Honda SPORTRAX 400X Owner'S Manual Download Page 82

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Servicing Your Honda

Service Procedures
Fluids & Filters

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Air Cleaner

Engine

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Throttle

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Clutch System

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Engine Idle Speed

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Spark Plug

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Valves

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Spark Arrester

Chassis

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Brakes

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Engine Guard & Skid Plates

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Drive Chain

Electrical

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Battery

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Appearance Care

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Reverse Lock System

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Suspension

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Tires

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Fuel

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Engine Oil & Filter

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Summary of Contents for SPORTRAX 400X

Page 1: ...mission 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 ve...

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

Page 3: ...nt 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 reproduc...

Page 4: ...ave 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 pos...

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 importance of wearing a helmet and other protective gear how to make sure you and your ATV are ready to ride...

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

Page 8: ......

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

Page 10: ...important The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle Refer to the age warnings provided in this manual and on the ATV Your ATV is desi...

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

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

Page 13: ...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...

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

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

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

Page 17: ...ions for other components are presented in other sections of this manual where they will be most useful This section shows the location of all indicators and controls you would normally use before or...

Page 18: ...e Lever Ignition Switch Start Button Engine Stop Switch Headlight Switch Headlight Dimmer Switch Throttle Lever Clutch Lever Parking Brake Lever Reverse Assist Knob Front Brake Lever Rear Brake Pedal...

Page 19: ...ver start button ignition switch headlight switch clutch lever parking brake lever reverse assist knob headlight dimmer switch engine stop switch throttle lever 11 Indicators Controls Operation Compon...

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

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

Page 22: ...e on when it should have your Honda dealer check for burned out bulbs or other problems The reverse indicator and the neutral indicator are located on the handle cover The reverse indicator will light...

Page 23: ...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...

Page 24: ...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 25: ...gnition 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...

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: ...ss 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 T...

Page 29: ...reverse assist knob located on the right fender 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 p...

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

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

Page 35: ...ng An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker on any helmet you buy USA only Always wear...

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

Page 37: ...cause a crash and you or your passenger could be injured or killed Never carry a passenger on this ATV 29 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended a...

Page 38: ...ume alcohol or drugs before or while operating this ATV 30 No Alcohol or Drugs Are You Ready to Ride Before Riding Alcohol drugs and ATVs don t mix Even a small amount of alcohol can impair your abili...

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

Page 40: ...n 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 inter...

Page 41: ...st if needed page Squeeze the front brake lever 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 pa...

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 tires are properly inflated Be sure to observe the weight limits and follow these guid...

Page 45: ...page A blown fuse can cause a loss of lights or engine power page Make sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls Mak...

Page 46: ...ake any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make your ATV illegal in your area We strongly advise you not t...

Page 47: ...f road Use Only Keep Hands and Feet on Controls Control Speed Use Care on Unfamiliar or Rough Terrain Do Not Perform Stunts Starting Stopping the Engine Preparation Starting Procedure This section giv...

Page 48: ...c Operation Riding Braking Riding Your ATV Making Turns Riding Up Hills Skidding or Sliding 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 Always keep both hands on the handlebars and both feet on the footpegs when riding your ATV This is important to maintain your balance...

Page 51: ...cle the terrain visibility and other operating conditions and your experience 43 Control Speed Basic Operation Riding Safe Riding Precautions Riding at excessive speed increases the chance of an accid...

Page 52: ...errain Always be alert to changing terrain conditions when operating the ATV 44 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Page 53: ...on these kinds of terrain Attempting wheelies jumps and other stunts increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off 45 D...

Page 54: ...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 sy...

Page 55: ...ing 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 transmissi...

Page 56: ...the start button To restart a warm engine follow the procedure for The carburetor is equipped with an accelerator pump Do not open the throttle when starting the engine This will flood the engine with...

Page 57: ...mediately after the engine starts 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...

Page 58: ...ne wear Follow steps under Warm up the engine by opening and closing the throttle slightly If the engine does not start after several attempts operate the start button after opening and closing the th...

