Honda TRX450ER Owner'S Manual Download Page 125

Page: 125 / 257

−

3/8

13/16 in

(10

20 mm)

3/8

13/16 in (10

20 mm)

(1)

LEFT HANDLEBAR

(1) clutch lever/parking brake lever

116

Clutch Adjustment

Clutch System

Servicing Your Honda

Saf ety Precautions

Refer to

on page

Inspection

Clutch adjustment may be required if the ATV stalls when shifting into
gear, if it tends to creep, or if the clutch slips, causing acceleration to lag
behind engine speed.

Check freeplay.
Freeplay:

If necessary, adjust to the specified range.
Improper freeplay adjustment can cause premature clutch wear.

07/04/04 11:26:02 31HP1640_125

Summary of Contents for TRX450ER

Page 1: ...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...

Page 2: ...to US EPA 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...

Page 3: ...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 4: ...e harm If you have any questions or if you ever need special service or repairs remember that your Honda dealer knows your ATV best and is dedicated to your complete satisfaction You may also want to...

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

Page 6: ...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 7: ...safety information you should know plus a look at the safety related labels on your ATV The location and function of indicators and controls on your ATV and operating instructions for various controls...

Page 8: ...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 9: ......

Page 10: ...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 11: ...e a few that we consider most important The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle Your ATV is designed for one person only There are...

Page 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...

Page 13: ...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 14: ...the vehicle If a label comes off or becomes hard to read contact your Honda dealer for replacements Your ATV comes with a hang tag and several labels containing important safety information Anyone wh...

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

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

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

Page 18: ...they will be most useful Operation Component Locations 10 Indicators 13 High Coolant Temperature Indicator 13 Neutral Indicator TRX450ER only 14 Controls Features 15 Fuel Valve 15 Choke Knob 16 Hot S...

Page 19: ...king brake lever parking brake lock lever front brake lever start button TRX450ER only TRX450R only engine stop switch parking brake pin ignition switch headlight dimmer switch headlight switch 10 Ind...

Page 20: ...rear brake pedal kickstarter TRX450R only 11 Operation Component Locations Indicators Controls...

Page 21: ...fuel valve seat lock lever choke knob flag pole bracket shift lever 12 Indicators Controls Operation Component Locations...

Page 22: ...ator comes on at the same time If the engine is running the indicator will goes off after a few seconds If the engine is stopping the indicator will goes off at the same time Lights when the engine co...

Page 23: ...Indicators Indicators Controls TRX450ER only If the indicator does not come on when it should have your Honda dealer check for a burned out bulb or other problems The neutral indicator will light when...

Page 24: ...ing Reserve Fuel Remember to check that the fuel valve is in the ON position each time you refuel If the fuel valve is left in the RES position you may run out of fuel with no reserve For complete inf...

Page 25: ...A A B B 1 LEFT SIDE A fully ON B fully OFF 1 choke knob 16 Choke Knob Controls Features Indicators Controls The choke knob may be used when starting the engine See page 1 50...

Page 26: ...1 LEFT HANDLEBAR 1 hot start lever 17 Hot Start Lever TRX450R only Controls Features Indicators Controls The hot start lever 1 may be used when starting a warm engine See page 53...

Page 27: ...TER OF HANDLEBAR 1 ON OFF 1 ignition switch OFF ON Key Position Function 18 Ignition Switch Indicators Controls Controls Features The ignition switch is used for starting and stopping the engine page...

Page 28: ...arting Procedure The start button is used for starting the engine Pushing the button in starts the engine See page When the start button is pushed the starter motor will crank the engine The starter m...

Page 29: ...arter TRX450R only Controls Features Indicators Controls The kickstarter is used to start the engine To operate swing the kickstarter out from its stored position and depress it through its entire str...

Page 30: ...in an emergency To operate 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...

Page 31: ...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 32: ...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 33: ...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 34: ...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...

Page 35: ...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 36: ...nd adjustments to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride 28 Protective Apparel 28 Rider Training 30 Age Recomm...

Page 37: ...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 38: ...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 39: ...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 40: ...his ATV and could cause a crash and you or your passenger could be injured or killed Never carry a passenger on this ATV 31 Age Recommendation No Passengers Are You Ready to Ride Before Riding The min...

