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Honda FOURTRAX 350 4x4 2001 Owner's Manual

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01/04/28 16:27:35 3CHN5620_001
READ THIS MANUAL CAREFULLY
Your Owner's Manual contains important information on safety, opera-
tion, and maintenance. Anyone who operates this FOURTRAX should
carefully read and understand the contents of this manual before
riding the vehicle.
AGE RECOMMENDATION
The minimum recommended age for this FOURTRAX model is 16.
Children under age 16 should never operate this vehicle.
SPECIAL MESSAGES
Honda provides many important safety messages both in this manual
and on the vehicle. For your safety and the safety of others, pay special
attention to all warnings preceded by this alert symbol
follow the warnings contained in this manual can result in SERIOUS
INJURY or DEATH.
To protect your vehicle from damage, pay attention to cautions.
The Owner's Manual should be considered a permanent part of your
FOURTRAX. It should remain with the vehicle at all times and stay with
the FOURTRAX if it is sold.
IMPORTANT NOTICES
Indicates that severe personal injury or death
will result if instructions are not followed.
Indicates a strong possibility that serious injury
or death may result if instructions are not
followed.
Indicates a possibility that equipment or property
damage could result if instructions are not
followed.
Gives helpful information.
. Failure to

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Summary of Contents for Honda FOURTRAX 350 4x4 2001

  • Page 1 Children under age 16 should never operate this vehicle. SPECIAL MESSAGES Honda provides many important safety messages both in this manual and on the vehicle. For your safety and the safety of others, pay special attention to all warnings preceded by this alert symbol .
  • Page 2 01/04/28 16:27:39 3CHN5620_002 TRX 350 FM Honda FOURTRAX 350 4 4 × OWNER’S MANUAL...
  • Page 3 01/04/28 16:27:48 3CHN5620_003 PREFACE Thank you for buying a Honda FOURTRAX. Honda takes pride in a worldwide reputation for quality in research, design, production and − service. Quality is the hallmark of all Honda products and one reason why Honda is the leading manufacturer of ATVs.

  • Page 4: Table Of Contents

    01/04/28 16:27:53 3CHN5620_004 CONTENTS Page FOURTRAX SAFETY ................Special Safety Messages ..............Warning Information ................PARTS LOCATION AND OPERATION ........... . 10 Parts Location ..................10 Parts Operation ..................14 Power Controls ................14 Lights ....................21 Gearshift Controls ................
  • Page 5 01/04/28 16:27:57 3CHN5620_005 CONTENTS Page MAINTENANCE AND REPAIRS ............. . 89 Maintenance Schedule ............... 89 Maintenance Precautions ..............91 Tool Kit ....................92 Fuel System ..................94 Lubrication ..................106 Engine ....................114 Clutch ....................

  • Page 6: Fourtrax Safety

    01/04/28 16:28:03 3CHN5620_006 FOURTRAX SAFETY SPECIAL SAFETY MESSAGES AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.
  • Page 7 01/04/28 16:28:11 3CHN5620_007 Never carry a passenger on an ATV. Never operate an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even a dirt or gravel one. Never operate an ATV without wearing an approved motorcycle helmet that fits properly.
  • Page 8 01/04/28 16:28:18 3CHN5620_008 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operat- ing the ATV. Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
  • Page 9 01/04/28 16:28:23 3CHN5620_009 Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground.
  • Page 10 01/04/28 16:28:29 3CHN5620_010 Never operate an ATV in fast flowing water or in water deeper than that specified in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. Always be sure there are no obstacles or people behind you when you operate in reverse.

  • Page 11: Warning Information

    Anyone who rides the vehicle should read and understand this information before riding. The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your Honda dealer for replacements.
  • Page 12 01/04/28 16:28:37 3CHN5620_012 While reading this manual, remember: Indicates a strong possibility that serious injury or death may result if instructions are not followed.
  • Page 13 01/04/28 16:28:50 3CHN5620_013...
  • Page 14 01/04/28 16:29:07 3CHN5620_014...

  • Page 15: Parts Location And Operation

    01/04/28 16:29:13 3CHN5620_015 PARTS LOCATION AND OPERATION PARTS LOCATION Rear brake lever Parking brake Headlight switch Engine stop switch Headlight dimmer switch Starter button Reverse selector knob Horn button Choke knob Fuel gauge Ignition switch Throttle lever Front brake lever Fig.
  • Page 16 01/04/28 16:29:18 3CHN5620_016 (10) Reverse indicator (11) Neutral indicator (12) Oil high temperature indicator (13) Multi-function display Speedometer Odometer/Tripmeter Digital clock/Hourmeter (14) Minute select button (15) Hour select button (16) Hourmeter/Digital clock select button (17) Odometer/Tripmeter select button (11) (12) (10) (13) (14)
  • Page 17 01/04/28 16:29:23 3CHN5620_017 (18) Flag pole bracket (19) Rear cargo rack (20) Seat lock lever (21) Fuel fill cap (22) Front brake fluid reservoir (23) Front cargo rack (24) Recoil starter (behind the recoil starter cover) (25) Right footpeg (26) Rear brake pedal (27) Dipstick...
  • Page 18 01/04/28 16:29:29 3CHN5620_018 (29) Accessory socket (30) Fuel valve (31) Starting primer knob (32) Storage compartment, containing: Tool kit Air pressure gauge Owner’s Manual (33) Oil filler cap (34) Gearshift pedal (35) Left footpeg (36) Trailer hitch (31) (30) (32) (29) (36) (35)

