This manual contains the information on how to do that; please read it carefully. This owners manual describes the operation and maintenance of the HP400 power carrier. All information in this publication is based on the latest product information available at the time of printing.
SAFETY LABEL LOCATIONS The labels shown here contain important safety information. Please read them carefully. These labels are considered permanent parts of your power carrier, so if a label comes off or becomes hard to read, contact your authorized Honda power carrier dealer for a replacement.
SAFETY INFORMATION Honda power carriers are designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the power carrier. Failure to do so could result in personal injury or equipment damage. Keep children and pets away from the area of operation to avoid possible injury from contact with the power carrier.
*FRAME SERIAL CARRIER TRACK STEERING CLUTCH LEV GEAR SHIFT LEVE *Record the frame and engine serial numbers for your reference. Refer to the serial numbers when ordering parts, and when making technical or warranty inquiries (see page 49). Frame serial number: Engine serial number: 2.
3. CONTROLS Fuel valve The fuel valve opens and closes the fuel passage to the carburetor. Turn the fuel valve to the ON position before starting the engine and to the OFF position when the engine is stopped. When the power carrier is not in use, always leave the fuel valve in the OFF position to reduce the possibility of fuel leakage.
Throttle lever The throttle lever controls engine speed. When the throttle lever is moved to the START (CHOKE) position, it also closes the choke for cold starting. The choke is open when the throttle lever is in the HI, NORMAL, or LO position. Starter grip Pull the starter grip to operate the recoil starter.
Gear shift lever Use the gear shift lever to select drive speed or to back up. Shift gears with the engine running and the drive clutch levers released. Drive clutch levers Use the drive clutch levers to propel or stop the power carrier. The two levers are connected and move simultaneously.
Steering clutch levers Use the steering clutch levers to steer the power carrier. Pull up the right lever to steer right. Pull up the left lever to steer left. STEERIN LEVERS Carrier bed release lever Pull the release lever to unlock the carrier bed when you wish to tilt the bed for dumping a load.
Fuel Recommendation Check the power carrier on level ground with the engine stopped. Unscrew the fuel tank cap, and check the fuel level. Refill the tank if the fuel level is low. Do not fill above the UPPER LEVEL. Gasoline is extremely flammable and is explosive under certain conditions.
Occasionally you may hear light “spark knock’ or “pinging” (metallic rapping noise) while operating under heavy loads, This is no cause for concern. If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. authorized Honda power carrier dealer.
ENGINE OIL Engine oil is a major factor affecting engine performance and service life. Nondetergent oils and 2-stroke oils are not recommended be- cause they have inadequate lubricating characteristics. Check the oil level with the power carrier on a level surface and the engine stopped.
AIR CLEANER 1. Remove the two wing bolts to remove the air cleaner cover. Remove and inspect the air cleaner elements. follow the cleaning procedure described on page 33. 3. Reinstall the air cleaner elements, cover and wing bolts. Securely tighten the wing bolts.
5. STARTING THE ENGINE Starting the engine 1. Check that the gear shift lever is in the NEUTRAL position. Allow the drive clutch levers to remain in the STOP position. GEAR SHIFT LEVER STOP NEUTRAL 2. Turn the fuel valve to the ON position. Check for tighteness of drain knob.
3. Move the throttle lever to the START (CHOKE) position. START (CHOKE) THROTTLE LEVER NOTE: If restarting a warm engine, the choke will not be needed. Restart a warm engine with the throttle lever in the LO position. 4. Turn the engine switch to the ON position.
5. Pull the starter grip lightly until you feel resistance, then pull briskly. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter. Do not pull the starter grip while the engine is running, as that may damage the starter.
1. Move the throttle lever to the LO position. THROTTLE LEVER 2. Move the gear shift lever to the desired position. To avoid loss of control, descend steep slopes in low (1) gear, using LO throttle position. Do not shift gears while the power carrier is moving. Ai ways shift gears with the engine running and the drive clutch levers released.
3. Squeeze the drive clutch levers down against the handlebars smoothly and quickly. After the power carrier starts to move, adjust the throttle lever to maintain the desired speed. DRIVE CLUTCH LEVERS If the engine stalls on a slope, release the drive clutch levers immediately to stop the power carrier...
