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Servicing Your Honda

89

Servicing Your Honda

(cont’d)

Servicing Your Honda

To help keep your ATV in good shape, this section includes a
Maintenance Schedule for required service and step-by-step
instructions for specific maintenance tasks. You’ll also find important
safety precautions, information on fuels and oils, and tips for
keeping your Honda looking good.

For information about replacing fuses, see page 180.

Before You Service Your Honda

The Importance of Maintenance ................................................. 91
Maintenance Safety .................................................................... 93

Important Safety Precautions ................................................... 94

Maintenance Schedule ............................................................... 95
Maintenance Record................................................................... 99

Service Preparations

Maintenance Component Locations ......................................... 100
Tool Kit .................................................................................... 103
Owner’s Manual Storage .......................................................... 104
Seat Removal............................................................................ 105

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Summary of Contents for TRX90X

Page 1: ...nual should be considered a permanent part of the ATV and should remain with the ATV when it is resold This publication includes the latest production information available before printing Honda Motor...

Page 2: ...Honda TRX90X SPORTRAX 90X OWNER S MANUAL Original instructions 14 TRX90X 32HP26700 book 2...

Page 3: ...Scheduled service is a must of course But it s just as important to observe the break in guidelines and perform all pre ride and other periodic checks detailed in this manual We also recommend that y...

Page 4: ...irrors Can use the lights Can use the clutch Can use the gearbox Can use the accelerator Can use the braking systems First manoeuvres make 2 at reduced speed among which one slalom Can use the clutch...

Page 5: ...wn a slope Crossing a slope horizontally Driving on rough terrain Skidding and wheel spin If you have any questions or if you ever need special service or repairs remember that your dealer knows your...

Page 6: ...on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with ope...

Page 7: ...ety Instructions how to use this ATV correctly and safely This entire manual is filled with important safety information please read it carefully 3DANGER You WILL be KILLED or SERIOUSLY HURT if you do...

Page 8: ...ety related labels on your ATV Indicators Controls 21 The location and function of indicators and controls on your ATV and operating instructions for various controls and features Before Riding 37 The...

Page 9: ...e and adjustment items Tips 161 How to store and transport your ATV and how to be an environmentally responsible rider Taking Care of the Unexpected 171 What to do if you have a flat tyre your engine...

Page 10: ...commendations to help you ride your ATV safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your ATV Important Safety Inf...

Page 11: ...ghout this manual The following are a few that we consider to be most important Follow the Age Recommendation The minimum recommended age for this ATV model is 12 For safety children under age 12 shou...

Page 12: ...s Take Time to Learn Practice Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice in a safe area until you build your skills and get accustomed...

Page 13: ...iding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink and ride and don t let your friend...

Page 14: ...e Riding readiness varies widely from one person to another and while the minimum age recommended for this ATV is 12 years old there are other factors that you should consider PHYSICAL ABILITY are imp...

Page 15: ...not the youngster is not physically ready to ride this ATV Before you let a youngster ride an ATV decide whether they are physically mentally and emotionally ready to ride ATHLETIC ABILITY is another...

Page 16: ...and the Owner s Manual before riding Also be sure that your youngster always wears a helmet and other appropriate riding equipment when operating or sitting on it page 38 Because good instruction is a...

Page 17: ...iders to follow the instructions and warnings in this manual And remember it s the parents responsibility to see that the ATV is properly maintained and kept in safe operating condition If you choose...

Page 18: ...If a label comes off or becomes hard to read contact your dealer for a replacement There is a specific symbol on each label The meanings of each symbol and label are as follows Read instructions cont...

Page 19: ...ouch a battery unless they understand proper handling and hazards of the battery very well Handle battery electrolyte with extreme care as it contains dilute sulfuric acid Contact with your skin or ey...

Page 20: ...s Always use proper riding techniques for hills slopes and rough terrain Use care when changing riding surfaces ATVs handle differently on different surfaces such as sand dirt or pavement Never carry...

Page 21: ...e as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH TYRE OVERLOAD WARNING LABEL WARNING Improper tyre pressure or overloading can cause loss of control Loss of...

Page 22: ...ATV Safety 13 Labels ED type CE MARK Engine net power 4 7 kW Machine mass 119 kg 14 TRX90X 32HP26700 book 13...

Page 23: ...ATV Safety 14 Labels ED type AGE RECOMMENDATION WARNING LABEL GENERAL WARNING LABEL BATTERY LABEL 14 TRX90X 32HP26700 book 14...

Page 24: ...ATV Safety 15 Labels ED type PASSENGER WARNING LABEL DRIVE CHAIN LABEL TYRE OVERLOAD WARNING LABEL 14 TRX90X 32HP26700 book 15...

Page 25: ...ATV Safety 16 Labels ED type CE MARK 14 TRX90X 32HP26700 book 16...

