Honda TRX680FA Owner'S Manual Download

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Servicing Your Honda

Service Procedures

Fluids & Filters

Engine

Chassis

Electrical

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Fuel

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Engine Oil & Filter

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Gear Case Oil

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Differential Oil

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Coolant

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Air Cleaner

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Throttle

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Spark Plug

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Valves

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Spark Arrester

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Brakes

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Tyres

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Engine Guard & Skid Plates

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Driveshaft Boots

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Battery

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Appearance Care

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114
122
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131

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Summary of Contents for TRX680FA

Page 1: ...test production information available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation This manual should be consid...

Page 2: ...Honda TRX680FA FOURTRAX RINCON OWNER S MANUAL...

Page 3: ...in guidelines and perform all pre ride and other periodic checks detailed in this manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety inf...

Page 4: ...duction Introduction If you have any questions or if you ever need special service or repairs remember that your Honda dealer knows your ATV best and is dedicated to your complete satisfaction Happy r...

Page 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 control...

Page 8: ...gular maintenance what you need to know before servicing your Honda an owner maintenance schedule and instructions for specific maintenance and adjustment items How to store and transport your ATV and...

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: ...few that we consider to be 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 ar...

Page 12: ...you need to cross a paved or public road get off and walk your ATV across The terrain can present a variety of challenges when you ride off road Continually read the terrain for unexpected turns drop...

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

Page 15: ...Engine net power Machine mass 6 Safety Labels ATV Safety...

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

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

Page 18: ...this page are described in this section Instructions for other components are presented in other sections of this manual where they will be most useful cont d Operation Component Locations Indicators...

Page 19: ...Engine Stop Switch Headlight Switch Headlight Dimmer Switch Horn Button Recoil Starter Throttle Lever Gearshift Switch Front Brake Lever Rear Brake Pedal Parking Brake Flag Pole Bracket Trailer Hitch...

Page 20: ...switch engine stop switch start button gearshift switches 2WD 4WD select switch drive mode select switch front brake lever horn button shift lever parking brake lock lever rear brake lever parking br...

Page 21: ...rear cargo rack front cargo rack accessory socket recoil starter rear brake pedal 12 Instruments Controls Operation Component Locations...

Page 22: ...trailer hitch seat latch flag pole bracket 13 Instruments Controls Operation Component Locations...

Page 23: ...7 multi function display 8 hour select button 9 minute select button 10 ADJ button 11 PGM FI indicator 14 Indicators Displays Instruments Controls The indicators and displays on your ATV keep you inf...

Page 24: ...ou can make sure the liquid crystal display is functioning properly Display Check If one of these indicators does not come on when it should have your Honda dealer check for problems When applicable t...

Page 25: ...ansmission is in neutral Lights when the transmission is in reverse 4WD indicator Lights when the drive mode is in the 4WD mode The 4WD indicator blinks if there is a possible problem with the 2WD 4WD...

Page 26: ...tor The display includes the following functions Hour select button Minute select button Advances the hour displayed by the digital clock page Advances the minutes displayed by the digital clock page...

Page 27: ...t button 10 ADJ button 11 hourmeter 12 odometer tripmeter 13 digital clock 14 oil change indicator 18 Multi function Display Indicators Displays Instruments Controls The multi function display include...

Page 28: ...uments Controls The drive mode indicator shows the selected drive mode when the ignition switch is in the ON position The drive mode indicator displays ESP when the manual shift ESP mode is selected T...

Page 29: ...tion switch is in the ON position will be displayed on the gear position indicator when the transmission is not shifted into gear properly Before riding check that the gear position is properly displa...

Page 30: ...ge interval specified on the maintenance schedule If the oil is changed before the oil change indicator appears be sure to reset the oil change indicator after changing the oil The indicator will appe...

Page 31: ...s two functions odometer and tripmeter The tripmeter has two sub modes tripmeter A and tripmeter B The odometer registers total distance traveled in kilometers while the ignition switch is ON The trip...

Page 32: ...5 RESET button 23 Indicators Displays Instruments Controls To reset the tripmeter to zero press and hold the RESET button for more than 2 seconds with the display in the tripmeter A or tripmeter B mod...

Page 33: ...eter mark 24 Hourmeter Indicators Displays Instruments Controls The hourmeter shows accumulated hours while the ignition is ON The hourmeter provides accurate service period information for initial an...