Page 41: ...ume alcohol or drugs before or while operating this ATV 32 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 42: ...problem 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 inv...

Page 43: ...check the chain slider and chain roller for wear and replace if needed page Make sure the headlight brakelight and taillight are working properly Check the cable housings for wear Check the fittings...

Page 44: ...steering positions page Check for smooth operation and adjust if needed page Squeeze the front brake lever and step on the rear brake pedal to check that the controls operate normally Make sure there...

Page 45: ...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 46: ...an carry includes the weight of the rider all cargo and accessories The following load limit applies to standard equipment only Modifying your ATV using non standard equipment or riding on terrain tha...

Page 47: ...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 limit and follow these guide...

Page 48: ...e accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls We strongly recommend that you use only Honda Genuine Accessories that have been s...

Page 49: ...ride We also advise you not to 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...

Page 50: ...tment for riding at high altitude see page Safe Riding Precautions 42 Off Road Use Only 42 Keep Hands and Feet on Controls 43 Control Speed 44 Use Care on Unfamiliar or Rough Terrain 45 Do Not Perform...

Page 51: ...e 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 ac...

Page 52: ...Feet on Controls Safe Riding Precautions Basic Operation Riding You should never ride your ATV on public streets roads or highways even if they are not paved Drivers of street vehicles may have diffi...

Page 53: ...cle the terrain visibility and other operating conditions and your experience 44 Control Speed Safe Riding Precautions Basic Operation Riding Riding at excessive speed increases the chance of an accid...

Page 54: ...errain Always be alert to changing terrain conditions when operating the ATV 45 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Page 55: ...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 46 D...

Page 56: ...ing or operating the engine in an enclosed area such as 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...

Page 57: ...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 engine stop switch is set to RUN The transmission...

Page 58: ...ct a level surface and lock the parking brake page Turn the fuel valve and ignition switch to ON Turn the handlebar all the way to left Confirm the following The transmission is in neutral the tires r...

Page 59: ...engine kick back and engine damage The carburetor is equipped with an accelerator pump Do not open the throttle when starting the engine This will flood the engine with excess fuel resulting in hard s...

Page 60: ...ke With the throttle closed operate the kickstarter Pull the choke knob left all the way to fully ON position if the engine is cold Normal Air Temperature 10 35 C 50 95 F If idling is unstable open th...

Page 61: ...let kickstarter return to the top of its stroke With the throttle closed operate the kickstarter Kick from the top of the stroke through to the bottom with a rapid continuous motion Allowing the kick...

Page 62: ...gine starts release the hot start lever Push the hot start lever and kick start the engine Do not open the throttle As soon as the engine starts release the hot start lever Shift the transmission into...

Page 63: ...Wait 10 seconds then turn the engine stop switch to RUN Repeat the starting procedure but don t use the choke With the throttle fully opened repeat kickstarter operation approximately 10 times very sl...

Page 64: ...n 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 make sure the transmission is in neutral and turn the ignit...

Page 65: ...eleased Your ATV has five forward gears 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 un...

Page 66: ...ep the following tips in mind As a general rule shift while moving in a straight line Close the throttle and pull the clutch lever in completely before shifting Improper shifting may damage the engine...

Page 67: ...r maximum braking close the throttle and firmly apply the brake lever and pedal controls Applying the brakes too hard may cause the wheels to lock and slide reducing control of your ATV If this happen...

Page 68: ...mittent use of both brakes Continuous brake application can overheat the brakes and reduce their effectiveness To prevent stalling the engine pull the clutch lever parking brake lever in before coming...

Page 69: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 60 Making Turns Riding Your ATV Basic Operation Riding Learn how to tur...

Page 70: ...rating from a full stop To make a sharp turn at low speed It helps to shift your body slightly forward on the seat and lean inside as you steer the handlebar Shifting weight forward allows the rear wh...

Page 71: ...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 72: ...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 73: ...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 74: ...t 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 brak...

Page 75: ...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 76: ...scribed in this owner s manual 67 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 77: ...ft into a lower gear shift your weight back with your arms extended and braced against the handlebar then go down slowly with the throttle closed Use mainly the rear brake to control speed Avoid using...