  • Page 19: Parts Operation

    01/04/28 16:29:40 3CHN5620_019 PARTS OPERATION POWER CONTROLS Ignition Switch The ignition switch (Fig. ) is in the center of the handlebars directly in front of the seat. Fig. 2-5 (1) Ignition switch Key Position Function Removal The engine and headlight can- The key can not be operated.
  • Page 20 01/04/28 16:29:46 3CHN5620_020 Engine Stop Switch The engine stop switch (Fig. ) is next to the left handgrip, and it has three positions. When the switch is in the (RUN) position, the engine will operate. When the switch is in either (OFF) position, the engine will not operate.
  • Page 21 01/04/28 16:29:54 3CHN5620_021 Choke Knob The choke knob (Fig. ) is located on the left side of the handlebar. The choke has two positions: fully ON ( ), and fully OFF ( ). To start a cold engine when air temperature is −...
  • Page 22 01/04/28 16:30:02 3CHN5620_022 Starter Button The starter button (Fig. ) is below the engine stop switch. To start the engine, press the starter button ( ), with the transmission in neutral, the ignition switch (ON) and the engine stop switch ( ) at (RUN).
  • Page 23 01/04/28 16:30:06 3CHN5620_023 Starting Primer Knob The starting primer knob (Fig. ) is on the carburetor float bowl on 2-10 the left side of the FOURTRAX. To start the engine when air temperature is below − 15 °C (5 °F), push the knob in two or three times before pressing the starter button.
  • Page 24 Pull the grip up briskly and fully. After the engine starts, allow the starter grip to return slowly. If the starter grip does not return smoothly (because of dirt in the assembly), see your Honda dealer. Fig. 2-11 (1) Recoil starter cover...
  • Page 25 01/04/28 16:30:18 3CHN5620_025 Throttle Lever The throttle lever (Fig. 2-12 ) is next to the right handgrip, and it is operated by the thumb. Pressing the lever opens the throttle. When pressure is released, spring tension automatically closes the throttle. Fig.

  • Page 26: Lights

    01/04/28 16:30:24 3CHN5620_026 LIGHTS Headlight and Dimmer Switches The headlight and dimmer switches (Fig. 2-13 ) are above the engine stop switch, next to the left handgrip. Turning the headlight switch ( ) (ON) turns the headlight on. Use the dimmer switch ( ) to select either high beam (HI) or low beam (LO).
  • Page 27 If the light does not come on with ignition switch (ON), contact your authorized Honda dealer for assistance if you cannot correct the problem. If the oil high temperature indicator comes on while you are riding, immediately bring the vehicle to a stop, turn the engine off and let it cool.
  • Page 28 01/04/28 16:30:38 3CHN5620_028 Fig. 2-14 (1) Reverse indicator (3) Oil high temperature (2) Neutral indicator indicator...
  • Page 29 01/04/28 16:30:53 3CHN5620_029 Multi-function Display (Ref. No.) Description Function Multi-function display The display includes the following functions. Speedometer Shows riding speed. Odometer Shows accumulated mileage. (page Tripmeter Shows mileage per trip. (page Digital clock Shows the time (hours and minutes). (page Hourmeter Shows hours and tenths of hours of engine operation.
  • Page 30 01/04/28 16:30:58 3CHN5620_030 Initial Display When the ignition switch is turned (ON), the display ( ) (Fig. 2-16 will temporarily show all the modes and digital segments so you can make sure the liquid crystal display is functioning properly. The digital clock will reset if the battery is disconnected. Fig.
  • Page 31 01/04/28 16:31:07 3CHN5620_031 Odometer/Tripmeter Odometer When selected, the odometer ( ) (Fig. 2-17 ) registers total distance traveled in kilometers while the ignition is (ON). To change the display ( ) from tripmeter to odometer, press and release the Odometer/Tripmeter select button ( ). Fig.
  • Page 32 01/04/28 16:31:12 3CHN5620_032 Hourmeter When selected, the hourmeter ( ) (Fig. ) shows accumulated hours 2-19 while the ignition is (ON). The hourmeter provides accurate service period information for initial and regular maintenance. To change the display from the digital clock to the hourmeter mark ( ), press and release the hourmeter/digital clock select button ( ).
  • Page 33 01/04/28 16:31:20 3CHN5620_033 Digital Clock When selected, the digital clock ( ) (Fig. ) shows the time while the 2-20 ignition is (ON). To change the display from hourmeter to digital clock, press and release the hourmeter/digital clock select button ( ). Fig.

  • Page 34: Gearshift Controls

    01/04/28 16:31:27 3CHN5620_034 GEARSHIFT CONTROLS Gearshift Pedal The gearshift pedal is near the left footpeg. One full stroke of the pedal shifts the transmission to the next higher or lower gear in the shifting sequence (Fig. 2-22 ). The pedal automatically returns to the horizontal position when released.
  • Page 35 01/04/28 16:31:33 3CHN5620_035 Reverse Selector Knob The reverse selector knob (Fig. 2-23 ) ( ) is on the rear brake lever. To shift into reverse, first bring the FOURTRAX to a complete stop and make sure the transmission is in neutral. While pushing the reverse selector knob ( ) in, squeeze the rear brake lever ( ), then depress the gearshift pedal.
  • Page 36 01/04/28 16:31:37 3CHN5620_036 While reading this manual, remember: Indicates a strong possibility that serious injury or death may result if instructions are not followed.

  • Page 37: Brake Controls

    01/04/28 16:31:46 3CHN5620_037 BRAKE CONTROLS Front Brakes The front brakes are operated by squeezing the front brake lever, near the right handgrip. Rear Brake The rear brake is operated either by depressing the brake pedal or by squeezing the rear brake lever (Fig. 2-24 Although the front and rear brakes have separate controls, your FOURTRAX’s four-wheel drive interconnects all four wheels.

  • Page 38: Fuel Tank Controls

    01/04/28 16:31:54 3CHN5620_038 FUEL TANK CONTROLS Fuel Gauge The fuel gauge (Fig. 2-25 ) ( ) shows the approximate fuel supply available. At F (Full), the fuel tank capacity including reserve is: 13.0 (3.43 US gal , 2.86 Imp gal) When the gauge needle ( ) enters the red band ( ), fuel will be low and you should refill the tank as soon as possible.
  • Page 39 01/04/28 16:31:59 3CHN5620_039 Fuel Fill Cap After refueling, be sure to tighten the fuel fill cap (Fig. ) until it 2-26 clicks. Insert the breather tube ( ) into the handlebar cover hole ( ). To refuel refer to page Fig.
  • Page 40 01/04/28 16:32:08 3CHN5620_040 Fuel Valve The fuel valve (Fig. 2-27 ) is on the left side of the fuel tank, and it has three positions: When the fuel valve is in the OFF position, fuel cannot flow to the carburetor. Turn the valve OFF whenever the FOURTRAX is not in use. When the fuel valve is in the ON position, fuel will flow from the main fuel supply to the carburetor.