Page 26: ...d understand this information before riding Parents of young riders should make sure their youngsters read and understand the label information before allowing them to ride The labels should be consid...

Page 27: ...ATV Safety 18 Labels U type 14 TRX90X 32HP26700 book 18...

Page 28: ...ATV Safety 19 Labels U type 14 TRX90X 32HP26700 book 19...

Page 29: ...14 TRX90X 32HP26700 book 20...

Page 30: ...on Instructions for other components are presented in other sections of this manual where they will be most useful Operation Component Locations 22 Indicator 25 Neutral Indicator Lamp 25 Controls Feat...

Page 31: ...ontrols 22 Operation Component Locations rear brake lever parking brake lever start button front brake lever engine stop switch throttle lever parking brake lock lever ignition switch 14 TRX90X 32HP26...

Page 32: ...Indicators Controls 23 Operation Component Locations storage compartment flag pole bracket rear brake pedal 14 TRX90X 32HP26700 book 23...

Page 33: ...Indicators Controls 24 Operation Component Locations fuel valve seat lock lever choke lever shift lever 14 TRX90X 32HP26700 book 24...

Page 34: ...neutral indicator lamp will light when the transmission is in neutral and the ignition switch is ON q If the indicator does not come on when it should have your dealer check for a burned out bulb or...

Page 35: ...n for riding OFF for parking storing or transportation RES for extra fuel to get to a gas supply for refuelling Reserve Fuel Remember to check that the fuel valve is in the ON position each time you r...

Page 36: ...ndicators Controls 27 Controls Features The choke lever 1 may be used when starting the engine See page 66 Choke Lever d LEFT SIDE A B 1 choke lever A fully ON B fully OFF 1 14 TRX90X 32HP26700 book 2...

Page 37: ...and stopping the engine page 65 Insert the key and turn it to the right for the ON q position Ignition Switch Key Position Function ON q Electrical circuits on OFF w No electrical circuits function CE...

Page 38: ...ts the engine See Starting Procedure page 66 When the start button is pushed the starter motor will crank the engine The starter motor will not operate if the engine stop switch is in the OFF r positi...

Page 39: ...N e position to start the engine and it should normally remain in the RUN e position even when the engine is OFF If your ATV is stopped with the ignition switch ON q and the engine stop switch OFF r t...

Page 40: ...rpm press the throttle lever 1 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 yo...

Page 41: ...ion on braking techniques see page 73 The rear brake lever parking brake lever 2 is used to slow or stop your ATV To operate pull the lever For information on braking techniques see page 73 Front Brak...

Page 42: ...trols Features The rear brake pedal 1 is used to slow or stop your ATV To operate depress the pedal For information on braking techniques see page 73 Rear Brake Pedal RIGHT SIDE 1 1 rear brake pedal 1...

Page 43: ...as a parking brake 1 Squeeze the rear brake lever parking brake lever 2 Lock it with the lock lever 3 Unlock the parking brake by squeezing the rear brake lever parking brake lever until the lock lev...

Page 44: ...ailable from your dealer To mount a pole in the bracket 1 follow the instructions that come with the flag pole kit Flag poles are required in some riding areas Check local regulations before riding Fl...

Page 45: ...Indicators Controls 36 14 TRX90X 32HP26700 book 36...

Page 46: ...stments to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride 38 Protective Apparel 38 Rider Training 40 Age Recommendatio...

Page 47: ...thing 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 gloves trousers and a long sleeve...

Page 48: ...egs Off road motorcycle gloves to help protect your hands Riding trousers with knee and hip pads a riding jersey with padded elbows and a chest shoulder protector WARNING 3WARNING Operating this ATV w...

Page 49: ...customed to the ATV s controls and feel comfortable with its size and weight Rider Training WARNING 3WARNING Operating this ATV without proper instruction could increase your risk of an accident which...

Page 50: ...Never let a passenger ride on the seat or on the front or rear cargo racks Age Recommendation WARNING 3WARNING A child using an ATV that is not recommended for their age could lose vehicle control wh...

Page 51: ...perating an ATV Consult your doctor to be sure it is safe to operate a vehicle after taking medication No Alcohol or Drugs WARNING 3WARNING Operating this ATV after consuming alcohol or drugs can seri...

Page 52: ...le until it has been inspected by your dealer There may be damage or other problems you cannot see Note to parents If a youngster will be performing any of the following pre ride inspection procedures...

Page 53: ...ed Also look for signs of damage or excessive wear page 137 Drive Chain Check the condition and slack Adjust and lubricate if needed Also check the chain slider for wear and replace if needed page 145...

Page 54: ...d Throttle 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 11...

Page 55: ...ng modifications that change this ATV s design and performance can also make it unsafe Also the weight of any accessories will reduce the maximum load the ATV can carry More specific information on lo...

Page 56: ...ce the maximum cargo weight you can carry As discussed on page page 46 we recommend that you do not carry any cargo on this ATV However if you decide to carry cargo ride at reduced speeds and follow t...