Page 34: ...the display reaches the desired hour To advance the minute display one unit at a time press and release the minute select button To advance the minute display automatically press and hold the minute s...

Page 35: ...ls The fuel gauge liquid crystal display shows the approximate fuel supply available The fuel tank capacity is All segments will flash when the fuel gauge function is fails See your Honda dealer When...

Page 36: ...gnition switch 1 ON OFF CENTRE OF HANDLEBAR ON OFF Key Position Function 27 Ignition Switch Controls Features Instruments Controls The ignition switch is used for starting and stopping the engine page...

Page 37: ...ever LEFT SIDE OF HANDLE COVER 28 Shift Lever Controls Features Instruments Controls Shifting Gears Riding in Reverse The shift lever has three positions drive D neutral N and reverse R See page and p...

Page 38: ...1 1 drive mode select switch RIGHT HANDLEBAR 29 Drive Mode Select Switch Controls Features Instruments Controls Shifting Gears The drive mode select switch has two positions AUTO and ESP See page 1 71...

Page 39: ...ine is running It remains engaged until the 2WD mode is selected or the engine is stopped Upon starting your ATV will be in the 2WD mode regardless of the 2WD 4WD select switch position Your ATV is eq...

Page 40: ...starter motor will not operate if the engine stop switch is in the OFF position when the start button is pushed If your ATV is stopped with the ignition switch ON and the engine stop switch OFF the ba...

Page 41: ...tch Controls Features Instruments Controls Press the horn button to sound the horn The headlight dimmer switch is used to change between the high and low beams of the headlight To operate turn the swi...

Page 42: ...RIGHT SIDE 1 recoil starter 1 33 Recoil Starter Controls Features Instruments Controls Using the Recoil Starter The recoil starter is used to start the engine when the battery is low See page 70 1...

Page 43: ...ures Instruments Controls The throttle controls engine rpm speed To increase engine rpm press the throttle lever with your thumb To reduce engine rpm release pressure on the throttle lever The throttl...

Page 44: ...trols Shifting Gears Two gearshift switches are used in the manual shift ESP mode These switches are used to select the next higher or lower gear in the transmission To operate press the upshift switc...

Page 45: ...ATV To operate pull the lever For information on braking techniques see page The rear brake lever parking brake lever is used to slow or stop your ATV To operate pull the lever For information on bra...

Page 46: ...r parking brake lever allows it to be used as a parking brake To operate first squeeze the rear brake lever parking brake lever using your left hand and then lock it with the lock lever using your rig...

Page 47: ...tures Instruments 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 48: ...railer hitch is located on the rear axle housing To use the hitch you ll need a proper size ball as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the t...

Page 49: ...n automobile cigarette lighter because it can damage the socket The accessory socket is attached to the right side of the meter cover You can use the accessory socket to power a trouble light spotligh...

Page 50: ...e accessory socket otherwise you may drain the battery The accessory socket s rated capacity is DC 12V 120 Watts 10A or less If you exceed this limit you may blow a fuse See page When you are done usi...

Page 51: ...42 Instruments Controls...

Page 52: ...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 53: ...ection and other protective clothing You don t have any alcohol or drugs in your system For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gl...

Page 54: ...t and long pants 45 Are You Ready to Ride Before Riding Additional Riding Gear In addition to a helmet and eye protection we also recommend Sturdy off road motorcycle boots to help protect your feet a...

Page 55: ...ls learned in the course and the operating techniques described in the owner s manual 46 Rider Training Are You Ready to Ride Before Riding Developing your riding skills is an on going process Even if...

Page 56: ...cause a crash and you or your passenger could be injured or killed Never carry a passenger on this ATV 47 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended a...

Page 57: ...ume alcohol or drugs before or while operating this ATV 48 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 58: ...llision do not ride the vehicle until it has been inspected by your Honda dealer There may be damage or other problems you cannot see Before each ride it s important to inspect your ATV and make sure...

Page 59: ...tight Check for and remove any dirt vegetation or other debris that could be a fire hazard or interfere with the proper operation of the vehicle Check for deposits in the drain tube If necessary clean...

Page 60: ...Check the freeplay and adjust if needed Press the throttle to make sure it moves smoothly without sticking and snaps shut automatically when it is released in all steering positions page Squeeze the f...