  • Page 41: Engine Oil

    01/04/28 16:32:15 3CHN5620_041 ENGINE OIL Dipstick The dipstick (Fig. 2-28 ), on the right side of the front crankcase cover, is used to measure the oil level. The oil should be checked each day before operating the FOURTRAX and maintained between the upper level mark ( ) and the lower level mark ( ).

  • Page 42: Additional Features

    The flag pole bracket (Fig. 2-29 ) is on the rear cargo rack. 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.
  • Page 43 01/04/28 16:32:27 3CHN5620_043 Trailer Hitch The trailer hitch is located on the rear axle housing. As illustrated in Fig. 2-30 , 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 trailer manufacturer’s instructions.
  • Page 44 01/04/28 16:32:33 3CHN5620_044 Storage Compartment The storage compartment ( ) (Fig. ) is below the rear cargo rack 2-31 ( ). The owner’s manual ( ) and air pressure gauge ( ) are located in a plastic tray ( ) attached to the upper inside of the storage compartment.
  • Page 45 01/04/28 16:32:43 3CHN5620_045 Accessory Socket The accessory socket ( ) (Fig. 2-32 ) is attached to the left side of the front fender ( ). You can use the accessory socket to power a trouble light, spotlight, CB radio, or cell phone, etc. Do not plug in any heat-generating accessory such as an automobile cigarette lighter because it can damage the socket.
  • Page 46 01/04/28 16:32:47 3CHN5620_046 While reading this manual, remember: Indicates a strong possibility that serious injury or death may result if instructions are not followed.

  • Page 47: Riding Your Fourtrax

    01/04/28 16:32:54 3CHN5620_047 RIDING YOUR FOURTRAX This part of the Owner’s Manual discusses how to ride your FOURTRAX safely. Please review the special safety messages on pages − . While reading this manual, remember: Indicates a strong possibility that serious injury or death may result if instructions are not followed.
  • Page 48 01/04/28 16:32:57 3CHN5620_048 POTENTIAL HAZARD Failure to follow the age recommendation for this ATV. WHAT CAN HAPPEN If children use ATVs that are not recommended for their age, severe injury or death can result. Even though a child may be within the age group for which an ATV is recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident.

  • Page 49: Vehicle Preparation

    01/04/28 16:33:11 3CHN5620_049 VEHICLE PREPARATION Pre-Ride Inspection Inspect your FOURTRAX every day before you ride it. Checking the items below will take only a few minutes, and in the long run, they can save time, expense, and possibly your life. Engine oil level.
  • Page 50 01/04/28 16:33:14 3CHN5620_050 POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 51 Honda dealer for assistance. If your FOURTRAX has overturned or been involved in a collision, do not ride the vehicle until it has been inspected by an authorized Honda dealer. There may be damage or other problems you cannot see.
  • Page 52 01/04/28 16:33:31 3CHN5620_052 Loading Load Limits There are limits to how much weight can be carried on your FOURTRAX and be pulled in a trailer. The following weight limits apply to standard equipment only. Modi- fying your FOURTRAX, using non-standard equipment or riding on terrain that is not flat and smooth could further reduce these limits.
  • Page 53 01/04/28 16:33:42 3CHN5620_053 Loading and Operational Guidelines Carrying cargo or pulling a trailer will affect how your FOURTRAX handles and greatly reduce its ability in accelerating, braking and making turns and other maneuvers. Be sure to observe the weight limits and follow these guidelines: Do not place cargo anywhere on the FOURTRAX other than on the front and rear racks.
  • Page 54 01/04/28 16:33:45 3CHN5620_054 POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling, stability and braking which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load limits for this ATV. Cargo should be properly distributed and securely attached.
  • Page 55 01/04/28 16:33:50 3CHN5620_055 Accessories Genuine Honda accessories have been specifically designed for and tested on this vehicle. Because Honda cannot test all other accessories, you are personally responsible for properly selecting, installing, and using non-Honda accessories. Always follow the loading instructions...
  • Page 56 Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Honda or equivalent components designed for use on this ATV and should be installed and used according to instructions.

  • Page 57: Safe Riding Rules

    01/04/28 16:34:01 3CHN5620_057 No Modifications Modifying this FOURTRAX or removing original equipment may render the vehicle unsafe or illegal. Spark arresters and mufflers are required in most areas. Don’t modify your exhaust system. Remember, excessive noise bothers everyone and creates a bad image for off-road vehicles.
  • Page 58 01/04/28 16:34:04 3CHN5620_058 POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident.
  • Page 59 01/04/28 16:34:10 3CHN5620_059 No Passengers This FOURTRAX is designed as an operator-only vehicle. The long seat is designed to allow the rider to change body position, not for carrying a passenger. Never let a passenger ride on the seat or on the front or rear cargo racks.
  • Page 60 01/04/28 16:34:14 3CHN5620_060 No Alcohol or Drugs Alcohol, drugs and FOURTRAX’s don’t mix. Even a small amount of alcohol can impair your ability to operate a FOURTRAX safely. Likewise, drugs even if prescribed by a physician can be dangerous − −...
  • Page 61 01/04/28 16:34:19 3CHN5620_061 Off-Road Only Your FOURTRAX is designed and manufactured for off-road use only, not for pavement. Riding on pavement can affect handling and control. You should not ride your FOURTRAX on pavement. Fig. 3-3 Never ride on paved surfaces. POTENTIAL HAZARD Operating this ATV on paved surfaces.
  • Page 62 01/04/28 16:34:24 3CHN5620_062 You should never ride your FOURTRAX on public streets, roads or highways, even if they are not paved. Drivers of street vehicles may have difficulty seeing and avoiding you, which could lead to a collision. Fig. 3-4 Never ride on public roads or highways.
  • Page 63 01/04/28 16:34:28 3CHN5620_063 When riding off-road, also 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.
  • Page 64 01/04/28 16:34:32 3CHN5620_064 Keep Hands and Feet on Controls Always keep both hands on the handlebars and both feet on the footpegs when riding your FOURTRAX. This is important to maintain your balance and to control the vehicle. If you put your feet on the ground while the FOURTRAX is moving, they could come in contact with the rear wheels, causing injury.
  • Page 65 01/04/28 16:34:36 3CHN5620_065 Control Speed Riding at excessive speed increases the chance of an accident. In choosing a proper speed, you need to consider the capability of your vehicle, the terrain, visibility and other operating conditions, plus your own skills and experience. POTENTIAL HAZARD Operating this ATV at excessive speeds.
  • Page 66 01/04/28 16:34:41 3CHN5620_066 No Stunts When riding, you should keep all four wheels of your FOURTRAX on the ground. Avoid ‘‘wheelies,’’ jumps and other stunts, as they could cause loss of control. POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn.
  • Page 67 01/04/28 16:34:47 3CHN5620_067 Use Care on Unfamiliar Terrain Before riding in a new area, always check the terrain thoroughly. Don’t ride fast on unfamiliar terrain or when visibility is limited. (It’s some- times difficult to see obstructions.) Fig. 3-6 Be alert for changes in the terrain. POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 68 01/04/28 16:34:52 3CHN5620_068 Never ride past your limit of visibility. Maintain a safe distance be- tween your FOURTRAX and other off-road vehicles. Always exercise caution, and use extra care on rough, slippery and loose terrain. Fig. 3-7 Use extra care on rough terrain. POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain.