Page 59: ...e engine still won t start refer to page Press the start button for 5 seconds Move the choke lever to the fully OFF position Normal Engine Stop To stop the engine make sure the transmission is in neut...

Page 60: ...rs 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...

Page 61: ...gets too high Learn the relationship between engine sound and the normal shifting points As a general rule shift while moving in a straight line Learning when to shift gears comes with experience Kee...

Page 62: ...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 Bring the vehicle to a complete stop pull in the clutch lever parking bra...

Page 63: ...t out of reverse into 1st gear pull in the clutch lever parking brake lever and raise the shift lever one click to 1st gear Make sure that the reverse indicator goes off To stop pull in the clutch lev...

Page 64: ...hen operating in reverse gear could cause the front wheels to lift off the ground and the ATV could overturn backwards Carefully apply both the front and rear brakes when stopping in reverse gear 56 R...

Page 65: ...Your ATV is equipped with disc braking systems which are hydraulically activated Depressing the brake pedal applies the rear disc brake Operating the brake lever applies the front disc brake For maxim...

Page 66: ...mittent 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...

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 59 Making Turns Riding Your ATV Basic Operation Riding Learn how to tur...

Page 68: ...ique to master in riding an ATV 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...

Page 69: ...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 70: ...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 71: ...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 72: ...Shift into neutral set the parking brake and turn the engine off Then assess the situation If you are about to lose all forward speed If the ATV starts rolling backwards before you begin braking If t...

Page 73: ...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 74: ...wnhills shift your weight back 66 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 75: ...l path shift 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 Riding on hills or slopes is different from...

Page 76: ...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 77: ...as described in this owner s manual 69 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 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 gettin...

Page 79: ...o start the engine when your ATV in gear and is stopped on a grade rock the vehicle back and forth to allow shifting the transmission into neutral If you must park your ATV on a steep incline or loose...

Page 80: ...72 Basic Operation Riding...

Page 81: ...ific maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking good For information about replacing a fuse see page For info...

Page 82: ...ngine Throttle Clutch System Engine Idle Speed Spark Plug Valves Spark Arrester Chassis Brakes Engine Guard Skid Plates Drive Chain Electrical Battery Appearance Care Reverse Lock System Suspension Ti...

Page 83: ...crash be sure your Honda dealer inspects all major parts even if you are able to make some repairs More frequent service is needed if you subject your ATV to severe use or ride in unusually wet or du...

Page 84: ...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 85: ...Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around gasoline Use only non flamm...

Page 86: ...dule can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual Other items involve more extensive procedures and may require special training...

Page 87: ...e more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the o...

Page 88: ...ULAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL HOURS MAINT INTERVAL MAINT 100mi 150km 20 operating hours or 1 month R Every 600mi 1000km 100 operating hours or 12 months R INITIAL REGULAR 80 Maint...

Page 89: ...I 1200 2000 200 I I I I I I I I I C I I I I I Refer to page 141 143 125 129 131 125 111 140 107 119 117 134 175 FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITIAL HOURS NOTE 1 2 NOTE 1 2 MAINT INTE...

Page 90: ...e new owner Make sure whoever performs the maintenance completes this record All scheduled maintenance including the 100 mile 150 km or 20 hours initial maintenance is considered a normal owner operat...

Page 91: ...front brake fluid reservoir front brake lever throttle lever clutch lever parking brake lever fuel fill cap 83 Servicing Your Honda Maintenance Component Locations...

Page 92: ...spark arrester spark plug front suspension spring pre load adjuster rear brakelight switch engine oil drain bolt oil tank front brake caliper engine oil check bolt crankcase 84 Servicing Your Honda Ma...

Page 93: ...stick drive chain air cleaner housing drain tube rear suspension compression damping adjuster rear suspension rebound damping adjuster rear brake caliper engine oil drain bolt crankcase throttle stop...

Page 94: ...Servicing Your Honda The tool kit is stored on the underside of the seat page fastened with a rubber band The air pressure gauge should be stored in the tool kit An optional larger tool kit may be av...