Page 61: ...k for proper function page Check for proper function page Check that the wheels turn properly as you steer the handlebar Move the handlebar right and left and check that there is no excessive backlash...

Page 62: ...erfere with your balance and control of the ATV In addition exceeding the weight limits or carrying an unbalanced load can seriously affect your ATV s handling braking and stability Adding accessories...

Page 63: ...wing load limits apply to standard equipment only Modifying your ATV using non standard equipment or riding on terrain that is not flat and smooth could further reduce these limits includes the weight...

Page 64: ...by tying a rope or cable to the rear rack Load cargo on the rear rack as far forward as possible Make sure cargo on the front rack does not interfere with handlebar movement Do not allow cargo to ext...

Page 65: ...designed and tested for your ATV Because Honda cannot test all other accessories you must be personally responsible for proper selection installation and use of non Honda accessories Check with your...

Page 66: ...equipment or modify your ATV in any way that would change its design or operation Such changes could seriously impair your ATV s handling stability and braking making it unsafe to ride Removing or mod...

Page 67: ...58 Before Riding...

Page 68: ...erformance and service life refer to Break in Guidelines page cont d Safe Riding Precautions Off road Use Only Keep Hands and Feet on Controls Control Speed Use Care on Unfamiliar or Rough Terrain Do...

Page 69: ...c Operation Riding Riding Your ATV Braking Making Turns Skidding or Sliding Riding Up Hills Riding Down Hills Crossing or Turning on Hills or Slopes Riding Over Obstacles Riding Through Water Parking...

Page 70: ...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 71: ...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 72: ...e terrain visibility and other operating conditions and your experience 1 footpeg 1 63 Control Speed Safe Riding Precautions Basic Operation Riding Riding at excessive speed increases the chance of an...

Page 73: ...errain Always be alert to changing terrain conditions when operating the ATV 64 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Page 74: ...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 65 D...

Page 75: ...r 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 Before st...

Page 76: ...has a fuel injected engine with an automatic choke Follow the procedure indicated below Any Air Temperature Press the start button with the throttle completely closed The engine will not start if the...

Page 77: ...erate the recoil starter several times Follow the normal starting procedure If the engine starts then open the throttle slightly if idling is unstable If the engine does not start wait 10 seconds then...

Page 78: ...ignition if the throttle is open while attempting to start in gear Once you have started the engine release the front brake lever then apply throttle gradually Normal Engine Stop The engine stop swit...

Page 79: ...dealer After the engine starts allow the starter grip to return slowly Grasp the starter grip firmly then pull it out slowly approximately 100 mm 4 in Pull the grip up briskly and fully Unsnap and re...

Page 80: ...icator shows D and the drive mode indicator disappears Manual shift ESP mode In this mode you can shift gears much like a manual transmission but without operating a clutch You can select three forwar...

Page 81: ...mission may be damaged To shift the shift lever bring the ATV to a complete stop The shift lever is located on the left side of the fuel tank The drive mode select switch is located on the right handl...

Page 82: ...t AUTO shifting the lever to D drive provides a 3 speed automatic transmission While pulling up the shift lever shift to D Pull down the shift lever and confirm that the lever is locked and the gear p...

Page 83: ...ing Two gearshift switches are located next to the left handlebar grip upshift and downshift To upshift the transmission press the upshift switch once To downshift the transmission press the downshift...

Page 84: ...drive train Upshift to a higher gear or reduce throttle before engine rpm speed gets too high Learn the relationship between engine sound and the normal shifting points Downshift to a lower gear befor...

Page 85: ...ransmission damage do not coast or tow the ATV for long distances with the engine off Recommended Shift Points Ride in the highest gear that lets the engine run and accelerate smoothly This will give...

Page 86: ...while riding in reverse gear If the gearshift lever is moved while the vehicle is moving the transmission may be damaged If you need to ride in reverse make sure the area behind you is clear and only...

Page 87: ...rn backwards Carefully apply both the front and rear brakes when stopping in reverse gear 78 Riding in Reverse Basic Operation Riding To stop close the throttle and gradually apply both the front and...

Page 88: ...ke controls steer straight ahead until you regain control then reapply the brakes more gently Gradually increase braking as you feel the brakes slowing your speed The increase in engine compression fr...