Page 78: ...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 79: ...as described in this owner s manual 70 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 80: ...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 81: ...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 If you must park your ATV on a steep incline or loose o...

Page 82: ...ions 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 the exhaust emission...

Page 83: ...r 92 Transmission Oil 99 Coolant 104 Air Cleaner 110 Engine Throttle 114 Clutch System 116 Engine Idle Speed 120 Spark Plug 121 Valves 124 Spark Arrester 125 Chassis Suspension 127 Brakes 133 Tires 14...

Page 84: ...od maintenance are especially important because your ATV is designed to be ridden over rough off road terrain To help you properly care for your ATV this section of the manual provides a Maintenance S...

Page 85: ...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 86: ...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 87: ...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 88: ...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 89: ...C I R R I I I 1200 2000 200 I I C I I R R I I I Every 600 mi 1 000 km 100 operating hours or 12 months R REGULAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL INITIAL REGULAR HOURS MAINT INTERVAL MAI...

Page 90: ...BEARINGS STEERING SYSTEM 600 1000 100 I I I I I I I C I I 100 150 20 I L I I I I I I FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITIAL HOURS NOTE 1 2 NOTE 3 NOTE 1 2 MAINT INTERVAL MAINT I L EVERY...

Page 91: ...V is properly maintained Retain detailed receipts to verify the maintenance was performed If the ATV is sold these receipts should be transferred with the ATV to the new owner Make sure whoever perfor...

Page 92: ...front brake fluid reservoir hot start lever front brake lever fuel fill cap throttle lever TRX450R only clutch lever parking brake lever 83 Servicing Your Honda Maintenance Component Locations...

Page 93: ...damping adjuster front suspension compression damping adjuster front suspension rebound damping adjuster coolant reserve tank front brake caliper rear brake pedal transmission oil filler cap throttle...

Page 94: ...bound damping adjuster engine oil drain bolt engine oil filter engine oil filler cap spark arrester rear brake caliper battery transmission oil drain bolt tool kit air pressure gauge owner s manual ma...

Page 95: ...tored in the storage compartment under the seat After using the tools be sure to use the rubber band to fasten the tool kit securely An optional larger tool kit may be available Check with your Honda...

Page 96: ...l so you ll have it with you for easy reference Store your owner s manual in the storage compartment under the seat Be careful not to flood this area when washing your ATV To access the owner s manual...

Page 97: ...rom the rear to remove the studs from the grommets Slide the seat back and up Insert the front prongs into the hooks on the frame and press the studs into the grommets The seat must be removed for the...

Page 98: ...pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gas...

Page 99: ...fueling Procedure Fuel Servicing Your Honda Safety Precautions Fuel tank capacity including reserve Reserve capacity Refer to on page The tank should be refilled as soon as possible after switching to...

Page 100: ...es 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 If you replace the fuel fill cap use onl...

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 oi...

Page 102: ...alent motorcycle oil 93 Engine Oil Recommendation Engine Oil Filter Servicing Your Honda Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular AP...

Page 103: ...chart may be used when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines...

Page 104: ...ATV and add if needed Reinstall the engine oil filler cap Check for oil leaks If required remove the engine oil filler cap from the left side of the crankcase and add the specified oil into the filler...

Page 105: ...model or a filter of equal quality Start the engine in a well ventilated area and let it idle for 3 5 minutes Stop the engine and wait 2 3 minutes This procedure requires mechanical skill and professi...

Page 106: ...n 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 mar...

Page 107: ...lace the sealing washer Reinstall the engine oil drain plug and tighten it to the specified torque Stop the engine wait 2 3 minutes and check the engine oil level Make sure the engine oil level is at...

Page 108: ...smission Oil Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label Your ATV does not need oil additives Use the recommended oil...

Page 109: ...chart may be used when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines...

Page 110: ...kcase cover Start the engine in a well ventilated area and let it idle for 3 5 minutes Stop the engine and wait 2 3 minutes to allow the oil to properly distribute itself in the clutch and transmissio...

Page 111: ...the engine in a well ventilated area and let it idle for 3 5 minutes Stop the engine and wait 2 3 minutes Drain the Transmission Oil With the ATV on level ground remove the transmission oil filler ca...

Page 112: ...he specified torque Fill the crankcase with the recommended grade oil approximately Reinstall the transmission oil filler cap Check that there are no oil leaks If a torque wrench is not used for insta...