  • Page 69: Riding

    01/04/28 16:34:57 3CHN5620_069 RIDING For your initial riding practice, select a safe area free of obstacles with a level surface of dirt or sand. Practice at low speed until you are confident in shifting gears, braking, and making turns. POTENTIAL HAZARD Running the engine in an enclosed area.

  • Page 70: Starting The Engine

    01/04/28 16:35:05 3CHN5620_070 STARTING THE ENGINE Preparation Select a level surface and lock the parking brake (page ) before starting the engine. Turn the fuel valve ( ) and ignition switch ( ) to ON. Make sure the engine stop switch ( ) is at (RUN).
  • Page 71 01/04/28 16:35:13 3CHN5620_071 Starting Procedure (After Preparation) To restart a warm engine, follow the procedure for High Air Tempera- ture. The starter motor will operate only when the transmission is in neutral. Normal Air Temperature 10° 35 °C (50° 95 °F) −...
  • Page 72 01/04/28 16:35:22 3CHN5620_072 High Air Temperature 35 °C (95 °F) or above Do not use the choke. With the throttle slightly open, press the starter button ( ). Fig. 3-10 (1) Starter button Low Air Temperature 10 °C (50 °F) or below Follow the procedure for ‘‘Normal Air Temperature.’’...
  • Page 73 01/04/28 16:35:29 3CHN5620_073 Flooded Engine If the engine does not start after several attempts, it may have become flooded with excess fuel. To clear the engine: Turn the engine stop switch (OFF). Push the choke knob to the OFF position. Hold the throttle fully open and briefly press the starter button or operate the recoil starter several times.

  • Page 74: Shifting Gears

    01/04/28 16:35:38 3CHN5620_074 SHIFTING GEARS After starting the engine and letting it warm up, follow these proce- dures: With the transmission in neutral, release the parking brake, but continue squeezing the rear brake lever. With the throttle closed, raise the gearshift pedal one full stroke to shift into 1st (first) gear.

  • Page 75: Riding In Reverse

    01/04/28 16:35:48 3CHN5620_075 RIDING IN REVERSE To shift into reverse, first bring the vehicle to a complete stop and make sure the transmission is in neutral. Then follow these proce- dures: Be sure there are no obstacles or people in the way. While pushing the reverse selector knob in, squeeze the rear brake lever, then depress the gearshift pedal (page Release the rear brake lever.
  • Page 76 01/04/28 16:35:51 3CHN5620_076 POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind you.

  • Page 77: Making Turns

    01/04/28 16:35:56 3CHN5620_077 MAKING TURNS To make a turn on level ground, steer the handlebars and lean your body toward the inside of the turn. (Fig 3-11 ) Leaning helps balance the vehicle, and it feels more comfortable. Leaning into a turn is an impor- tant technique to master in riding a FOURTRAX.
  • Page 78 01/04/28 16:36:02 3CHN5620_078 Fig. 3-11 Lean your body to the inside of a turn and forward. POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN The ATV can go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner’s Manual.
  • Page 79 01/04/28 16:36:06 3CHN5620_079 The terrain surface can be a major factor affecting turns. Skidding during a turn is more likely to occur on slippery surfaces, such as snow, ice, mud and loose gravel. If you skid on ice, you may lose all directional control.

  • Page 80: Riding Up Hills

    01/04/28 16:36:10 3CHN5620_080 RIDING UP HILLS The FOURTRAX’s ability to safely climb hills largely depends on the rider’s skill and judgment. Begin by practicing on smooth, gentle slopes. As you gain experience, you’ll learn the hazards and your own limitations. You may then proceed to ride on more difficult terrain. However, you must be able to decide which hills or hazards might cause the FOURTRAX to overturn.
  • Page 81 01/04/28 16:36:15 3CHN5620_081 When climbing hills, you must shift weight 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 forward.
  • Page 82 01/04/28 16:36:20 3CHN5620_082 POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill.
  • Page 83 01/04/28 16:36:27 3CHN5620_083 Get off the FOURTRAX while you continue holding the brakes. Shift into neutral, set the parking brake and turn the engine off. Then assess the situation. If the FOURTRAX starts rolling backwards before you begin braking, keep your weight uphill, carefully apply the front brakes first, then carefully apply the rear brake as well.
  • Page 84 01/04/28 16:36:30 3CHN5620_084 POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 85 01/04/28 16:36:38 3CHN5620_085 If the hill is not too steep and you have good footing, you may be able to walk the FOURTRAX back down the hill. Make sure your intended path is clear in case you lose control of the FOURTRAX. If you decide you can walk the FOURTRAX safely: Stand with your body facing downhill, beside the vehicle so you can reach the rear brake lever with your right hand (see Figure...
  • Page 86 01/04/28 16:36:42 3CHN5620_086 While reading this manual, remember: Indicates a strong possibility that serious injury or death may result if instructions are not followed.

  • Page 87: Riding Down Hills

    01/04/28 16:36:50 3CHN5620_087 RIDING DOWN HILLS It’s usually advisable to descend hills with the FOURTRAX pointed straight downhill. Avoid angles that would cause the vehicle to lean sharply to one side. As you approach a downhill, stop and survey the terrain below. Never ride past the limit of your visibility.
  • Page 88 01/04/28 16:36:52 3CHN5620_088 POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner’s Manual. Note: a special technique is required when braking as you go down a hill.