Page 95: ...ood this area when washing your ATV or riding 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...

Page 96: ...back and lift it Removal Installation Insert the front prongs into the hooks on the frame and press the studs into the grommets on the frame Press down on the seat until it locks The seat must be rem...

Page 97: ...ging 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 gasolin...

Page 98: ...ueling Procedure Servicing Your Honda Fuel Safety Precautions Fuel tank capacity including reserve Reserve capacity Refer to on page The tank should be refilled as soon as possible after switching to...

Page 99: ...terclockwise Pull the breather tube 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 nec...

Page 100: ...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 oi...

Page 101: ...rvicing Your Honda Engine Oil Filter Your ATV does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation Do no...

Page 102: ...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 class...

Page 103: ...ove the oil filler cap dipstick from the oil tank 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 If the oil...

Page 104: ...se the oil level reading will be inaccurate Remove the oil check bolt and washer If oil flows out of the check bolt hole install and tighten a new oil check bolt and washer and proceed to the Oil Tank...

Page 105: ...e engine idle for an additional 5 minutes a total of 10 minutes Stop the engine and wait 2 3 minutes Remove the oil filler cap dipstick from the oil tank and wipe it clean Check the oil level by inser...

Page 106: ...ity This procedure requires mechanical skill and professional tools such as a torque wrench and oil filter wrench as well as a means for disposing of the drained fluid page If you do not have the skil...

Page 107: ...an approved manner page Reposition the spring to the engine crankcase and install a new oil filter with the rubber seal facing out away from the engine You will see the OUTSIDE TOWARDS FILTER COVER ma...

Page 108: ...s on the drain bolts are in good condition If necessary replace the sealing washers Reinstall the oil filler cap dipstick Reinstall the engine guard Reinstall the oil filler cap dipstick Check for oil...

Page 109: ...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 110: ...y 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 c...

Page 111: ...nds 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...

Page 112: ...ld 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...

Page 113: ...nda Safety Precautions Refer to on page Inspection Check freeplay at the throttle lever Freeplay Adjustment Slide the rubber sleeve back to expose the throttle cable adjuster Loosen the lock nut Turn...

Page 114: ...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 115: ...tem Safety Precautions Refer to on page Inspection Check freeplay Freeplay Clutch adjustment may be required if the ATV stalls when shifting into gear if it tends to creep or if the clutch slips causi...

Page 116: ...utch does not work correctly the cable or clutch friction discs may be worn See your Honda dealer Pull back the dust cover Loosen the lock nut and turn the clutch cable adjuster Tighten the lock nut a...

Page 117: ...play 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 maxi...

Page 118: ...oothly and accelerate gradually Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion Check the clutch cable for kinks or signs of wear If ne...

Page 119: ...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 t...

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

Page 121: ...Safety Precautions Using spark plugs with an improper heat range can cause engine damage Refer to on page Clean any dirt from around the spark plug base Using a spark plug wrench provided in the tool...

Page 122: ...e 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 we...

Page 123: ...he 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: ...ssive clearance will cause noise Insufficient clearance will cause loss of power and possibly damage the valves For those who are mechanically proficient and have the proper tools instructions on adju...

Page 125: ...ency Allow the engine and muffler to cool Remove the bolts the spark arrester and the gasket from the muffler Regular servicing prevents carbon build up which can diminish engine performance and also...

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: ...acting 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 pro...

Page 128: ...ing conditions The front shock absorber assembly includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer Th...

Page 129: ...3 to 5 for when the ATV is more heavily loaded Also increase spring pre load for stiffer suspension Make sure that both shock absorbers are adjusted to the same position Always adjust the shock absor...

Page 130: ...y includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are...

Page 131: ...itions turn the adjuster counterclockwise toward SOFT S For a firmer ride and rough road conditions turn the adjuster clockwise toward HARD H Turn the damping adjuster clockwise until it will no longe...

Page 132: ...t the punch mark on the adjuster aligns with the reference punch mark This is the standard position Turn the damping adjuster clockwise until it will no longer turn lightly seats This is the full hard...