Page 89: ...al or your hands on the brake levers may overheat the brakes reducing effectiveness For information on how to apply the brakes in various riding situations see the following section When descending a...

Page 90: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 81 Making Turns Riding Your ATV Basic Operation Riding Learn how to tur...

Page 91: ...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 92: ...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 93: ...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 94: ...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 95: ...to lose all forward speed Using the front and rear brakes together bring the ATV to a stop with the vehicle pointed straight uphill Get off the ATV while you continue holding the brakes Shift into ne...

Page 96: ...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 Stand with your body facing downhill...

Page 97: ...scribed in this owner s manual 88 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 98: ...when riding down hills Remember that operating any brake control in the 4WD mode will cause braking at both the front and rear wheels Remember braking effectiveness is reduced on any hill with a loose...

Page 99: ...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 100: ...as described in this owner s manual 91 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 101: ...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 102: ...fting the transmission into neutral The brakelights are activated by applying the parking brake When using the parking brake be sure to turn the ignition switch OFF to avoid discharging the battery If...

Page 103: ...94 Basic Operation Riding...

Page 104: ...pecific maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking good For information about replacing fuses see page cont d...

Page 105: ...ine Chassis Electrical Fuel Engine Oil Filter Gear Case Oil Differential Oil Coolant Air Cleaner Throttle Spark Plug Valves Spark Arrester Brakes Tyres Engine Guard Skid Plates Driveshaft Boots Batter...

Page 106: ...engine repair If your ATV overturns or is involved in a crash be sure your Honda dealer inspects all major parts even if you are able to make some repairs A well maintained ATV is essential for safe e...

Page 107: ...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 108: ...to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around petrol Use only non...

Page 109: ...f performing a given task or need assistance remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only Honda...

Page 110: ...require more technical information and tools Consult your Honda dealer In the interest of safety we recommend these items be serviced only by your Honda dealer Service more frequently when riding in d...

Page 111: ...I R I I Every 1 000 km 600 mi 100 operating hours or 12 months R 2000 1200 200 I I C I I I R I I REGULAR ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL INITIAL REGULAR HOURS MAINT INTERVAL MAINT 102 Ma...

Page 112: ...600 100 I I I I I I C I I 2000 1200 200 I I I I I I I I C I I I I I Refer to page 160 122 124 144 147 151 144 159 142 152 FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITIAL HOURS NOTE 1 2 R EVERY 2...

Page 113: ...V to the new owner Make sure whoever performs the maintenance completes this record All scheduled maintenance including the 150 km 100 mile or 20 hours initial maintenance is considered a normal owner...

Page 114: ...front brake fluid reservoir fuel fill cap front brake lever throttle lever rear brake lever parking brake lever 105 Servicing Your Honda Maintenance Component Locations...

Page 115: ...drain tube rear brake fluid reservoir rear brake light switch front brake caliper front brake caliper engine oil filler fuse box main fuse 1 main fuse 2 other fuses differential oil filler cap differe...

Page 116: ...ster engine oil dipstick engine oil filler cap gear case oil filler cap owner s manual storage compartment air pressure gauge gear case oil drain bolt engine oil drain bolt 107 Servicing Your Honda Ma...

Page 117: ...pliers spark plug wrench and handlebar 17 mm box end wrench 14 mm box end wrench 10 12 mm open end wrench screwdriver handle standard Phillips screwdriver The tools in the kit are sufficient to perfor...

Page 118: ...rea when washing your ATV Your ATV provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual in the storage compartment at the left side of the fr...

Page 119: ...lide the seat back and lift it Installation Pull the seat latch at the rear of the seat Insert the front prongs into the hooks and press the studs into the grommets on the rear fender The seat must be...

Page 120: ...trol pumps at service stations normally display the pump octane number For information on the use of see page Use of lower octane petrol can cause persistent pinging or spark knock a loud rapping nois...

Page 121: ...3 2 1 4 3 handlebar cover hole 4 filler neck 112 Fuel Capacity Refueling Procedure Fuel Servicing Your Honda Safety Precautions Refer to on page Fuel tank capacity The tank should be refilled as soon...

Page 122: ...until the level reaches the bottom of the filler neck Avoid over filling the tank There should be no fuel in the filler neck To open the fuel fill cap turn it counterclockwise Pull the breather tube o...