Page 57: ...assistance and always follow these guidelines Make sure the accessory does not reduce ground clearance limit suspension travel or steering travel or interfere with operating any controls Make sure th...

Page 58: ...sly impair your ATV s handling stability and braking making it unsafe to ride Because safety vehicle movement and clearance must be taken into consideration you must consult your tyre maker or Honda d...

Page 59: ...Before Riding 50 14 TRX90X 32HP26700 book 50...

Page 60: ...e 194 For information about carburetor adjustment for riding at high altitude see page 195 Safe Riding Precautions 53 Speed Restrictors for New Riders 53 Off road Use Only 57 Keep Hands and Feet on Co...

Page 61: ...ding Braking 73 Riding Your ATV 76 Making Turns 76 Skidding or Sliding 78 Riding Up Hills 79 Riding Down Hills 83 Crossing or Turning on Hills or Slopes 84 Riding Over Obstacles 86 Riding Through Wate...

Page 62: ...dles Practice in a safe area until you build your skills and get accustomed to the ATV s size and weight To limit top speed to about one half of normal in every gear your ATV has an adjustable throttl...

Page 63: ...r screw 4 clockwise to reduce throttle lever movement or counterclockwise to increase throttle lever movement Hold the throttle limiter screw in place and tighten the lock nut 4 Reinstall the stay and...

Page 64: ...eel it contact the throttle lever 7 Release the throttle lever and turn the throttle limiter screw counterclockwise 3 4 turn 8 Hold the throttle limiter screw in place and tighten the lock nut 9 Reins...

Page 65: ...the seat page 105 2 Unlatch the four retainer clips 5 3 Remove the air cleaner housing cover 6 4 Remove the air intake restrictor 7 Reinstall in the reverse order of removal UNDER SEAT 5 retainer clip...

Page 66: ...remember to always obey local off road riding laws and regulations Obtain permission to ride on private property Avoid posted areas and obey no trespassing signs Off road Use Only WARNING 3WARNING Ope...

Page 67: ...from the handlebars or one foot from the footpegs can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV WARNING 3WARNING Operating this ATV on public...

Page 68: ...vehicle as shown below keeping your hands on the handlebars and feet on the footpegs Riding Position Safety Equipment Helmet and eye protection Long sleeved apparel and trousers Off road motorcycle g...

Page 69: ...backwards see page 82 1 After confirming that the engine is off stand beside the ATV so you can reach the rear brake lever with your left hand 2 Be sure your legs are clear of the wheels 3 Check you...

Page 70: ...rrain visibility and other operating conditions plus your own skills and experience Control Speed WARNING 3WARNING Operating this ATV at excessive speeds increases your chances of losing control of th...

Page 71: ...structions like hidden rocks bumps or holes in time to react Use Care on Unfamiliar or Rough Terrain WARNING 3WARNING Failure to use extra care when operating this ATV on unfamiliar terrain could resu...

Page 72: ...ING 3WARNING Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control which could result in an accident including an over...

Page 73: ...ring the daytime You should ride only when visibility is good Plan to stop riding well before it gets dark Operation at night without lights may be illegal in some states Do Not Perform Stunts WARNING...

Page 74: ...de gas which can collect rapidly in an enclosed area and cause illness or death 1 Before starting select a level surface and lock the parking brake page 34 2 Turn the fuel valve 1 and ignition switch...

Page 75: ...if the engine is cold 2 With the throttle 1 8 1 4 open press the start button 2 If the throttle limiter is adjusted as delivered open the throttle fully Pressing the electric start button for more th...

Page 76: ...the Engine 3 Warm up the engine by opening and closing the throttle slightly 4 After the engine has warmed up push the choke lever down all the way to fully OFF B 5 If idling is unstable open the thr...

Page 77: ...engine is cold 2 With the throttle 1 8 1 4 open start the engine 3 Warm up the engine by opening and closing the throttle slightly 4 Continue warming up the engine until it runs smoothly and responds...

Page 78: ...r Temperature procedure page 68 If the engine still won t start refer to If Your Engine Quits or Won t Start page 174 Normal Engine Stop To stop the engine make sure the transmission is in neutral by...

Page 79: ...ssion to the next higher or lower gear in the shifting sequence The shift lever automatically returns to the horizontal position when released To upshift to a higher gear put the toe of your boot unde...

Page 80: ...raise the shift lever one full stroke to shift into 1st first gear 3 Release the rear brake lever and increase engine speed by gradually opening the throttle 4 When speed increases release the thrott...

Page 81: ...tween engine sound and the normal shifting points Downshift to a lower gear before you feel the engine laboring lugging at low rpm Avoid downshifting to help slow your ATV when engine rpm is high Down...

Page 82: ...rear axle housing is mechanically activated by depressing the brake pedal or operating the left brake lever As a general rule the front braking system provides about 70 percent of total stopping powe...