  • Page 89: Crossing Slopes

    01/04/28 16:36:57 3CHN5620_089 CROSSING SLOPES To maintain balance and stability when riding across a slope, you need to shift weight toward the uphill side of the vehicle. To do this, move your body off the center of the seat and lean toward the uphill side. On a slippery or loose surface, you may also need to steer slightly uphill to maintain a straight course across the slope.

  • Page 90: Making Turns On Slopes

    01/04/28 16:37:02 3CHN5620_090 MAKING TURNS ON SLOPES Compared to riding on level ground, you may need to shift more weight and lean more when making turns on slopes. Do not make turns on any slopes until you have first mastered the techniques for making turns on level terrain.

  • Page 91: Riding Over Obstacles

    01/04/28 16:37:07 3CHN5620_091 RIDING OVER OBSTACLES Watch out for bumps, rain ruts, potholes and other obstacles in the terrain. When you approach any obstacle, reduce your speed and be prepared to stop. Never try to ride over large obstacles, such as large rocks or fallen logs. POTENTIAL HAZARD Improperly operating over obstacles.

  • Page 92: Riding Through Water

    01/04/28 16:37:12 3CHN5620_092 RIDING THROUGH WATER Your FOURTRAX is designed to travel through water up to approxi- mately 250 mm (10 in) deep. Before crossing a stream, make sure the water is not too deep or flowing too fast. Choose a path where both banks have gradual slopes, then proceed through the water at a slow, steady speed.

  • Page 93: Parking

    01/04/28 16:37:16 3CHN5620_093 PARKING Always choose a level place to park. After bringing your FOURTRAX to a stop, hold the brakes while you shift into neutral. Then set the parking brake and turn the ignition switch (OFF). If you’re through riding for the day, also turn the fuel valve OFF.

  • Page 94: Maintenance And Repairs

    01/04/28 16:37:26 3CHN5620_094 MAINTENANCE AND REPAIRS MAINTENANCE SCHEDULE Whichever REGULAR INITIAL FREQUENCY comes first MAINTENANCE MAINTENANCE INTERVAL 1200 Refer to ITEMS 1000 2000 page NOTE HOURS FUEL LINE − THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER (NOTE 1) 99 101 − AIR CLEANER HOUSING (NOTE 2) DRAIN TUBE...
  • Page 95 − Should be serviced by your authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. Refer to the official Honda service manual. In the interest of safety, we recommend these items be serviced only by your authorizes Honda dealer.

  • Page 96: Maintenance Precautions

    Choose a clean area that is level and has good ventilation and good light. Make sure the engine is off unless otherwise instructed. If you need to replace any parts, remember to use only new genuine Honda parts or their equivalents.

  • Page 97: Tool Kit

    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 authorized Honda dealer. The tool kit includes the following items: Standard/Phillips screwdriver...
  • Page 98 01/04/28 16:37:55 3CHN5620_098 While reading this manual, remember: Indicates a strong possibility that serious injury or death may result if instructions are not followed.

  • Page 99: Fuel System

    01/04/28 16:38:07 3CHN5620_099 FUEL SYSTEM FUEL Refueling The fuel tank capacity, including reserve, is: 13.0 (3.43 US gal , 2.86 Imp gal) The reserve fuel supply is: 3.2 (0.85 US gal , 0.70 Imp gal) To open the fuel fill cap ( ), pull out the breather tube ( ) from the handle cover hole ( ).
  • Page 100 01/04/28 16:38:11 3CHN5620_100 POTENTIAL HAZARD Refueling this ATV or handling fuel improperly. WHAT CAN HAPPEN The fuel could explode or ignite. HOW TO AVOID THE HAZARD Always refuel this ATV and handle fuel in a well-ventilated area with the engine off. Do not smoke or allow flames or sparks in the area where fuel is handled.
  • Page 101 If ‘‘spark knock’’ or ‘‘pinging’’ occurs at a steady engine speed under normal load, change brands of petrol. If spark knock or pinging persists, consult your authorized Honda dealer. Failure to do so is considered misuse, and damage caused by misuse is not covered by...
  • Page 102 Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is not yet complete.
  • Page 103 Make sure the cable does not bind or interfere with smooth operation of the throttle in any steering position. If the cable is worn or kinked, have it replaced by your Honda dealer. Throttle Free Play Throttle free play, measured at the tip of the throttle lever (Fig.
  • Page 104 01/04/28 16:38:41 3CHN5620_104 AIR CLEANER Air Cleaner The air cleaner accumulates dust and must be cleaned periodically. If the FOURTRAX is ridden in dusty areas, the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule.
  • Page 105 01/04/28 16:38:49 3CHN5620_105 Remove the screws ( ) (Fig. ) and remove the air cleaner assembly ( ) from the air cleaner housing. Unscrew the clamp ( ). Remove the air cleaner ( ) from the air cleaner body ( ). Fig.
  • Page 106 01/04/28 16:38:56 3CHN5620_106 Soak the air cleaner in clean gear oil (SAE 80 SAE 90) or an − equivalent until saturated, then squeeze out the excess oil. Twisting the air cleaner when squeezing out excess oil could damage the air cleaner. Reassemble by reversing the disassembly sequence.
  • Page 107 01/04/28 16:39:03 3CHN5620_107 Air Cleaner Housing Drain Tube The air cleaner housing drain tube (Fig. ) should be serviced in accordance with the Maintenance Schedule. (Riding through water may require more frequent inspection.) If deposits can be seen in the drain tube, the tube must be cleaned before starting the vehicle.
  • Page 108 Check the condition of the choke cable (Fig. ) and the operation of the choke knob ( ). If the cable is damaged or kinked, have it replaced by your Honda dealer. Fig. 4-8 (1) Choke cable (2) Choke knob...
  • Page 109 01/04/28 16:39:17 3CHN5620_109 Adjusting Idle Speed and Air-Fuel Mixture Do not try to compensate for faults in other systems by adjusting the carburetor. To adjust the idle speed: Wa rm up th e engine. The engine must be warm for accurate idle adjustment.
  • Page 110 For those who are mechanically proficient and have the necessary tools, installation and adjustment procedures are given in the official Honda Service Manual available from your Honda dealer. All others should have this carburetor modification performed by an authorized Honda dealer.