Page 123: ...ife Even the best oil wears out Changing oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil...

Page 124: ...s Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation Do not use API SH or higher oils displaying a circular API energy conserving...

Page 125: ...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 126: ...ating your ATV and add if needed Insert the dipstick without screwing it in then remove the dipstick and check the oil level The oil level should be between the upper level mark and the lower level ma...

Page 127: ...engine with an improper oil level can cause serious engine damage If required remove the oil filler cap lid and oil filler cap and add the specified oil into the filler cap hole up to the upper level...

Page 128: ...ew Honda Genuine oil filter specified for your model or a filter of equal quality cont d This procedure requires mechanical skill and professional tools such as a torque wrench and oil filter wrench a...

Page 129: ...ring and washer Do not discard the washer with the old oil filter Discard the oil filter Check the O rings are in good condition and then insert a new oil filter to the oil filter cover Use only the H...

Page 130: ...to the O ring Reinstall the engine oil drain plug and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Reinstall the oil filler cap Start the engine...

Page 131: ...E 80 Honda shaft drive oil or equivalent 122 Changing Oil Oil Recommendation Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the gear case at normal operatin...

Page 132: ...the ATV on level ground Place an oil drain pan under the oil drain plug Remove the oil filler cap and the drain plug After the oil has completely drained reinstall the drain plug and tighten it to th...

Page 133: ...0 Honda shaft drive oil or equivalent 124 Oil Recommendation Changing Oil Differential Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the differential at normal opera...

Page 134: ...rk the ATV on level ground Place an oil drain pan under the oil drain plug Remove the oil filler cap and the drain plug After the oil has completely drained reinstall the drain plug and tighten it to...

Page 135: ...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 136: ...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 137: ...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 138: ...nt Replacement Coolant Servicing Your Honda Safety Precautions You the Environment Improper disposal of drained fluids is harmful to the environment Refer to on page To properly dispose of drained coo...

Page 139: ...ler The pressured water can damage the radiator core Refer to on page Check the air passages for clogging or damage Remove insects mud or any obstruction with low water pressure Have the radiator chec...

Page 140: ...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 141: ...retainer clips 2 3 air cleaner housing cover UNDER SEAT 132 Cleaning Air Cleaner Servicing Your Honda Remove the seat by pulling the seat latch up Unlatch the retainer clips Remove the air cleaner hou...

Page 142: ...remove the air cleaner assembly from the air cleaner housing Remove the element holder Gently wash the air cleaner in clean non flammable high flash point solvent such as kerosene not petrol After cle...

Page 143: ...ep your hands dry place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner Install the air cleaner on the air cleaner body Apply a thin coat of grease to the sealing...

Page 144: ...be serviced in accordance with the Maintenance Schedule Riding through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the...

Page 145: ...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 the...

Page 146: ...om fully open to fully closed in all steering positions If there is a problem see your Honda dealer Check the cables for tension or stress in all steering positions Lubricate the cables with a commerc...

Page 147: ...V uses spark plugs that have an iridium coated centre electrode Be sure to observe the following when servicing the spark plugs Do not clean the spark plugs If an electrode is contaminated with accumu...

Page 148: ...sonance chamber Inspect the electrode and centre porcelain for deposits corrosion or carbon fouling If the corrosion or deposits are heavy replace the plug Using a spark plug wrench provided in the to...

Page 149: ...st tighten the plug NGK turn after it seats DENSO turn after it seats Then loosen the plug Next tighten the plug again 1 8 turn after it seats If installing a new plug tighten it twice to prevent loos...

Page 150: ...take exhaust Excessive 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 ins...

Page 151: ...ster Servicing Your Honda Safety Precautions Refer to on page Allow the engine and muffler to cool The exhaust system must be periodically purged of accumulated carbon To purge the system Remove the b...

Page 152: ...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 153: ...ly The system must be 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 wea...

Page 154: ...Honda dealer add the recommended fluid Do not add or replace brake fluid except in an emergency If you do add fluid have your Honda dealer check the system as soon as possible With the ATV in an upri...

Page 155: ...essary call a doctor Check for deterioration or cracks in the hoses and fittings If the hoses are worn or cracked have them replaced by your Honda dealer Make sure there are no fluid leaks It should b...