Page 83: ...e levers and brake pedal smoothly while downshifting to match your speed Gradually increase braking as you feel the brakes slowing your speed The increase in engine compression from downshifting will...

Page 84: ...heels to slip and reduce your control of your ATV Your ability to brake in a turn and to brake hard in an emergency situation are important riding skills When descending a long steep grade use engine...

Page 85: ...l you are confident in making turns Making Turns WARNING 3WARNING Turning improperly can make the ATV go out of control causing a collision or overturn Always follow proper procedures for turning as d...

Page 86: ...It helps to shift your body slightly forward on the seat and lean inside as you steer the handlebar Shifting weight forward allows the rear wheels to turn easier and it also improves front wheel stee...

Page 87: ...eep your speed low and ride with caution If your ATV skids sideways during a turn steer in the direction of the skid Avoid hard braking or accelerating until you have regained directional control Skid...

Page 88: ...ight toward the front wheels to help keep them on the ground To do this shift your body slightly forward on the seat and lean forward For greater weight shift move your body farther forward and lean f...

Page 89: ...in an appropriate gear and speed for the conditions Maintain a steady speed as you ascend the hill Never open the throttle suddenly or make sudden gear changes The ATV could flip over backward Never...

Page 90: ...ntinue holding the brakes 3 Shift into neutral set the parking brake and turn the engine off 4 Then assess the situation If the ATV starts rolling backwards before you begin braking 1 Keep your weight...

Page 91: ...g 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 1 Stand with your body facing downhill beside the vehicle so you can reac...

Page 92: ...ach a downhill stop and survey the terrain below Never ride past the limit of your visibility Never go down a hill at high speed Riding Down Hills WARNING 3WARNING Going down a hill improperly could c...

Page 93: ...ss is reduced on any hill with a loose surface Riding on hills or slopes is different from riding on level terrain Be careful when riding on any hill Make sure that you practice on gentle smooth slope...

Page 94: ...y or loose surface you may also need to steer slightly uphill to maintain a straight course across the slope Avoid crossing hills that are excessively steep slippery or rough Making Turns on Slopes Co...

Page 95: ...le reduce your speed and be prepared to stop Never try to ride over large obstacles such as large rocks or fallen logs Riding Over Obstacles WARNING 3WARNING Improperly operating over obstacles could...

Page 96: ...he water always test both the front and rear brakes Riding through water can make the brakes less effective than normal and may reduce stopping ability If necessary apply the brakes repeatedly until t...

Page 97: ...your ATV in gear and is stopped on a grade rock the vehicle back and forth to allow shifting the transmission into neutral Parking on a Steep Incline or a Loose or Slippery Surface If you must park yo...

Page 98: ...ortant safety precautions information on fuels and oils and tips for keeping your Honda looking good For information about replacing fuses see page 180 Before You Service Your Honda The Importance of...

Page 99: ...ngine Oil 109 Air Cleaner 115 Engine Throttle 119 Clutch System 121 Engine Idle Speed and Air Fuel Mixture 122 Spark Plug 124 Valves 127 Spark Arrester 128 Chassis Brakes 129 Wheels Tyres 137 Guards 1...

Page 100: ...are based on average riding conditions More frequent service is needed if you subject your ATV to severe use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especiall...

Page 101: ...ting condition For youngsters learning how to take care of an ATV and perform basic maintenance can be an important part of their riding experience However if you allow a youngster to perform or assis...

Page 102: ...dled only by a Honda technician or other qualified mechanic Instructions are included in this manual only to assist in emergency service Some of the most important safety precautions follow However we...

Page 103: ...parts Do not run the engine unless instructed 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 c...

Page 104: ...e provided in this manual Other items involve more extensive procedures and may require special training tools and equipment We recommend that you have your dealer perform these tasks unless you have...

Page 105: ...l information and tools Consult your dealer Summary of Maintenance Schedule Notes Procedures NOTES 1 Service more frequently when riding in dusty areas sand or snow 2 Service more frequently after rid...

Page 106: ...viced only by your dealer FREQUENCY WHICHEVER COMES FIRST INITIAL MAINT REGULAR MAINT INTERVAL Refer to page ITEMS km 150 1000 2000 mi 100 600 1200 MONTH 1 6 12 NOTE HOURS 20 100 200 FUEL LINE I THROT...

Page 107: ...INITIAL MAINT REGULAR MAINT INTERVAL Refer to page ITEMS km 150 1000 2000 mi 100 600 1200 MONTH 1 6 12 NOTE HOURS 20 100 200 DRIVE CHAIN NOTE 1 NOTE 2 I L I L EVERY 500 km 300 mi or 50 operating hours...

Page 108: ...aintenance including the 150 km 100 mile or 1 month or 20 hours initial maintenance is considered a normal owner operating cost and will be charged for by your dealer Use the space under Notes to reco...