Page 133: ...ill 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...

Page 134: ...a 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 A...

Page 135: ...ld 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...

Page 136: ...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 flu...

Page 137: ...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 bo...

Page 138: ...icing 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...

Page 139: ...Brake Only Check the operation of the rear brakelight switch at the right side behind the engine from time to time Remove the right side brakelight switch guard The brakelight should turn on at 0 6 in...

Page 140: ...arking 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...

Page 141: ...revent 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 br...

Page 142: ...es must be the proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tires Although the tires are designed specifically for...

Page 143: ...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 new caps Always check air pressure when your tires are c...

Page 144: ...e 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 pr...

Page 145: ...our Honda Also 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 tir...

Page 146: ...ur Honda dealer A permanent repair such as an internal plug patch can be made if a tire has only a small puncture in the tread area However you may not be able to safely carry as much weight If you ch...

Page 147: ...re 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...

Page 148: ...plates replaced if they are cracked or damaged If the guard and plate bolts are loose tighten them securely The engine guard protects the engine crankcase The skid plates protect the frame lower arm t...

Page 149: ...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 wh...

Page 150: ...inked 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 damag...

Page 151: ...een the sprockets measure the distance between 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 t...

Page 152: ...FT SIDE 144 Servicing Your Honda Drive Chain 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...

Page 153: ...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...

Page 154: ...every 30 days of riding or sooner if chain appears dry Lubricant Pro Honda HP Chain Lube or an equivalent chain lubricant designed specifically for use on O ring chains Commercial chain lubricants no...

Page 155: ...steam 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 ri...

Page 156: ...when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your ATV or do not ride frequently we recommend that you charge the battery freque...

Page 157: ...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 158: ...ervicing Your Honda Make sure the ignition switch is OFF The battery is located in a compartment under the rear fender Removal Remove the battery holder by removing the mount bolts Disconnect the nega...

Page 159: ...emperature 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...

Page 160: ...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 161: ...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...

Page 162: ...fter 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 surfa...

Page 163: ...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 164: ...riding 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 wat...

Page 165: ...washing your ATV consider using a commercially available spray cleaner polish or quality liquid or paste wax to finish the job Use only a non abrasive polish or wax made specifically for motorcycles...

Page 166: ...158 Servicing Your Honda...

Page 167: ...and store your Honda and how to be an environmentally responsible ATV owner Preparing for a Ride Transporting Your Honda Storing Your Honda You the Environment What to Take to the Riding Area What to...

Page 168: ...USA only the Ministry of Natural Resources Canada only riding clubs and off road magazines are good sources of information Along with your ATV and riding gear you should take along some tools and supp...

Page 169: ...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 170: ...ecommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking gasoline could be a h...

Page 171: ...ehicle 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...

Page 172: ...y problem before storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again For more information about storage refer to the available from your Honda dea...

Page 173: ...efer 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 install...

Page 174: ...e spark plug Do not connect the spark plug to the spark plug cap Pour a tablespoon 15 20 cc of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth Reinstall the spar...

Page 175: ...trict 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 be...

Page 176: ...y 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 so...

Page 177: ...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 178: ...doesn t feel right If you continue riding you could cause more damage and endanger your own safety After stopping take time to assess the situation Carefully inspect your ATV to identify the problem...

Page 179: ...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 180: ...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 181: ...ion not in neutral Shift into neutral blown fuse battery lead loose Tighten the battery lead low or dead battery Charge the battery page If charging doesn t help see your Honda dealer Replace with a n...

Page 182: ...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 pin...

Page 183: ...a temporary repair As soon as possible have the tire permanently repaired by your Honda dealer Any tire that cannot be repaired should be replaced Whenever the ATV is to be operated far from service...

Page 184: ...f the temporary repair fails you can crash and be seriously injured or killed If you must ride with a temporary tire repair ride slowly and carefully until the tire is permanently repaired or replaced...

Page 185: ...firm level surface 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 reass...

Page 186: ...ce the wheel rim Hand tighten the wheel nuts on the wheel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque If a torque w...