Page 156: ...onditions The pads will wear faster in wet or muddy conditions Inspect the pads visually during all regular service intervals to determine the pad wear Always inspect both pads in both the right and l...

Page 157: ...wear indicator 2 reference mark 148 Brakes Servicing Your Honda Check the wear indicator If the wear indicator aligns with the reference mark replace both pads as a set see your Honda dealer for this...

Page 158: ...lay Brakes Servicing Your Honda Inspection Measure the distance the rear brake lever parking brake lever moves before the brake starts to take hold Freeplay measurement at the tip of the end of the br...

Page 159: ...and brake pedal assemblies are positioned properly and the securing bolts are tight Make sure that the brake cables brake arm spring parking and fasteners are in good condition Turn the brake lever a...

Page 160: ...page Rear Brake Only Check the operation of the rear brakelight switch at the right side behind the engine from time to time The brakelight should turn on at 15 mm 0 6 in of pedal stroke Adjustment is...

Page 161: ...es must be the proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tyres Although the tyres are designed specifically for...

Page 162: ...dling tread life and riding comfort Generally underinflated tyres wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tyres make your ATV ride harshl...

Page 163: ...your tyres are cold If you check air pressure when your tyres are warm even if your ATV has only been ridden for a few miles the readings will be higher If you let air out of warm tyres to match the...

Page 164: ...e system found in service stations This will minimize the possibility of tyre damage from overinflation If you use a high pressure system at a service station add air in small amounts and check the pr...

Page 165: ...Your Honda Also if you hit a pothole or other hard object while riding stop as soon as you safely can and carefully inspect the tyres for damage Tread Wear For best performance you should replace a ty...

Page 166: ...temporary repairs see page A tyre that is repaired either temporarily or permanently will have lower speed and performance limits than a new or undamaged tyre If you have a tyre professionally repaire...

Page 167: ...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 tyres however if that is not possible you...

Page 168: ...he engine guard and skid plate 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 plate protec...

Page 169: ...oots 1 FRONT REAR 1 160 Driveshaft Boots Servicing Your Honda Safety Precautions Refer to on page Check the rubber driveshaft boots for damage or leaking grease If necessary have your Honda dealer rep...

Page 170: ...ccessories use current from the battery even when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your ATV or do not ride frequently we...

Page 171: ...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 172: ...ur Honda The battery is located under the rear fender Remove the battery from battery box Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Releas...

Page 173: ...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 174: ...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 175: ...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 176: ...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 177: ...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 178: ...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 179: ...After 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 motorc...

Page 180: ...adventure how to transport and store your Honda and how to be an environmentally responsible ATV owner Preparing for a Ride What to Take to the Riding Area What to Take on the Trail Transporting Your...

Page 181: ...iculties you might encounter see which begins on page We recommend that you always take water food a first aid kit and your owner s manual Other items you should consider loading on your truck or trai...

Page 182: ...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 183: ...When you transport your ATV we recommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle a...

Page 184: ...wn straps in the areas shown Suitable tie down straps are available from your Honda dealer Ordinary rope is not recommended because it can stretch under load Using tie down straps in any other areas c...

Page 185: ...ct your ATV and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again We suggest you perform the following procedures to...

Page 186: ...is procedure requires a means for draining and disposing of drained fuel page Change the engine oil and filter page Make sure the cooling system is filled with a 50 50 antifreeze solution page Fill th...

Page 187: ...nstall the spark plug and spark plug cap Remove the battery and charge it fully Store it in an area protected from freezing temperatures and direct sunlight Slow charge the battery page once a month C...

Page 188: ...as been stored for more than two months ask your Honda dealer to drain and replace the fuel Perform a pre ride inspection page then test ride your ATV at low speeds Charge the battery page as required...

Page 189: ...t only 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 whi...

Page 190: ...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 Quits or Won t Start If the Transmission Is Not Functi...

Page 191: ...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 192: ...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 193: ...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 194: ...onda dealer SYMPTOM POSSIBLE CAUSE out of fuel flooded engine loose or unconnected spark plug cap loose battery cables weak battery WHAT TO DO Fill the fuel tank See page Install the spark plug cap se...

Page 195: ...le switch to the recommended octane petrol page or change your brand of petrol If the problem persists see your Honda dealer afterfires backfires See your Honda dealer See your Honda dealer blubbers r...