  • Page 111: Lubrication

    01/04/28 16:39:32 3CHN5620_111 LUBRICATION ENGINE OIL Checking Engine Oil Level and Adding Oil Check the engine oil level each day before operating your FOURTRAX and add oil if needed. To check the oil level: Make sure the vehicle is on level ground. Start the engine in a well-ventilated area and let it idle for 5 minutes.
  • Page 112 4-11 may be used when the average temperature in your riding area is within the indicated range. USE HONDA 4-STROKE OIL OR AN EQUIVALENT. Do not use oils with graphite or molybdenum additives. They may adversely affect clutch operation. Use only high detergent, premium quality motor oil certified to meet API Service Classification SE, SF or SG.
  • Page 113 01/04/28 16:39:48 3CHN5620_113 Changing the Engine Oil and Oil Filter Engine oil should be changed in accordance with the Maintenance Schedule. Use motor oils of the grade and viscosity recommended. When changing oil, drain the oil from the crankcase while the engine is still warm.
  • Page 114 Discard the oil filter ( ). Check that the oil filter cover O-rings ( ) are in good condition and then install a new oil filter. Use only the Honda genuine oil filter or a filter of equivalent quality specified for your model. Using the wrong Honda filter or a non-Honda filter which is not of equivalent quality may cause engine damage.
  • Page 115 If a torque wrench was not used for installation, see your authorized Honda dealer before operating the vehicle to verify proper assembly. While reading this manual, remember: Indicates a strong possibility that serious injury or...
  • Page 116 01/04/28 16:40:15 3CHN5620_116 REAR FINAL GEAR CASE OIL Change the oil in the rear final gear case when specified by the Main- tenance Schedule. Change the oil with the final gear case warm, and the FOURTRAX on level ground to assure complete and rapid draining. To change the rear final gear case oil: To drain the oil, first place an oil drain pan under the oil drain plug (Fig.
  • Page 117 01/04/28 16:40:25 3CHN5620_117 DIFFERENTIAL OIL Change the oil in the differential when specified by the Maintenance schedule. Change the oil with the differential warm, and the FOURTRAX on level ground to assure complete and rapid draining. To change the differential oil: To drain the oil, first place an oil drain pan under the oil drain plug (Fig.
  • Page 118 01/04/28 16:40:28 3CHN5620_118 Fig. 4-15 (1) Oil filler cap (3) Lower edge of (2) Oil drain plug inspection hole...

  • Page 119: Engine

    ( ) should not be eroded. If the electrodes and insulator tip appear unusually fouled or burned, we suggest that you contact your authorized Honda dealer. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped.
  • Page 120 For those who are mechanically proficient and have the proper tools, instructions on adjusting valve clearances are given in the official Honda Service Manual. All others should have valves adjusted by an authorized Honda dealer.

  • Page 121: Clutch

    01/04/28 16:40:53 3CHN5620_121 CLUTCH Clutch Adjustment To adjust the clutch: Make sure the ignition switch is (OFF). Loosen the lock nut (Fig. 4-17 ), and turn the clutch adjuster ( ) counterclockwise until you feel slight resistance. Then turn the adjuster 1/4 turn clockwise, and tighten the lock nut to hold the adjuster in this position.
  • Page 122 Tighten the lock nut and reinstall the sleeve. Other Checks: Check the reverse assist lever and cable for loose connections or other damage. If the cable is worn or kinked, have it replaced by your Honda dealer. 2 4 mm −...

  • Page 123: Electrical System

    The battery is sealed, so it is not necessary to check the electrolyte level or add distilled water. If the battery seems weak, see your authorized Honda dealer for information on recharging or replacement. If you replace the battery, choose one that is sealed and equivalent to the original.
  • Page 124 01/04/28 16:41:21 3CHN5620_124 Battery Removal Make sure the ignition switch is (OFF). Remove the seat (page To remove the rear fender lid ( ), remove the clips ( ) (Fig. 4-19 (Fig.4-20) Release the rings and remove the rubber band ( ). Disconnect the negative ( ) terminal lead ( ) from the battery ( ) −...
  • Page 125 01/04/28 16:41:25 3CHN5620_125 Fig. 4-20 (3) Battery (5) Negative ( ) terminal − (4) Rubber band lead (6) Positive ( ) terminal ＋ lead...
  • Page 126 × 2, 10 A × If a fuse fails frequently, it usually indicates a short circuit or an over- load in the electrical system. See your authorized Honda dealer for repair. Fig. 4-21 (1) Fuse box (2) Fuse box cover...
  • Page 127 01/04/28 16:41:40 3CHN5620_127 Remove the seat (page Remove the rear fender lid (page Remove the fuse box cover (page Pull the old fuse out of the clips. Push a new fuse into the clips and install the fuse box cover. Install the rear fender lid.
  • Page 128 01/04/28 16:41:47 3CHN5620_128 Remove the seat (page Remove the rear fender lid (page Remove the fuse box cover (page Pull the old fuse out of the clips. Push a new fuse into the clips and install the fuse box cover. Install the rear fender lid.
  • Page 129 01/04/28 16:41:50 3CHN5620_129 While reading this manual, remember: Indicates a strong possibility that serious injury or death may result if instructions are not followed.