Page 113: ...rrosion Use Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines Check the anti...

Page 114: ...rovide additional protection against freezing Check the cooling system frequently during freezing weather Refer to on page Check the engine coolant level each day before operating your ATV and add if...

Page 115: ...eserve tank as required to bring the coolant level to the UPPER level mark Remove the steering cover and reserve tank cap Always add coolant to the reserve tank Do not attempt to add coolant by removi...

Page 116: ...lacement Servicing Your Honda Coolant Safety Precautions You the Environment Improper disposal of drained fluids is harmful to the environment Refer to on page Coolant should be replaced by your Honda...

Page 117: ...ove insects mud or any obstruction with low water pressure Have the radiator checked by your Honda dealer if the air flow is restricted over more than 20 of the radiator surface Clean the radiator cor...

Page 118: ...ing Your Honda High pressure water or air can damage the radiator core Wash the radiator grill and radiator core Remove the radiator grill from the frame Install the radiator grill right and left shro...

Page 119: ...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...

Page 120: ...SEAT 1 1 2 1 retainer clips 2 air cleaner housing cover 111 Cleaning Air Cleaner Servicing Your Honda cont d Unlatch the retainer clips Remove the air cleaner housing cover Remove the seat page 1 2 3...

Page 121: ...oil into the air cleaner Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not fully absorb the oil Inspect for tears or cracks in the foam or seams of the air cleaner...

Page 122: ...in coat of grease to the sealing surface of the air cleaner assembly Install the clamp Insert the air cleaner assembly into the air cleaner housing Fasten the screw B Install the stay and fasten the s...

Page 123: ...Check freeplay at the throttle lever Freeplay Adjustment Slide the rubber sleeve back to expose the throttle cable adjuster Loosen the lock nut Turn the adjuster to obtain the correct freeplay Tighte...

Page 124: ...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 125: ...nda Safety Precautions Refer to on page Inspection Clutch adjustment may be required if the ATV stalls when shifting into gear if it tends to creep or if the clutch slips causing acceleration to lag b...

Page 126: ...lly made with the upper clutch cable adjuster 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 th...

Page 127: ...reeplay cannot be obtained Loosen the upper lock nut and turn the upper clutch cable adjuster all the way in to provide maximum freeplay Tighten the upper lock nut and pull the dust cover back to its...

Page 128: ...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 129: ...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 leve...

Page 130: ...ck the spark plug gap use only a wire type feeler gauge To prevent damaging the iridium coating of the center electrode never use a leaf type feeler gauge This ATV uses spark plug that have an iridium...

Page 131: ...avoid damaging the spark plug wire when disconnecting the cap Using a spark plug wrench provided in the tool kit remove the spark plug Make sure that a 1 2 mm wire type feeler gauge cannot be inserted...

Page 132: ...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 133: ...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 you...

Page 134: ...ncy Regular servicing prevents carbon build up which can diminish engine performance and also complies with USDA regulations for regular maintenance to assure proper function The spark arrester preven...

Page 135: ...the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary Check the gasket Replace if necessary Install...

Page 136: ...damper systems hydraulically control the natural compression and rebound of the suspension springs so that traction and comfort are maintained as the wheels ride over road surfaces The way you ride y...

Page 137: ...ns by changing the rebound and compression damping The shock absorber assemblies include a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the...

Page 138: ...adjuster clockwise until it will no longer turn lightly seats This is the full hard setting Make sure that both shock absorbers are adjusted to the same position For a light load and smooth road condi...

Page 139: ...o the same position For a light load and smooth road conditions turn the adjuster counterclockwise toward SOFT S For a firmer ride and rough road conditions turn the adjuster clockwise toward HARD H T...

Page 140: ...Damping For a firmer ride and rough road conditions turn the adjuster clockwise toward HARD H For a light load and smooth road conditions turn the adjuster counterclockwise toward SOFT S Turn the rebo...

Page 141: ...ight load and smooth road conditions turn the adjuster counterclockwise toward SOFT S For a firmer ride and rough road conditions turn the adjuster clockwise toward HARD H Turn the compression damping...

Page 142: ...e inspected frequently to ensure there are no fluid leaks 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 sho...