Page 196: ...eck the gear position indicator If the gear position indicator shows and blinks while riding perform the following When the automatic transmission is not shifting properly the gear position indicator...

Page 197: ...won t move it is possible the transmission is locked Use the following procedure to unlock the transmission Shift the shift lever in neutral N position Apply the parking brake Turn the ignition switc...

Page 198: ...conventional tubeless tyres A plug type repair kit available at most auto parts stores or service stations provides a plug an installation tool tyre cement and an instruction sheet Follow the instruct...

Page 199: ...o not try to ride with a flat tyre The ATV will be hard to handle and if the tyre comes off the rim it may lock up the wheel and cause you to crash If the leak is more serious or a temporary repair do...

Page 200: ...e oil or dirt on the disc or pad surfaces when removing and installing each wheel Any contamination can cause poor brake performance or rapid pad wear after reassembly Remove the wheel Raise the front...

Page 201: ...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 202: ...If there s no obvious problem leave the engine on so the fan and coolant circulating system can continue working Monitor the high coolant temperature indicator The indicator may turn off after a brief...

Page 203: ...there is an oil leak do not ride the ATV until the leak is repaired by Honda dealer If there s a mild coolant leak you can ride for awhile carefully watching the indicator Be prepared to stop and add...

Page 204: ...damage caused by excess current flow short circuit or overload If something electrical on your ATV stops working the first thing you should check for is a blown fuse Check all the fuses before looking...

Page 205: ...ng Care of the Unexpected Main Fuse Access To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuses To access the main fuse remove the fuse box cover...

Page 206: ...f damage to the electrical system Circuit Fuse Access To check or replace a circuit fuse pull the old fuse out of its retaining clips If the fuse is blown replace it with a spare fuse of the same rati...

Page 207: ...n do without temporarily If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses that...

Page 208: ...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 209: ...y 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 listed in their records I...

Page 210: ...sition Apply the parking brake Turn the ignition switch to the ON position Use the recoil starter page to start the engine Jump starting is not recommended especially if you use an automobile battery...

Page 211: ...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 212: ...on This section contains dimensions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification Specifications Break in Guidelin...

Page 213: ...echnical Information The VIN is stamped on the front of the frame The engine number is stamped on the upper side of the rear crankcase The VIN engine serial number and key number may be required when...

Page 214: ...entification Technical Information The colour code is helpful when ordering replacement parts Record the colour and code here for your reference The colour label is attached to the frame under the sea...

Page 215: ...on inhibitors specifically recommended for use in aluminum engines API Service Classification SE SF or SG Honda 4 stroke oil or an equivalent 2 9 3 1 US qt 2 6 Imp qt after disassembly after draining...

Page 216: ...00 50 min rpm operator only 220 kg 485 lbs IFR6L11 NGK VK16PRZ11 DENSO VK20PRZ11 DENSO or or intake exhaust passenger capacity maximum weight capacity displacement bore stroke compression ratio spark...

Page 217: ...ront rear rear front reverse forward reverse 2 2 primary reduction secondary reduction final reduction transmission ratio final drive 3rd 2nd 1st caster trail tyre size front tyre size rear tyre press...

Page 218: ...15 A 2 10 A 3 30 A 30 A LED LED battery generator headlight brake tail light neutral indicator reverse indicator high oil coolant temperature indicator wheel nuts rear final gear case oil drain bolt d...

Page 219: ...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 25 km 15 miles During this period avoid full throttl...

Page 220: ...use petrol containing more than 5 methanol even if it has cosolvents and corrosion inhibitors Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the...

Page 221: ...t Locations Digital Clock Drive Mode Indicator Fuel Gauge Gear Position Indicator Hourmeter Multi function Display Odometer Tripmeter Controls Features 2WD 4WD Select Switch Drive Mode Select Switch E...

Page 222: ...h Rear Brake Lever Parking Brake Lever Loading Load Limits Loading Guidelines Accessories Modifications Are You Ready to Ride Is Your ATV Ready to Ride Load Limits Guidelines Accessories Age Recommend...

Page 223: ...Starting Procedure Flooded Engine How to Stop the Engine Keep Hands and Feet on Controls Off road Use Only Preparation Using the Recoil Starter Use Care on Unfamiliar or Rough Terrain Braking Parking...