Page 109: ...Servicing Your Honda 100 Service Preparations Maintenance Component Locations rear brake lever parking brake lever front brake lever fuel fill cap throttle lever 14 TRX90X 32HP26700 book 100...

Page 110: ...Servicing Your Honda 101 Maintenance Component Locations engine oil drain bolt rear brake pedal clutch spark plug engine oil fill cap dipstick 14 TRX90X 32HP26700 book 101...

Page 111: ...g Your Honda 102 Maintenance Component Locations spark arrester fuel valve drive chain throttle stop screw engine idle speed battery tool kit owner s manual main fuse air cleaner 14 TRX90X 32HP26700 b...

Page 112: ...ol kit securely The tools in the kit are sufficient to perform routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your dealer The tool kit incl...

Page 113: ...n the plastic document bag underside of the seat 2 The owner s manual spare fuse 3 and screw 4 should be stored in the plastic document bag 5 and fastened with the rubber band 6 Be careful not to floo...

Page 114: ...Pull the seat lock lever 1 up behind the seat 2 Slide the seat 2 back and lift it Installation 1 Insert the front prongs 3 into the hooks 4 on the frame and press the studs 5 into the grommets on the...

Page 115: ...r information on the use of Petrol Containing Alcohol see page 196 Use of lower octane petrol can cause persistent pinging or spark knock a loud rapping noise which if severe can lead to engine damage...

Page 116: ...be refilled as soon as possible after switching to reserve and the fuel valve should be returned to the ON position after refuelling to avoid running out of fuel with no reserve Refer to Safety Precau...

Page 117: ...elling turn the fuel fill cap clockwise until it clicks 5 Insert the breather tube into the handlebar cover hole 6 If the fuel valve was set to RES turn the fuel valve ON If you replace the fuel fill...

Page 118: ...best oil wears out Changing oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause se...

Page 119: ...y affect clutch operation Do not use API SH or higher oils displaying a circular API energy conserving or resource conserving service label on the container They may affect lubrication and clutch perf...

Page 120: ...thin the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is label...

Page 121: ...r and wipe it clean 4 Insert the oil fill cap dipstick without screwing it in then remove the oil fill cap dipstick and check the oil level The oil level should be between the upper level mark 2 and t...

Page 122: ...ans for disposing of the drained fluid page 170 If you do not have the skills or the tools see your dealer Drain the Engine Oil 1 With the ATV on the level ground remove the oil fill cap dipstick from...

Page 123: ...bf ft 2 Fill the crankcase with the recommended grade oil approximately 0 7 0 7 US qt 0 6 Imp qt 3 Reinstall the oil fill cap dipstick 4 Start the engine and let it idle for 3 5 minutes 5 Stop the eng...

Page 124: ...rmine the correct service interval for your riding conditions Your ATV s air cleaner has very specific performance requirements Use a new Honda Genuine air cleaner specified for your model or an air c...

Page 125: ...ck lever 1 up 2 Unlatch the four retainer clips 2 3 Remove the air cleaner housing cover 3 4 Remove the set plate 4 and remove the air cleaner assembly 5 from the case Cleaning 1 2 3 1 seat lock lever...

Page 126: ...leaner and sub air cleaner in clean non flammable high flash point solvent such as kerosene not petrol After cleaning gently squeeze out the remaining solvent Avoid twisting or wringing the air cleane...

Page 127: ...Pour clean air filter oil over the entire surface of the air cleaner Use both hands to evenly spread the oil into the air cleaner Gently squeeze out any excess oil To keep your hands dry place the air...

Page 128: ...tle cable adjuster 3 2 Loosen the lock nut 4 3 Turn the adjuster to obtain the correct freeplay 4 Tighten the lock nut and reinstall the sleeve 5 After adjustment check for smooth operation of the thr...

Page 129: ...m fully open to fully closed in all steering positions If there is a problem see your dealer 3 Inspect the condition of the throttle cables from the throttle lever down to the carburetor If the cable...

Page 130: ...r 2 counterclockwise until you feel slight resistance 4 Turn the adjuster 1 8 turn clockwise then tighten the lock nut to hold the adjuster in this position 5 After adjustment start the engine and tes...

Page 131: ...ating temperature for accurate idle speed adjustment For information about high altitude carburetor adjustment see page 195 Refer to Safety Precautions on page 94 1 If the engine is cold start it and...

Page 132: ...fuel mixture For those who are mechanically proficient and have the necessary tools adjustment procedures are given in the official Honda Shop Manual available from your dealer All others should have...

Page 133: ...spark plug base 2 Disconnect the spark plug cap Take care to avoid damaging the spark plug wire when disconnecting the cap 3 Using a spark plug wrench provided in the tool kit remove the spark plug S...