Page 143: ...page If your 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 deale...

Page 144: ...for wear page Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks Rear Brake Fluid Level With the ATV in an upright position check the fluid level I...

Page 145: ...Inspections Brakes Servicing Your Honda Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings If the hoses are worn or cracked have them replaced by your Hond...

Page 146: ...ity of 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 Check the wear indicato...

Page 147: ...on page The distance between the tip of the front brake lever and the grip can be adjusted Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several...

Page 148: ...s Servicing Your Honda Safety Precautions Refer to on page The right side mudguard must be removed to adjust the rear brakelight switch Install the right side mudguard in the reverse order of removal...

Page 149: ...heck the operation of the rear brakelight switch at the right side behind the engine from time to time The brakelight should turn on at 0 6 in 15 mm of pedal stroke Remove the right side mudguard see...

Page 150: ...ke does not hold properly Loosen the lock nut on the parking brake cable and screw in the adjuster completely Loosen the lock nut on the parking brake arm and turn the adjusting bolt clockwise until y...

Page 151: ...ck 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 it replaced by your Honda dealer Push down the...

Page 152: ...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 153: ...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 harshl...

Page 154: ...r 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 tire...

Page 155: ...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 156: ...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 157: ...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 158: ...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 159: ...ngine 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 t...

Page 160: ...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...

Page 161: ...ed 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...

Page 162: ...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 the driv...

Page 163: ...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...

Page 164: ...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 165: ...r 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...

Page 166: ...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 167: ...y even when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your ATV or do not ride frequently we recommend that you charge the battery...

Page 168: ...ons Battery 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...

Page 169: ...ver 2 screws 160 Battery TRX450ER only Servicing Your Honda Removal Make sure the ignition switch is OFF The battery is located in a compartment under the left rear fender Remove the battery cover by...

Page 170: ...ur battery in an easy to reach location off the floor in an area protected from freezing temperature and direct sunlight Charge the battery see following section unless you have been riding regularly...

Page 171: ...oper charging 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 inte...

Page 172: ...that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your ATV If your ATV is still warm from recent operation give the engine and exhaust system time to...

Page 173: ...s Start the engine and let it idle for several minutes The engine heat will help dry moist areas As a precaution ride your ATV at a slow speed and apply the brakes several times This will help dry the...

Page 174: ...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 175: ...ing 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 a...

Page 176: ...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 177: ...168 Servicing Your Honda...

Page 178: ...and store your Honda and how to be an environmentally responsible ATV owner Preparing for a Ride 170 What to Take to the Riding Area 170 What to Take on the Trail 171 Transporting Your Honda 172 Stor...

Page 179: ...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 180: ...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 181: ...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 182: ...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 183: ...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 184: ...sting in the cylinder perform the following Remove the spark plug cap from the spark plug Remove the spark plug Do not connect the spark plug to the spark plug cap Drain the carburetor into an approve...

Page 185: ...er the spark plug hole with a piece of cloth With the engine stop switch in the OFF position press the start button several times to crank the engine and distribute the oil With the engine stop switch...

Page 186: ...to the UPPER level mark If your ATV has been stored for more than four months change the engine oil page and transmission oil page Uncover and clean your ATV Refer to on page Cover your ATV with a po...

Page 187: ...y increase noise they also reduce engine performance and may be illegal Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which da...

Page 188: ...ce 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 180 If Your Engine Quits or Won t Start 182 If You Have...

Page 189: ...t doesn t feel right If you continue riding you could cause more damage and endanger your own safety After a stop take time to assess the situation Carefully inspect your ATV to identify the problem t...

Page 190: ...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 191: ...ses 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 c...

Page 192: ...da dealer SYMPTOM POSSIBLE CAUSE WHAT TO DO engine stop switch OFF Turn the engine stop switch to RUN low or dead battery weak battery loose battery cables Charge the battery page If charging doesn t...

Page 193: ...out of fuel Fill the fuel tank flooded engine loose or unconnected spark plug cap Install the spark plug cap securely If the engine still won t start see your Honda dealer SYMPTOM See page Check the t...

Page 194: ...st rich fuel mixture See your Honda dealer blubbers rich fuel mixture See your Honda dealer runs erratically misfires See your Honda dealer high coolant temperature Check the high coolant temperature...