Page 224: ...nual Storage Maintenance Safety Maintenance Schedule Maintenance Record Maintenance Component Locations Seat Removal The Importance of Maintenance Tool Kit Important Safety Precautions Air Cleaner Coo...

Page 225: ...ou the Environment What to Take to the Riding Area What to Take on the Trail If Your Engine Quits or Won t Start If You Have a Flat Tyre If a Fuse Blows If the High Oil Coolant Temperature Indicator L...

Page 226: ...f Contents MANUFACTURER AND AUTHORISED REPRESENTATIVE FOR EU MARKET TECHNICAL INFORMATION TABLE OF CONTENTS INDEX 203 212 218 231 Break in Guidelines Petrol Containing Alcohol Specifications Vehicle I...

Page 227: ...40 age recommendation 47 air cleaner filter 131 housing drain tube 135 air pressure gauge 109 tyre 153 apparel protective 44 appearance care 166 bank angle sensor 68 Battery 161 Brakes cables 150 flu...

Page 228: ...r select 25 minute select 25 odometer tripmeter select 22 capacity fuel 112 care appearance 166 cargo Loading and operational guidelines 55 Weight limit 54 climbing hills 84 colour label 205 compartme...

Page 229: ...220 Index Index D differential oil 124 digital clock 25 dimmer switch headlight 32 dipstick 117 display multi function 18 driveshaft boots 160 drive mode indicator 19 drive mode select switch 29...

Page 230: ...F cont d final gear case oil 122 flag pole bracket 38 flat tyre 189 flooded engine 68 engine flooded 68 guard 159 number 204 oil 114 pinging 111 starting 66 stop switch 31 stopping 69 won t start 185...

Page 231: ...222 Index Index G H gap spark plug 207 gear case oil 122 gear shifting 71 headlight dimmer switch 32 headlight switch 32 fuel fill cap 112 gauge 26 recommendation 111 tank capacity 112 fuses 195...

Page 232: ...on 25 identification vehicle 204 ignition cut off system bank angle 68 ignition switch 27 indicators drive mode indicator 19 gear position indicator 20 neutral indicator 16 oil change indicator 21 hig...

Page 233: ...nance component locations 105 importance 97 precautions 99 record 104 safety 98 schedule 100 labels safety 6 lamp check 14 limit weight 54 loading guidelines 55 lubrication engine oil 114 differential...

Page 234: ...tive for EU market 231 maximum weight limit 54 minute select button 25 modifications 57 multi function display 18 obstacles riding over 91 odometer 22 oil differential 124 engine 114 gear case 122 oil...

Page 235: ...petrol 111 petrol containing alcohol 211 pinging engine 111 plug spark 138 pre ride inspection 49 problems unexpected 181 protective apparel 44 rear final gear case oil 122 recoil starter 33 removal s...

Page 236: ...tions 59 clothing 44 precautions 61 preparing for 172 over obstacles 91 safety 2 safety precautions 61 through water 92 safety important precautions 99 labels 5 riding precautions 61 schedule maintena...

Page 237: ...ster 142 spark knock 111 spark plug 138 specifications 206 speedometer 17 stalling on a hill 86 start button 31 starting engine 66 troubleshooting 185 stop switch engine 31 stopping engine 69 storage...

Page 238: ...s air pressure 153 flat 189 replacing 158 repairing 157 thread conditions 155 tool kit 108 trailer hitch 39 trailer towing operational guidelines 55 weight limits 54 training rider 46 transporting you...

Page 239: ...230 Index Index W warning labels 5 washing your ATV 167 water riding through 92 weight limit 54 wheel removal 191...

Page 240: ...olina 29161 U S A Honda Motor Europe Ltd Aalst Office Wijngaardveld 1 Noord V B 9300 Aalst Belgium Authorised Representative for EU Market Manufacturer 231 Manufacturer and Authorised Representative f...

Page 241: ......

Page 242: ...530 Fax 219 151 019 www motos honda pt GENERAL AUTOMOTIVE CO S A LEOFOROS ATHINON 71 PO BOX 1200 10173 ATHENS GREECE Tel 30 210 34 83300 Fax 30 210 34 67329 www honda gr info saracakis gr JUAN ARMAS S...

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Honda TRX680FA, Owner'S Manual

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