Page 134: ...tip and sharp edges and the side electrode 2 should not be eroded If the electrodes and insulator tip appear unusually fouled or burned we suggest that you contact your dealer 5 Discard the spark plu...

Page 135: ...prevent loosening a First tighten the plug b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats NOTICE An improperly tightened spark plug can damage the engine If a plug is to...

Page 136: ...ll cause loss of power and possibly damage the valves For those who are mechanically proficient and have the proper tools instructions on adjusting valve clearances are given in the official Honda Sho...

Page 137: ...ed area free of combustible materials and make sure the exhaust pipe is cool 2 Remove the bolt 1 3 Start the engine and rev it up approximately twenty times while momentarily creating exhaust system b...

Page 138: ...brake shoes for wear page 135 Worn shoes should be replaced Refer to Safety Precautions on page 94 Inspection Measure the distance the brake lever moves before the brakes start to take hold Freeplay...

Page 139: ...t fender Make sure the cutout on the adjusting nut is properly seated on the brake arm pin 3 2 Adjust the freeplay of the front brake lever Push the brake arm 4 then check the brake arm freeplay 2 UND...

Page 140: ...moves before the brake starts to take hold Freeplay measurement at the tip of the end of the brake pedal should be 10 20 mm 0 4 0 8 in If necessary adjust to the specified range Rear Brake Pedal Free...

Page 141: ...the frame Make sure the cutout on the adjusting nut is properly seated on the brake arm pin 3 2 Adjust the freeplay of the rear brake pedal Push the brake arm 4 then check the clearance between the br...

Page 142: ...oves before the brake starts to take hold Freeplay measurement at the tip of the end of the brake lever should be 10 20 mm 0 4 0 8 in If necessary adjust to the specified range Rear Brake Lever Freepl...

Page 143: ...d on the brake arm pin 3 2 Adjust the freeplay of the rear brake lever parking brake lever Push the brake arm 4 then check the clearance between the brake arm and the brake arm pin Check that the rear...

Page 144: ...ake wear indicators that let you check brake wear without disassembly Application of the brake control lever or pedal causes the arrow on the brake arm to move toward a reference mark on the brake pan...

Page 145: ...ake If replacement is necessary see your dealer Refer to Safety Precautions on page 94 1 Make sure the engine is off and the parking brake is set 2 Remove the rear brake drain bolt 1 from the bottom o...

Page 146: ...recommend that you leave this work to the experts with the proper equipment and experience Wheels that are deformed or damaged must be replaced Please consult your dealer for replacement Tyres age eve...

Page 147: ...res wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tyres make your ATV ride harshly are more prone to damage from surface hazards and wear uneve...

Page 148: ...ressures you should also look for Bumps or bulges in the side of the tyre or the tread Replace any tyre that has a bump or bulge Cuts slits or cracks in the tyres Replace the tyre if you can see fabri...

Page 149: ...re tread measure the groove depth 1 in the centre of the tyre or check the wear indicator 2 For best performance you should replace a tyre before the tread depth at the centre reaches the following li...

Page 150: ...have the tyre replaced or permanently repaired as soon as possible For more information on temporary repairs see If You Have a Flat Tyre page 177 A permanent repair such as an internal plug patch can...

Page 151: ...ot be installed if the previous usage record is unknown The recommended tyres for your ATV are When you replace a tyre remember Have the tyre replaced by your dealer if possible If you have a tyre pro...

Page 152: ...me lower arm the drive components and the rear brake Check the plates for cracks damage or looseness at intervals shown in the Maintenance Schedule Have the skid plates replaced if they are cracked or...

Page 153: ...The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets Under severe usage or when the ATV is rid...

Page 154: ...mm 0 8 1 2 in 2 Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate b...

Page 155: ...150 if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed 4 Check the drive chain slider 2 at the intervals specified in the M...

Page 156: ...ve chain tight between the sprockets measure the distance between a span of 21 pins from pin centre to pin centre If the distance exceeds the service limit the chain is worn out and should be replaced...

Page 157: ...eeth for excessive wear or damage If necessary have your dealer replace a worn sprocket NOTICE Use of a new chain with worn sprockets will cause rapid chain wear Normal Sprocket Teeth GOOD Damage Spro...

Page 158: ...2 to decrease or increase chain slack 3 Retighten the rear axle holder fixing bolts 4 Rear axle holder fixing bolts torque 88 N m 9 0 kgf m 65 lbf ft If a torque wrench is not used for this installati...

Page 159: ...ays of riding or sooner if chain appears dry Recommended lubricant Drive chain lubricant designed specially for O ring chains If not available use SAE 80 or 90 gear oil Commercial chain lubricants may...

Page 160: ...de surfaces of the chain with a dry cloth Use a high flashpoint solvent such as kerosene not petrol Do not brush the rubber O rings Brushing will damage them Use of a solvent may also damage the O rin...

