheel nuts Torque Specification Fuse 185 Specifications Technical Information ...

Page 195: ...al Information 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 and rapid acceleration ...

Page 196: ...meters 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 standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will b...

Page 197: ... The Vehicle Emission Control Information Label is attached on the right side of the frame The U S Environmental Protection Agency EPA and the California Air Resources Board CARB require that your ATV comply with applicable exhaust emission standards during its useful life when operated and maintained according to the instructions provided 1 ...

Page 198: ...hemical 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 hydrocarbons The exhaust emission control system is composed of appropriate carburetor settings No adjustments should be made except for an idle speed adjustment with the throttle stop screw or carburetor...

Page 199: ...ymptoms 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 backfiring Poor performance driveability and poor fuel economy Federal regulations prohibit removing or disabling a device or element of design that may affect your engine s emission performance unless your A...

Page 200: ... 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 by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases R...

Page 201: ...ted 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 ethanol may be marketed under the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may...

Page 202: ...ptoms 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 oxygenates mentioned above are not covered under warranty Oxygenated fuels can damage paint and plastic Be careful not to spill fuel when filling the fuel tank Wipe up any spills immediately ...

Page 203: ...194 Technical Information ...

Page 204: ...n This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 196 Warranty Coverage 199 Warranty Service 200 Contacting Honda 201 Your Honda Dealer 202 The Honda Rider s Club USA only 203 ...

Page 205: ...rom 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 capa...

Page 206: ...ling Charge Grand Total Sub Total 5 00 197 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00 PM EST By completing this form you can order the materials desired You can pay by check or money order or charge to your credit card Mail to Helm Inc at the address shown on the back of this order f...

Page 207: ...ytime 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 Discover MasterCard Account Number Expiration Mo Yr Customer Signature Date These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a...

Page 208: ...qualified Failures that occur due directly to improper maintenance are not covered It is important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage does not apply to normal wear or deterioration associated with using the ATV There are responsibilities restrictions and exclusions which apply to these warranties Please read the Warranti...

Page 209: ...e 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 repair it is best to talk to the service manager of your Honda dealer Sometimes in spite of the best intentions of all concerned a misunderstanding may occur If you aren t satisfied with your dealer s h...

Page 210: ...to 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 Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4C 7B telephone 866 784 1870 Canada Refer to the Warranties Booklet that was supplied with your vehicle P...

Page 211: ...products Canada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage USA only Your Honda dealer can inform you about competition and other riding events...

Page 212: ... free roadside assistance for your new Honda includes roadside assistance for your transport vehicle up to one ton as long as your Honda is aboard or in tow An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for successful completion of a Motorcycle Safety Foundation training course Separate compli...

Page 213: ...s ATV SAFETY 1 INDICATORS CONTROLS 9 The following presents the contents of each section of your owner s manual Important Safety Information 2 Safety Labels 5 Operation Component Locations 11 Indicators 14 Reverse and Neutral Indicators 14 ...

Page 214: ...r Parking Brake Lever 20 Reverse Assist Lever 21 Front Brake Lever 22 Rear Brake Pedal 22 Parking Brake 23 Flag Pole Bracket 24 Are You Ready to Ride 26 Protective Apparel 26 Rider Training 28 Age Recommendation 29 No 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 35 Loading Guidelines 36 Accessories Modific...

Page 215: ... Terrain 44 Do Not Perform Stunts 45 Starting Stopping the Engine 46 Preparation 47 Starting Procedure 48 Flooded Engine 51 How to Stop the Engine 51 Shifting Gears 52 Riding in Reverse 54 Braking 56 Riding Your ATV 58 Making Turns 58 Skidding or Sliding 60 Riding Up Hills 61 Riding Down Hills 65 Crossing or Turning on Hills or Slopes 66 Riding Over Obstacles 68 Riding Through Water 69 Parking 70 ...

Page 216: ...Maintenance Safety 74 Important Safety Precautions 75 Maintenance Schedule 76 Maintenance Record 80 Maintenance Component Locations 81 Tool Kit 84 Owner s Manual Storage 85 Seat Removal 86 Fluids Filters Fuel 87 Engine oil Filter 92 Air Cleaner 99 Engine Throttle 103 Clutch System 105 Reverse Lock System 109 Engine Idle Speed 110 Spark Plug 111 Valves 114 Spark Arrester 115 ...

Page 217: ...ng for a Ride 154 What to Take to the Riding Area 154 What to Take on the Trail 155 Transporting Your Honda 156 Storing Your Honda 158 Preparation for Storage 159 Removal from Storage 161 You the Environment 162 General Guidelines 164 If Your Engine Quits or Won t Start 166 If You Have a Flat Tire 169 If a Fuse Blows 172 If You Crash 174 If You Lose Your Key 175 If the Battery Is Low or Dead 176 I...