Page 187: ...use before looking elsewhere for another possible cause of the problem Replace a blown fuse and check component operation All of the electrical circuits on your ATV have a fuse to protect them from da...

Page 188: ...damage to the electrical system Main Fuse Access To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuse Remove the fuse case cover Pull the main fuse...

Page 189: ...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...

Page 190: ...e If you lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer where you purchased your Honda ATV They may have it list...

Page 191: ...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 192: ...he 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 slow...

Page 193: ...sions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification Specifications Break in Guidelines High Altitude Carburetor Ad...

Page 194: ...rmation The VIN engine serial number and key number may be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN is st...

Page 195: ...Identification Technical Information The color label is attached to the top right hand side of the frame The color code is helpful when ordering replacement parts You may record the color and code in...

Page 196: ...rving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 stroke oil USA Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil including reserve afte...

Page 197: ...in 0 10 mm 0 005 in 0 12 mm X24GPR U DENSO X27GPR U DENSO or or chain Intake Exhaust or passenger capacity bore stroke maximum weight capacity displacement spark plug standard compression ratio spark...

Page 198: ...2V 3 4W 4 0 psi 27 5 kPa 4 0 psi 27 5 kPa Front Rear 1 26 in 32 mm Low High caster trail tire size front tire size rear tire pressure front rear cold battery generator headlight brake tail light neutr...

Page 199: ...t 64 N m 6 5 kgf m 7 lbf ft 10 N m 1 0 kgf m 18 lbf ft 25 N m 2 5 kgf m main wheel nuts oil filter bolt engine oil drain bolt oil tank engine oil drain bolt left crankcase Torque Specification Fuse 19...

Page 200: ...l 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 throttl...

Page 201: ...eters have your servicing dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standar...

Page 202: ...Requirements The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Environment Canada EC require that your ATV comply with applicable exhaust emissions standards duri...

Page 203: ...emical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydro...

Page 204: ...mptoms have the vehicle inspected and repaired by your Honda ATV dealer Symptoms Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burning backfirin...

Page 205: ...E 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 Removal of or puncturing of...

Page 206: ...ed on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing e...

Page 207: ...toms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of...

Page 208: ...200 Technical Information...

Page 209: ...This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals Warranty Coverage Warranty Service Contacting Honda Your Honda Dealer The Honda R...

Page 210: ...m 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 operatio...

Page 211: ...7 25 Handling Charge Grand Total 3 75 203 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00...

Page 212: ...e 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...

Page 213: ...wner s card with your Warranties Booklet USA only It is important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage will not be voided if...

Page 214: ...you the results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the rep...

Page 215: ...o work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Mot...

Page 216: ...roducts Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the pa...

Page 217: ...Club USA only Consumer Information www hrca honda com You may be eligible for a Honda Rider s Club of America HRCA membership with the purchase of your new Honda You can log on to the HRCA Clubhouse w...

Page 218: ...ATV SAFETY INDICATORS CONTROLS 1 9 The following presents the contents of each section of your owner s manual Important Safety Information Safety Labels Operation Component Locations Indicators Rever...

Page 219: ...aining Protective Apparel Are You Ready to Ride Choke Lever Controls Features Fuel Valve Ignition Switch Start Button Flag Pole Bracket Engine Stop Switch Headlight Switch Headlight Dimmer Switch Clut...

Page 220: ...ot Perform Stunts Starting Stopping the Engine Preparation Starting Procedure Flooded Engine How to Stop the Engine Shifting Gears Riding in Reverse Braking Riding Your ATV Making Turns Skidding or Sl...

Page 221: ...ester cont d Maintenance Safety Important Safety Precautions Maintenance Schedule The Importance of Maintenance Maintenance Record Maintenance Component Locations Tool Kit Owner s Manual Storage Seat...

Page 222: ...Honda What to Take on the Trail What to Take to the Riding Area Preparing for a Ride You the Environment Preparation for Storage Removal from Storage If a Component Fails If the Battery Is Low or Dea...