High altitude operation At high altitude, the standard Performance will decrease, and fuel consumption mixture will also foul the spark plug, cause hard starting and contribute to air pollution. High altitude performance main fuel jet in the carburetor and readjusting the pilot screw. If you always operate the engine at altitudes higher than 1,800 meters (6,000 feet) above sea level, have an anthorized carburetor modification.
EMERGENCY STOP In an emergency: 1. To stop the engine in an emergency, position. NORMAL STOP 1. Release the drive clutch levers to disengage the drive and apply the brake. 2. Move the gear shift lever to the NEUTRAL position. turn the engine switch to the OFF DRIVE CLUTCH LEVERS GEAR SHIFT LEVER...
3. Move the throttle lever to the LO position. THROlTOLE LEVER 4. Turn the engine switch to either OFF position. ENGINE SWlTCH...
5. Turn the fuel valve to the OFF position.
Load carrying safety To avoid accidents or overturning: Observe the load limits described on page 27. Do not stack the load so that the power carrier becomes top-heavy and unstable. Carry only lightweight loads when the carrier side rails are extended. Do not allow the load to protrude from the power carrier or block visibility.
Tie-down hooks Secure the load in the carrier bed with strong ropes or straps attached to the tie-down hooks. Do not attach ropes or straps to locations other than the tie-down hooks. Side rails and side plates The side rails may be extended carrying bulky, lightweight To extend the side rails, loosen the four lock bolts, pull both side rails out an equal amount, then tighten the lock bolts securely.
Using the front stopper plate To open the front stopper plate, observe the following: 1. Slowly press down on the right and left lock release levers. Do not push the release levers quickly, or the stopper plate will swing open suddenly. 2.
Dumping loads Dump loads with the power carrier stopped released. 1. Pull the carrier bed release lever, and tilt the carrier bed by lifting the handlebar. 2. After dumping the load, push down firmly on the handlebar carrier bed in the normal position. CARRIER BEb RELEASE LEVER Before operating the power carrier, check that the carrier bed is locked.
Load carrying capacity For operation on level ground- Maximum load: 400 kg (881 lb) Maximum load height: 900 mm (35.4 in) For operation on slopes- Maximum load: 250 kg (551 lb) Maximum load height : 600 mm (23.6 in) Maximum slope: 25” upward/l 5” downwardLoad NOTE: To carry sand, gravel or dirt, extend the side rails with the front and side plates raised.
9. MAINTENANCE Periodic maintenance in good operating condition. Inspect or service as scheduled in the table below. Shut off the engine before performing any maintenance. If the engine must be run, make sure the area Is well ventilated. Exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
Maintenance schedule Your power carrier should be serviced regularly to assure maximum service life. REGULAR SERVICE ITEM Performateveryindicatedmonthoroperating hour interval, whichever comes first. Engine oil Check level Change Air cleaner Check Clean Tracks Check Adjust Drive clutch cable Check-Adjust Fuel line Check (Replace if necessary) NOTE:...
Tool Kit The tools supplied with the carrier are necessary for performing some periodic maintenance, simple adjustments and repairs. Always keep the tool kit with the carrier. TOOL BAG WRENCH 10 x 14 WRENCH 19 (2) OPEN END WRENCH 10 x 12 SPARK PLUG WRENCH HANDLE SPARK PLUG WRENCH OIL FUNNEL...
Engine oil change NOTE: Drain the oil while the enoine is still warm to assure rapid and complete draining. Changing the oil Remove the engine oil filler cap and loosen the oil drain bolt. Set the oil funnel as shown, remove the oil drain bolt and drain the oil into a suitable container.
Spark plug service Recommendedsparkplug: To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. 1. Remove the spark plug cap. The muffler becomes very hot during operation and re- mains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot.
If installing a new spark plug, tighten l/2 turn after the spark plug seats to compress the washer. If reinstalling after the spark plug seats. 1 NOTICE The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and may damage the engine. Use only the recommended spark plug or equivalent.
Adjusting the track tautness If the tracks are not properly taut, they may slip off the wheels or their service life may be markedly reduced. Inspection Check that the slackness (about 10 kg, 22.1 lb) is applied to the middle of the tracks. Track adjustment 1.