Page 218: ...0 QUICK REFERENCE Vehicle Identification 180 Specifications 182 Break in Guidelines 186 High Altitude Carburetor Adjustment 187 Emission Control Systems 188 Oxygenated Fuels 192 Authorized Manuals 196 Warranty Coverage 199 Warranty Service 200 Contacting Honda 201 Your Honda Dealer 202 The Honda Rider s Club USA only 203 ...

Page 219: ...ain tube 102 air pressure gauge 84 tire 130 altitude high 187 American Honda contacting 195 apparel protective 26 appearance care 148 authorized manuals 196 Battery 143 Brakes fluid 119 front brake lever 22 brake pad wear 123 parking 126 rear brake pedal 22 braking 56 break in guidelines 186 ...

Page 220: ...ce 148 chain drive 136 choke lever 16 cleaning appearance care 148 climbing hills 61 clutch system 105 color label 181 compartment owner s manual 85 tool kit 84 component fails 177 consumer information 195 crash if you 174 crossing or turning on hills or slops 66 customer service 201 ...

Page 221: ...t 19 dipstick 95 drive chain 136 emission control system 188 engine flooded 51 guard 135 idle speed 110 number 180 oil 92 pinging 87 starting 46 stop switch 18 stopping 51 won t start 166 environment 162 exhaust system cleaning 115 purging 115 ...

Page 222: ...F flag pole bracket 24 flat tire 169 flooded engine 51 fuel fill cap 88 high altitude fuel mixture adjustment 187 oxygenated 192 recommendation 87 refueling 88 reserve fuel supply 15 tank capacity 88 valve 15 fuse 172 ...

Page 223: ...hifting 52 headlight dimmer switch 19 headlight switch 19 high altitude carburetor adjustment 187 hills crossing or turning on slops 67 riding down hills 65 riding up hills 61 stopping on hills 63 Honda contacting 201 Rider s Club 203 dealer 202 Honda service manual 198 ...

Page 224: ...215 Index Index I K identification vehicle 180 idle speed engine 110 ignition switch 17 indicators neutral indicator 14 reverse indicator 14 inspection pre ride 31 key lost 175 number 175 kit tool 84 ...

Page 225: ...locations 81 importance 73 precautions 75 record 80 safety 74 schedule 76 manual service 198 maximum weight limit 34 modifications 38 labels safety 5 limit weight 35 load limits 35 loading guidelines 36 lubrication engine oil 92 drive chain 141 ...

Page 226: ... O neutral indicator 14 noise emission control systems 191 numbers serial 180 obstacles riding over 68 oil engine 92 operating controls 15 operation component locations 11 owner s manual storage 85 oxygenated fuels 192 ...

Page 227: ...nt no riding on 3 pinging engine 88 plug spark 111 pre ride inspection 31 problems unexpected 163 protective apparel 26 removal seat 86 reverse assist cable 109 assist lever 21 gear shifting into 52 indicator 14 riding in 54 rider training 28 Rider s Club Honda 203 ...

Page 228: ...precautions 41 preparing for 31 over obstacles 68 safety 2 safety precautions 41 through water 68 safety important precautions 75 labels 5 riding precautions 41 schedule maintenance 76 seat removal 86 serial numbers 180 service customer 201 manuals 198 warranty 199 ...

Page 229: ...k 87 spark plug 111 specifications 182 stalling on a hill 63 start button 18 starting engine 46 troubleshooting 166 stop switch engine 18 stopping engine 51 storage ATV 161 owner s manual 85 suspension adjustment 116 spring pre load 117 switch brakelight 125 headlight 19 headlight dimmer 19 ignition 17 ...

Page 230: ... 180 throttle lever 20 103 tires air pressure 130 flat 169 replacing 134 repairing 133 specifications 134 thread conditions 132 tool kit 84 training rider 28 transporting your ATV 156 trouble unexpected 163 troubleshooting starting 166 turning on level ground 58 on hills or slopes 67 ...

Page 231: ...222 Index Index W warning labels 5 warranty coverage 199 extended 199 service 200 washing your ATV 149 water riding through 69 weight limit 35 wheel removal 170 ...

Page 232: ...223 Memo ...

Page 233: ...224 Memo ...

Page 234: ...rtant 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 Frequent causes of costly repairs are Engine oil insufficient quantity improper oil Air cleaner dirty leaking because of improper installation poor seal Record important information on the following page ...

Page 235: ...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 236: ... before you ride page engine oil fuel tires drive chain nuts bolts underbody exhaust system air cleaner housing drain tube leaks loose parts cables throttle brakes clutch lever reverse assist lever indicators lights switches steering API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 s...

Page 237: ...f cm 4 8 psi 33 kPa 0 33 kgf cm 2 9 psi 20 kPa 0 20 kgf cm 4 4 psi 30 kPa 0 30 kgf cm AT 22 10 9 OHTSU P V 102 OHTSU P V 702 X22ESR U DENSO Front Rear maximum tire pressure minimum tire pressure or or or high speed riding standard Front Rear Front Rear main cold climate Front Rear Quick Reference Quick Reference Tires Fuse Spark Plugs Tire Pressure cold ...

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Honda SPORTRAX 300EX, Owner'S Manual

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