  • Page 130: Brakes

    01/04/28 16:41:57 3CHN5620_130 BRAKES FRONT BRAKES This FOURTRAX has hydraulic front drum brakes on both front wheels. Each day before riding you should check the brake lever free play and inspect the system for fluid leaks. The brake fluid level should be checked frequently, and the brake shoe linings should be inspected periodically.
  • Page 131 1.0 mm (0.04 in) If either lining is worn beyond the limit, both brake shoes must be replaced by an authorized Honda dealer. If the brake lever free play and the brake shoe lining thicknesses are within the recommended limits, reinstall the inspection hole plugs, seating them into the inspection holes as shown in Fig.
  • Page 132 Recheck the brake lever free play. If free play is still excessive after adjusting the brake lining clearance, there is probably air in the brake system and it must be bled out. See your authorized Honda dealer for this service.
  • Page 133 Honda dealer. If the fluid level approaches the lower level mark ( ), the brake system should be inspected by your authorized Honda dealer. A low fluid level may indicate fluid leakage. Brake failure may occur if this condition exists and is not corrected.
  • Page 134 Other Checks: Make sure there are no fluid leaks. Check the condition of brake hoses and fittings. If the hoses are worn or cracked, have them replaced by an authorized Honda dealer.
  • Page 135 01/04/28 16:42:31 3CHN5620_135 REAR BRAKE This FOURTRAX has a single mechanical drum brake on the rear axle housing. Each day before riding you should check the operation of both the rear brake pedal and the rear brake lever. You should also periodically check the brake shoes for wear.
  • Page 136 01/04/28 16:42:36 3CHN5620_136 To adjust the free play, turn the brake pedal adjusting nut ( ), (Fig. ), located on the brake operating rod at the rear of the frame. 4-29 Make sure the cut-out on the adjusting nut is properly seated on the brake arm pin ( ).
  • Page 137 01/04/28 16:42:42 3CHN5620_137 To check and adjust brake lever free play: Measure the distance the rear brake lever moves before the brake starts to take hold. Free play, measured at the tip of the brake lever (Fig. 4-30 ), should be: 15 20 mm (0.6 0.8 in) −...
  • Page 138 ( ) on the brake panel (see Fig. 4-31 If the arrow aligns with the reference mark on full application of the brake, the brake shoes must be replaced. See your authorized Honda dealer for this service. Fig. 4-31...
  • Page 139 ) from the front brakes, and the drain bolt (Fig. 4-33 ) from the bottom of the rear brake cover. If any water drains, the brake seals must be replaced by your Honda dealer as soon as possible. Fig. 4-32 (1) Front brake inspection hole plug Fig.

  • Page 140: Wheels And Tyres

    01/04/28 16:43:04 3CHN5620_140 WHEELS AND TYRES WHEEL REMOVAL If you need to remove a wheel from your FOURTRAX, follow these procedures: Raise the front (or rear) wheels off the ground and place a support securely under the vehicle. Loosen the wheel nuts (Fig. 4-34 ) with a 17 mm socket wrench.
  • Page 141 01/04/28 16:43:15 3CHN5620_141 If a torque wrench was not used for installation, see your authorized Honda dealer before operating the vehicle to verify proper assembly. Fig. 4-34 (1) Wheel nuts (2) Wheel rim TYRES This FOURTRAX is equipped with low pressure tubeless tyres.
  • Page 142 01/04/28 16:43:29 3CHN5620_142 FRONT REAR TYRE SIZE AT24 × 8-12 ★★ AT24 × 9-11 ★★ TYRE BRAND DIRT HOOKS DIRT HOOKS BRIDGESTONE BRIDGESTONE RECOMMENDED 25 kPa (0.25 kgf/cm , 25 kPa (0.25 kgf/cm , 3.6 psi) 3.6 psi) PRESSURE MAXIMUM 28 kPa (0.28 kgf/cm , 28 kPa (0.28 kgf/cm , PRESSURE...
  • Page 143 01/04/28 16:43:36 3CHN5620_143 Tyre Tread Condition To check the condition of a tyre tread, measure the groove depth ( ) (Fig. ) in the center of the tyre, or check the wear indicator ( ). 4-36 The minimum tread depth is 4 mm (0.16 in). When the tread depth is less than recommended, the tyre should be replaced.
  • Page 144 Follow the instructions provided with the repair kit to make a temporary repair. As soon as possible, have the tyre permanently repaired by an authorized Honda dealer. Any tyre that cannot be repaired should be replaced. Whenever the FOURTRAX is to be operated far from service facilities or available transportation, we recommend that you carry a tyre pump and a repair kit with the vehicle.

  • Page 145: Seat Removal

    01/04/28 16:43:47 3CHN5620_145 SEAT REMOVAL To remove the seat (Fig. 4-37 ), pull up the seat lock lever ( ) at the right side of the seat and lift it up. To reinstall the seat, insert the prongs ( ) into the hooks ( ) on the frame, and press the studs ( ) into the grommets on the battery holder.

  • Page 146: Engine Guard And Skid Plates

    01/04/28 16:43:53 3CHN5620_146 ENGINE GUARD AND SKID PLATES The engine guard (Fig. 4-38 ) protects the engine crankcase. The skid plates ( ) protect the frame and rear final gear case. Check the guard and plates for cracks, damage or looseness at intervals shown in the Maintenance Schedule (page 89 90 −...

  • Page 147: Spark Arrester

    01/04/28 16:44:00 3CHN5620_147 SPARK ARRESTER The exhaust system must be periodically purged of accumulated carbon. To purge the system: Select a well-ventilated area free of combustible materials and make sure the exhaust pipe is cool. Remove the bolt. (Fig. 4-39 Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel.
  • Page 148 01/04/28 16:44:03 3CHN5620_148 POTENTIAL HAZARD Improperly purging the exhaust system. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When purging the exhaust system: Always wear eye protection, and make sure no one stands behind the vehicle.

  • Page 149: Driveshaft Boots

    01/04/28 16:44:08 3CHN5620_149 DRIVESHAFT BOOTS Check the rubber driveshaft boots ( ) for damage or leaking grease. If necessary, have your authorized Honda dealer replace them. Fig. 4-40 (1) Drive shaft boots...
  • Page 150 01/04/28 16:44:11 3CHN5620_150 While reading this manual, remember: Indicates a strong possibility that serious injury or death may result if instructions are not followed.

  • Page 151: Transporting Your Fourtrax

    Turn the fuel valve OFF. Secure the vehicle with ‘‘tie downs’’ in the areas shown (Fig. 4-41 Suitable ‘‘tie downs’’ are available from your Honda dealer. Ordinary rope is not recommended because it can stretch under load. Using tie downs in any other areas can damage your FOURTRAX.
  • Page 152 01/04/28 16:44:25 3CHN5620_152 Fig. 4-42 Points to secure (2) Rear cargo rack FOURTRAX with (3) Trailer hitch tie downs If it is necessary to incline your FOURTRAX upright on the rear end: Follow steps on the previous page. Place a suitable container under the carburetor drain tube. Turn the drain screw counterclockwise and drain the fuel from the carburetor.
  • Page 153 01/04/28 16:44:28 3CHN5620_153 POTENTIAL HAZARD Inclining this ATV without first draining fuel from the carburetor. WHAT CAN HAPPEN The fuel could explode or ignite. HOW TO AVOID THE HAZARD Always drain fuel from the carburetor before inclining this ATV. Always handle fuel in a well-ventilated area with the engine off. Do not smoke or allow flames or sparks in the area where fuel is handled.