Page 161: ...not ride frequently we recommend that you charge the battery frequently see Battery Charging page 155 If you do not expect to ride your ATV for at least two weeks we recommend you remove the battery o...

Page 162: ...ge results from removing the battery and slow charging it every 30 days see Battery Charging page 155 Before you remove the battery be sure to read all the information that follows as well as the info...

Page 163: ...lead 4 5 Remove the battery 6 Charge the battery see following section 7 Store your battery in an easy to reach location off the floor in an area protected from freezing temperature and direct sunlig...

Page 164: ...e battery Improper charging may damage the battery We recommend using a charger 1 designed specifically for your Honda which can be purchased from your dealer These units can be left connected for lon...

Page 165: ...ic on your ATV If your ATV is still warm from recent operation give the engine and exhaust system time to cool off Park in a shady area Washing your ATV in bright sunlight may cause the finish to fade...

Page 166: ...emove the grime 4 After washing rinse your ATV thoroughly with plenty of clean water to remove any residue Detergent residue can corrode alloy parts 5 Dry your ATV with a chamois or a soft towel Leavi...

Page 167: ...int chrome glass and clear plastic Light road grimes Spray any difficult to reach or very dirty areas with a spray cleaner degreaser Rinse and dry Apply a spray cleaner polish and wipe with a non abra...

Page 168: ...er 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 or automobiles Apply the...

Page 169: ...Servicing Your Honda 160 14 TRX90X 32HP26700 book 160...

Page 170: ...our Honda and how to be an environmentally responsible ATV owner Preparing for a Ride 162 What to Take to the Riding Area 162 What to Take on the Trail 163 Transporting Your Honda 164 Storing Your Hon...

Page 171: ...hould take along some tools and supplies in case you have a problem For some of the difficulties you might encounter see Taking Care of the Unexpected which begins on page 171 We recommend that you al...

Page 172: ...ong you 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 This ATV is not designed to carry cargo Also be sure to follow...

Page 173: ...you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking petrol could be a hazard Follow th...

Page 174: ...om your dealer Ordinary rope is not recommended because it can stretch under load Using tie down straps in any other areas can damage your ATV 4 Rock the vehicle back and forth to make sure the tie do...

Page 175: ...d 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 keep your ATV...

Page 176: ...Drain the carburetor into an approved petrol container and dispose of it in an approved manner page 170 If storage will last longer than one month carburetor draining is important to assure proper pe...

Page 177: ...ne and distribute the oil Reinstall the spark plug and spark plug cap 6 Remove the battery and charge it fully Store it in an area protected from freezing temperatures and direct sunlight Slow charge...

Page 178: ...d materials that restrict air flow and allow heat and moisture to accumulate Refer to Safety Precautions on page 94 1 Uncover and clean your ATV 2 If your ATV has been stored for more than four months...

Page 179: ...nd may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s protect...

Page 180: ...gives practical advice to help you deal with a wide range of problems Take time to read this section before you ride Also review the tips in Preparing for a Ride page 162 General Guidelines 172 If You...

Page 181: ...e 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 then consider your options before...

Page 182: ...the situation and your options before deciding what to do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have permanent repairs ma...

Page 183: ...em starting the engine or experience poor engine performance the following information may help you If you can t correct the problem see your dealer If your ATV won t start listen as you press the sta...

Page 184: ...our dealer faulty starter motor If all possible causes are negative the starter motor may be faulty See your dealer SYMPTOM Starter motor works but the engine won t start POSSIBLE CAUSE WHAT TO DO eng...

Page 185: ...e carburetion with a high altitude jet Refer to High Altitude Carburetor Adjustment page 195 runs erratically misfires See your dealer blubbers rich fuel mixture See your dealer sooty exhaust rich fue...

Page 186: ...temporary repair As soon as possible have the tyre permanently repaired by your dealer Any tyre that cannot be repaired should be replaced Whenever the ATV is to be operated far from service facilitie...

Page 187: ...k your ATV on a firm level surface 2 Loosen but do not remove the wheel nuts 1 3 Raise the front or rear wheels off the ground and place a support block under the vehicle 4 Remove the wheel nuts 5 Rem...

Page 188: ...eel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque 54 N m 5 5 kgf m 40 lbf ft If a torque wrench was not used for inst...

Page 189: ...If something electrical on your ATV stops working the first thing you should check for is a blown fuse 1 Check the fuse before looking elsewhere for another possible cause of the problem Replace a bl...

Page 190: ...ess 1 To prevent an accidental short circuit turn the ignition switch OFF w before checking or replacing the fuses 2 To access the fuse 1 remove the seat page 105 3 Remove the fuse case cover 2 1 fuse...

Page 191: ...a replacement fuse with the proper rating for the circuit install one with a lower rating NOTICE Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electr...

Page 192: ...inspect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor d...

Page 193: ...are 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 If they don t transport your ATV to them or the neare...