Page 195: ...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 196: ...our ATV on a firm level surface Raise the front or rear wheels off the ground and place a support block under the vehicle Remove the wheel Removal Remove the wheel nuts Avoid getting grease oil or dir...

Page 197: ...heel nuts so that the tapered sides face the wheel rim Tighten the wheel nuts in a crisscross rather than a circular pattern to the specified torque If a torque wrench was not used for installation se...

Page 198: ...er adverse conditions If the indicator comes on while you re riding don t ignore it Pull safely to a stop Stop the engine as soon as it s safe to do so and let it cool Check the radiator fan If the fa...

Page 199: ...has gone down add more coolant Check for an oil leak Check the oil level If necessary add the recommended oil page to the upper level mark If you must leave your ATV to get oil secure it as much as po...

Page 200: ...hould 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 All of the electrical circuits on y...

Page 201: ...serious electrical problem on your ATV Leave the blown fuse in that circuit and have your ATV checked by your Honda dealer If you do not have a replacement fuse with the proper rating for the circuit...

Page 202: ...ly carefully inspect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If the...

Page 203: ...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 204: ...mmended 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 recom...

Page 205: ...throttle cable or other critical component your ATV may be unsafe to ride Carefully assess the damage and make any repairs that you can But if there is any doubt it s best to be conservative and safe...

Page 206: ...sions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 198 Specifications 200 Break in Guidelines 205 High Altitude C...

Page 207: ...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 208: ...ehicle Identification Technical Information The color label is attached to the front of the frame The color code is helpful when ordering replacement parts You may record the color and code in the Qui...

Page 209: ...ing 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...

Page 210: ...roke oil or an equivalent Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines...

Page 211: ...62 0 039 0 043 in 1 0 1 1 mm 0 011 in 0 28 mm 0 006 in 0 16 mm or or intake exhaust chain or passenger capacity bore stroke maximum weight capacity displacement spark plug standard compression ratio s...

Page 212: ...32 5 kPa 0 325 kgf cm 4 0 psi 27 5 kPa 0 275 kgf cm AT20 10R9 DUNLOP KT331H DUNLOP KT355H Front Rear caster trail tire size front tire pressure front rear cold tire size rear Chassis Suspension 203 Te...

Page 213: ...kgf m 18 lbf ft 25 N m 2 5 kgf m battery generator headlight brake tail light neutral indicator main high coolant temperature indicator wheel nuts transmission oil check bolt transmission oil drain bo...

Page 214: ...on Help assure your ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts ra...

Page 215: ...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 216: ...on 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 d...

Page 217: ...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 218: ...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 219: ...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 220: ...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 221: ...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 222: ...This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 214 Warranty Coverage 217 Warranty Service 218 Contacting Honda 219 Your Honda De...

Page 223: ...from Helm Inc USA only Canada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of opera...

Page 224: ...8 25 Handling Charge Grand Total 5 00 215 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 225: ...time Telephone Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Check here if your billing address is different from the shipping address shown above VISA Disco...

Page 226: ...ies 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 Your warranty coverage will not be voided if...

Page 227: ...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 228: ...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 229: ...products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the...

Page 230: ...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 231: ...rs 13 High Coolant Temperature Indicator 13 Neutral Indicator TRX450ER only 14 Controls Features 15 Fuel Valve 15 Choke Knob 16 Hot Start Lever TRX450R only 17 Ignition Switch 18 Start Button TRX450ER...

Page 232: ...ective Apparel 28 Rider Training 30 Age Recommendation 31 No Passengers 31 No Alcohol or Drugs 32 Is Your ATV Ready to Ride 33 Pre ride Inspection 33 Load Limits Guidelines 36 Loading 36 Load Limits 3...

Page 233: ...or Rough Terrain 45 Do Not Perform Stunts 46 Starting Stopping the Engine 47 Preparation 48 Starting Procedure 50 Flooded Engine 54 How to Stop the Engine 55 Shifting Gears 56 Braking 58 Riding Your...

Page 234: ...Maintenance 75 Maintenance Safety 76 Important Safety Precautions 77 Maintenance Schedule 78 Maintenance Record 82 Maintenance Component Locations 83 Tool Kit 86 Owner s Manual Storage 87 Seat Remova...