  • Page 154: Cleaning Your Fourtrax

    01/04/28 16:44:35 3CHN5620_154 CLEANING YOUR FOURTRAX CLEANING Clean your FOURTRAX regularly to protect the surface finishes and inspect for damage, wear, and oil or brake fluid leakage. Avoid cleaning products that are not specifically designed for ATV or automobile surfaces. They may contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic on your FOURTRAX.
  • Page 155 01/04/28 16:44:43 3CHN5620_155 Rinse the FOURTRAX thoroughly with cool water to remove loose dirt. Clean the FOURTRAX with a sponge or soft cloth using cool water. Avoid directing water to muffler outlets and electrical parts. After cleaning, rinse the FOURTRAX thoroughly with plenty of clean water.Detergent residue can corrode alloy parts.

  • Page 156: Storing Your Fourtrax

    01/04/28 16:44:48 3CHN5620_156 STORING YOUR FOURTRAX STORAGE Before storing your FOURTRAX for an extended time, be sure you thoroughly check the vehicle for needed repairs and have them corrected. Otherwise, the repairs may be forgotten by the time you remove the vehicle from storage. In addition, extended storage requires that you take the following steps to reduce the effects of deterioration from non-use of the vehicle: Change the engine oil and oil filter.
  • Page 157 01/04/28 16:44:52 3CHN5620_157 POTENTIAL HAZARD Refueling this ATV or handling fuel improperly. WHAT CAN HAPPEN The fuel could explode or ignite. HOW TO AVOID THE HAZARD Always refuel this ATV and handle fuel in a well-ventilated area with the engine off. Do not smoke or allow flames or sparks in the area where fuel is handled.
  • Page 158 01/04/28 16:44:58 3CHN5620_158 Remove the spark plug and pour one tablespoon (15 20 cm ) of − clean engine oil into the cylinder. Operate the starter for a few seconds to distribute the oil, then reinstall the spark plug. (Make sure the engine stop switch is (OFF) before pressing the starter button.) Remove the battery (page ) and store it in an area protected...

  • Page 159: Specifications

    01/04/28 16:45:14 3CHN5620_159 SPECIFICATIONS DIMENSIONS Overall length 1,983 mm (78.1 in) Overall width 1,143 mm (45.0 in) Overall height 1,130 mm (44.5 in) Wheelbase 1,246 mm (49.1 in) WEIGHT Dry weight 238 kg (525 lbs) CAPACITIES Engine oil 2.5 (2.6 US qt , 2.2 Imp qt) Fuel tank 13.0 (3.43 US gal , 2.86 Imp gal) Fuel reserve...
  • Page 160 01/04/28 16:45:31 3CHN5620_160 POWER TRANSMISSION Primary reduction 2.188 Secondary reduction 1.933 Final reduction Front: 3.769 Rear: 3.692 Gear ratio 1st 3.455 1.933 1.333 0.966 0.720 Reverse gear ratio 4.600 Noise level (ISO 5131) 80.0 dB (A) Vibration on seat Not exceed 0.5 m/s (EN 1032, ISO 5008) Vibration on handlegrip 3.27 m/s...

  • Page 161: Wiring Diagram

    01/04/28 16:45:45 3CHN5620_161 WIRING DIAGRAM...

  • Page 162: Serial Numbers And Color Label

    01/04/28 16:45:55 3CHN5620_162 SERIAL NUMBERS AND COLOR LABEL The frame, engine and key numbers (Fig. ) will be needed when you order replacement parts. The color is also helpful. Record the numbers and color here for your reference. The frame serial number ( ) is stamped on the front of the frame. The engine serial number ( ) is stamped on the upper side of the rear crankcase.

  • Page 163: Index

    01/04/28 16:46:01 3CHN5620_163 INDEX Accessories .................... . 50 Accessory socket ..................40 Age recommendation ................42 Air cleaner Filter ..................... 99 Housing drain tube ................102 Air pressure gauge ................. . 39 Apparel, recommended ................52 Battery ....................
  • Page 164 01/04/28 16:46:06 3CHN5620_164 Cleaning ....................149 Climbing hills ..................75 Clutch adjustment ................. 116 Crossing slopes ..................84 Differential oil ..................112 Digital clock .................... . 28 Dimmer switch ..................21 Dipstick ................... . 36, 106 Display (see Multi-function display) .............
  • Page 165 01/04/28 16:46:11 3CHN5620_165 Final gear case oil ................. 111 Flag pole bracket ..................37 Flooded engine ..................68 Fuel Fuel fill cap ..................34, 94 Fuel gauge ................... 32 Fuel recommendations ............... 96 Fuel tank capacity ................
  • Page 166 01/04/28 16:46:17 3CHN5620_166 Idle speed adjustment ................104 Ignition switch ..................14 Indicator Neutral indicator ................. . 22 Oil high temperature indicator ............22 Reverse indicator ................. 22 Inspection, pre-ride ................. 44 Loading Loading guidelines and procedures ..........
  • Page 167 01/04/28 16:46:22 3CHN5620_167 Parking ..................... 88 Parts location ................... 10 Parking brake ................... 32 Passenger carrying ................. 54 Pavement, no riding on ................56 Pinging ..................... 96 Pre-ride inspection ................. . 44 Rear final gear case oil ................
  • Page 168 01/04/28 16:46:26 3CHN5620_168 Throttle Cable ....................98 Lever ....................20, 98 Tool kit ..................... 93 Trailer hitch .................... . 38 Trailer towing Operational guidelines ............... . 48 Weight limits ..................47 Transporting procedures ..............146 Tripmeter ....................
  • Page 169 DENMARK SPAIN Tel.: 069-83091 Tel.: 6-17.41.00 Tel.: 33-77.10.00 HONDA FRANCE HONDA NEDERLAND B.V. HONDA MOTOR DE PORTUGAL SA Parc d’Activités Paris-Est Nikkelstraat 17 Bairro de Sao Francisco Lote 1-7 B.P. 46 Cedex 2 NL-2984 AM RIDDERKERK Corpo Norte-2-Piso Camarate F-77312 MARNE-LA-VALLEE...

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