Page 194: ...if you use an automobile battery The greater amperage of an automobile battery when the car engine is running can damage your ATV s electrical system Bump starting is also not recommended If you can...

Page 195: ...d what tools and supplies you have with you If any component of the brake system is damaged you may be able to ride carefully back to your base using the other brake components for slowing or stopping...

Page 196: ...s dimensions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 188 Specifications 190 Break in Guidelines 194 High Alt...

Page 197: ...umbers here for your reference The VIN 1 is stamped on the front of the frame VIN ______________________________________________________ The engine number 2 is stamped on the lower side of the rear cr...

Page 198: ...ge 105 to check the label The colour code is helpful when ordering replacement parts Record the colour and code here for your reference COLOUR__________________________________________________ CODE __...

Page 199: ...including reserve fuel tank reserve 1 0 0 26 US gal 0 22 Imp gal engine oil capacity after disassembly 0 9 1 0 US qt 0 8 Imp qt after draining 0 7 0 7 US qt 0 6 Imp qt engine oil recommendation API Se...

Page 200: ...CR6HSA NGK or U20FSR U DENSO spark plug high speed riding CR8HSA NGK or U24FSR U DENSO spark plug gap 0 60 0 70 mm 0 024 0 028 in valve clearance cold intake 0 05 mm 0 002 in exhaust 0 05 mm 0 002 in...

Page 201: ...M954 tyre pressure front rear cold 20 0 kPa 2 9 psi Electrical battery YTX5L BS 12 V 4 Ah 10HR 4 2 Ah 20HR generator 0 056 kW 5 000 min 1 rpm Lights neutral indicator 12 V 3 4 W Fuse main 7 5 A Torqu...

Page 202: ...e level EN 15997 Annex H 73 dB A Uncertainty of measurement 3 dB A Vibration on seat EN 15997 Annex I Not exceed 0 5 m s2 Uncertainty of measurement N A Vibration on handlegrip EN 15997 Annex I 4 5 m...

Page 203: ...Help assure your ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 25 km 15 miles During this period avoid full throttle starts and r...

Page 204: ...nt procedures are given in the official Honda Shop Manual available from your dealer All others should have this carburetor modification performed by your dealer However the carburetor must be returne...

Page 205: ...taining 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 warranty Hond...

Page 206: ...Technical Information 197 14 TRX90X 32HP26700 book 197...

Page 207: ...52 brakes draining water from 136 front brake lever 32 front brake lever freeplay 129 parking 34 rear brake lever 32 rear brake lever freeplay 133 rear brake pedal 33 rear brake pedal freeplay 131 sho...

Page 208: ...e lever 27 66 cleaning appearance care 156 climbing hills 79 clutch system 121 colour label 189 compartment owner s manual 104 tool kit 103 component fails 186 controls features 26 crash if you 183 cr...

Page 209: ...9 won t start 174 environment 170 exhaust system cleaning 44 purge 128 F flag pole bracket 35 flat tyre 177 flooded engine 69 fuel fill cap 107 high altitude fuel mixture adjustment 195 recommendation...

Page 210: ...pes 84 riding down hills 83 riding up hills 79 stopping on hills 81 I identification vehicle 188 idle speed engine 122 ignition switch 28 inspection pre ride 44 K key lost 184 number 184 kit tool 103...

Page 211: ...ht limit 47 modifications 49 N numbers serial 188 O obstacles riding over 86 oil engine 109 operation component locations 22 owner s manual storage 104 P parking 88 passenger no carrying 41 pavement n...

Page 212: ...R removal seat 105 rider training 40 riding basic operations 51 clothing 38 over obstacles 86 position 59 precautions 53 preparing for 162 safety 2 safety precautions 53 through water 87 14 TRX90X 32H...

Page 213: ...188 shifting gears 70 skid plates 143 skidding or sliding 78 spark arrester 128 spark knock 106 spark plug 124 specifications 190 speed restrictor 53 stalling on a hill 81 start button 29 starting en...

Page 214: ...aining rider 40 transporting your ATV 164 trouble unexpected 171 troubleshooting starting 174 turning on hills or slopes 84 on level ground 76 tyres air pressure 138 flat 177 repairing 141 replacing 1...

Page 215: ...Index 206 Index W warning labels 9 17 washing your ATV 157 water draining from brakes 136 riding through 87 weight limit 47 wheel removal 178 14 TRX90X 32HP26700 book 206...

Page 216: ...turer and Authorised Representative for EU Market Manufacturer Authorised Representative for EU Market Honda Motor Co Ltd 2 1 1 Minami Aoyama Minato ku Tokyo 107 8556 Japan Honda Motor Europe Ltd Belg...

Page 217: ...14 TRX90X 32HP26700 book 208...

Page 218: ...14 TRX90X 32HP26700 book 209...

Page 219: ...14 TRX90X 32HP26700 book 210...

Page 220: ...14 TRX90X 32HP26700 book 211...

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