Page 223: ...185 201 210 216 Vehicle Identification Specifications Break in Guidelines Oxygenated Fuels Emission Control Systems High Altitude Carburetor Adjustment The Honda Rider s Club USA only Your Honda Deal...

Page 224: ...r pressure gauge 86 tire 134 altitude high 193 American Honda contacting 207 apparel protective 26 appearance care 153 authorized manuals 202 Battery 148 Brakes fluid 125 front brake lever 22 parking...

Page 225: ...n drive 141 choke lever 16 cleaning appearance care 153 climbing hills 62 clutch system adjustment 108 lever 20 color label 187 compartment owner s manual 87 tool kit 86 component fails 184 consumer i...

Page 226: ...witch headlight 19 dipstick 96 drive chain 141 emission control system 194 engine flooded 51 guard 140 idle speed 112 number 186 oil 93 pinging 89 starting 46 stop switch 18 stopping 51 won t start 17...

Page 227: ...flag pole bracket 24 flat tire 175 flooded engine 51 fuel fill cap 90 high altitude fuel mixture adjustment 193 oxygenated 199 recommendation 89 refueling 90 reserve fuel supply 15 tank capacity 90 v...

Page 228: ...ifting 52 headlight dimmer switch 19 headlight switch 19 high altitude carburetor adjustment 193 hills crossing or turning on slopes 67 riding down hills 66 riding up hills 62 stopping on hills 64 Hon...

Page 229: ...21 Index Index I K identification vehicle 186 idle speed engine 112 ignition switch 17 indicators 14 neutral indicator 14 reverse indicator 14 inspection pre ride 31 key lost 182 number 182 kit tool 8...

Page 230: ...limit weight 35 load limits 35 loading guidelines 36 lubrication engine oil 93 drive chain 141 maintenance importance 75 component locations 83 precautions 77 record 82 safety 76 schedule 78 manual se...

Page 231: ...neutral indicator lamp 14 noise emission control systems 197 numbers serial 186 obstacles riding over 69 oil engine 93 operating controls 15 operation component locations 11 owner s manual storage 87...

Page 232: ...ension front 120 pre ride inspection 31 problems unexpected 169 protective apparel 26 removal seat 88 reverse assist knob 21 54 reverse indicator 14 rider training 28 Rider s Club Honda 209 riding bas...

Page 233: ...225 Index Index S cont d safety important precautions 77 labels 5 riding precautions 41 schedule maintenance 78 seat removal 88 serial numbers 186 service customer 207 manuals 202 warranty 206...

Page 234: ...ing on a hill 64 start button 18 starting engine 46 troubleshooting 172 stop switch engine 18 stopping engine 51 storage ATV 164 owner s manual 87 suspension front suspension adjustment 120 front susp...

Page 235: ...39 repairing 138 specifications 139 190 thread conditions 136 137 tool kit 86 training rider 28 transporting your ATV 162 trouble unexpected 169 troubleshooting starting 172 turning on level ground 59...

Page 236: ...228 Index Index W warning labels 5 warranty coverage 205 extended 205 service 206 washing your ATV 154 water riding through 70 weight limit 35 wheel removal 177...

Page 237: ...229 Memo...

Page 238: ...230 Memo...

Page 239: ...231 Memo...

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Page 241: ...233 Memo...

Page 242: ...234 Memo...

Page 243: ...235 Memo...

Page 244: ...tant notes The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequen...

Page 245: ...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 246: ...e 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 knob in...

Page 247: ...OHTSU M R 101 DPR8Z NGK X24GPR U DENSO DPR9Z NGK X27GPR U DENSO 15A 4 0 psi 27 5 kPa 4 0 psi 27 5 kPa or or high speed riding standard main Front Rear Front Rear Quick Reference Quick Reference Tires...

Page 248: ...ls Features section SYMBOL COMPONENT SEE PAGE 17 17 18 18 18 19 19 19 19 ON ignition switch OFF ignition switch START button RUN engine stop switch OFF engine stop switch ON headlight switch OFF headl...

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Honda SPORTRAX 400X, Owner'S Manual

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