Page 235: ...at to Take to the Riding Area 170 What to Take on the Trail 171 Transporting Your Honda 172 Storing Your Honda 174 Preparation for Storage 175 Removal from Storage 177 You the Environment 178 General...

Page 236: ...QUICK REFERENCE Vehicle Identification 198 Specifications 200 Break in Guidelines 205 High Altitude Carburetor Adjustment 206 Emission Control Systems 207 Oxygenated Fuels 211 Authorized Manuals 214...

Page 237: ...86 tire 144 American Honda contacting 219 apparel protective 28 appearance care 163 authorized manuals 214 battery TRX450ER only 158 brakes brake pad wear 137 cable 141 fluid 133 front brake lever 24...

Page 238: ...operational guidelines 38 choke knob 16 climbing hills 63 clutch system 116 color label 199 compartment owner s manual 87 tool kit 86 component fails 196 consumer information 213 coolant 104 crash if...

Page 239: ...itch headlight 22 emission control systems 207 engine flooded 54 guard 150 idle speed 120 number 198 oil 92 pinging 89 starting 47 stop switch 21 stopping 55 won t start 182 environment 178 exhaust sy...

Page 240: ...Index Index F flag pole bracket 26 flat tire 186 flooded engine 54 fuel fill cap 90 oxygenated 211 recommendation 89 refueling 90 reserve fuel supply 90 tank capacity 90 valve 15 fuse TRX450ER only 1...

Page 241: ...shifting 56 headlight dimmer switch 22 headlight switch 22 high altitude carburetor adjustment 206 hills crossing or turning on slopes 68 riding down hills 67 riding up hills 63 stopping on hills 65 H...

Page 242: ...ion vehicle 198 idle speed engine 120 ignition switch 18 indicators high coolant temperature indicator 13 189 neutral indicator TRX450ER only 14 inspection pre ride 33 key lost 194 number 194 kickstar...

Page 243: ...oad limits 37 loading guidelines 38 lubrication engine oil 92 transmission oil 99 drive chain 156 maintenance component locations 83 importance 75 precautions 77 record 82 safety 76 schedule 78 manual...

Page 244: ...pre ride inspection 33 problems unexpected 179 protective apparel 28 neutral indicator TRX450ER only 14 noise emission control system 210 numbers serial 198 obstacles riding over 70 oil engine 92 tra...

Page 245: ...dex Index R removal seat 88 rider training 30 Rider s Club Honda 221 riding basic operations 41 clothing 28 precautions 42 preparing for 170 over obstacles 70 safety 2 safety precautions 42 through wa...

Page 246: ...ng precautions 42 schedule maintenance 78 seat removal 88 serial numbers 198 service customer 219 manuals 214 warranty 218 shifting gears 56 skid plates 150 skidding or sliding 62 spark arrester 125 s...

Page 247: ...ex start button TRX450ER only 19 starting engine 47 troubleshooting 182 stop switch engine 21 stopping engine 55 storage ATV 174 owner s manual 87 switch brakelight 140 headlight 22 headlight dimmer 2...

Page 248: ...ires air pressure 144 flat 186 replacing 149 repairing 148 specifications 203 tread conditions 146 147 tool kit 86 training rider 30 transporting your ATV 172 trouble unexpected 179 troubleshooting st...

Page 249: ...W V valve fuel 15 valve clearance 124 vehicle identification no VIN 198 warning labels 5 warranty coverage 217 extended 217 service 218 washing your ATV 163 water riding through 71 weight limit 37 wh...

Page 250: ...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 251: ...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 252: ...ing brake lever switches steering premium unleaded gasoline pump octane number 91 or higher Fuel Capacity Engine Oil API Service Classification SG or higher except oils labeled as energy conserving on...

Page 253: ...H11 NGK VK24PRZ11 DENSO 15 A or or Front Rear standard high speed riding standard tire pressure Front Rear Quick Reference Quick Reference Tires Tire Pressure cold Spark Plugs Coolant ethylene glycol...

Page 254: ...ures section SYMBOL COMPONENT SEE PAGE LO headlight dimmer switch HI headlight dimmer switch OFF headlight switch ON headlight switch OFF engine stop switch RUN engine stop switch START button OFF ign...

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