Adjusting the drive clutch cable The clutch will slip and the power carrier may not move unless the drive clutch cable is adjusted properly. Measure and record the clearance holder with the drive clutch levers at their applied position (DRIVE). Next, measure the same clearance again with the levers at their released position (STOP).
Adjusting the brake cable 1. Check whether the brake spring collar is 14 -16 mm (0.55-0.63 spring holder when the drive clutch levers are at their released (STOP) position. 2. To adjust, loosen the lock nuts with the levers still at the stop position and set the distance to the prescribed value.
Checking brake wear Check the brake shoe wear indication only after the brake cable has been properly adjusted. Brake shoe wear is OK if you cannot see the “A” mark through the brake arm hole, when the drive clutch lever is in its released position (STOP). However, if you can see any part of the (“A”) mark, the brake has worn past its service limit;...
Adjusting the steering clutch cable Steering control will be impaired adjusted properly. 1. With the engine off, rock the power carrier forward and backward to find the position at which each lever can be pulled closest to the handle grip. 2.
Adjusting the dumping lock cable 1. With the carrier locked, check whether the play at the end of the carrier bed release lever is 15-20 mm (0.55-0.79 2. To adjust, loosen the lock nut and turn the adjust bolt to set the prescribed distance.
Checking the transmission oil Remove the check bolt and check that the oil is up to the lower edge of the check bolt hole. If it is low, refill with engine oil of the classification mended on page 12. Checking the clutch oil Remove the check bolt and check that the oil is up to the lower edge of the check bolt hole.
Spark arrester maintenance (Optional part) The muffler becomes very hot during operation and re- mains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Allow it to cool before proceeding. Th e spark arrester must be serviced every 100 hours to maintain its efficiency.
Lubrication Grease the points noted below, at least once a year or after any time you have washed the carrier. Recommended grease: SAE multipurpose grease. CARRIER JOINT SECTION JOINT SECTION CARRIER BED RELEASE GEAR SHIkT LEVER LOCK SECTION JOINT SECTION...
Temporary installation of a disengaged track In the unlikely event that a track slips off the sprockets proceed with the following: 1. Stop the engine (refer to page 20). 2. Remove any load in the carrier, by hand. Do not empty it by dumping the carrier.
6. Remove the sprocket. 7. Place the track over the driven wheel, and engage the sprocket with the track teeth. 8. Push the sprocket and track toward the rear, then slide the sprocket onto the sprocket shaft. 9. lnstal and tighten the sprocket bolts securely. DRIVEN WHEEL / - / TRACK...
When transporting or storing the power carrier, make sure the engine switch is in the STOP position and the spark plug cap is disconnected accidental engine start up. To avoid,severe burns or fire hazards, let the engine cool before transporting the power carrier or storing it indoors. When transporting the power carrier, turn the fuel valve to the OFF position, and keep the engine level to prevent fuel spillage.
5. Change the engine oil (see page 31 for details). 6. Clean the air cleaner (see page 33 for details). 7. Clean the power carrier and inspect all parts to make sure they are securely tightened. Lubricate the points noted on page 42. NOTE: If the carrier will be stored for more than three months, remove the spark plug, pour one tablespoon reinstall the spark plug securely.
To assure maximum unnecessarily. If the following basic troubleshooting carrier back to work, it is time to consult your authorized Check the following points if the engine does not start. Is there sufficient fuel? Is there sufficient engine oil? Is there a spark at the spark plug? a.
Transmission oil capacity Track width x length NOTE: Specifications ments. Honda power carrier HP400 (BA) 4-stroke, overhead valve, 1 cylinder 118 cm3 (7.2 cu in) 60 x 42 mm (2.4 x 1.7 in) Transistorized 0.6 e (0.63 US gal, 0.53 Imp gal) 1.6 V (1.68 US gal, 1.41 Imp gal)
13. CUSTOMER SERVICE INFORMATION Honda power equipment They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, it with the dealership’s Manager can halp. Almost all problems are solved in this way. If you are dissatisfied ment, contact the Honda Power Equipment Customer Service Office.
14. INDEX CARRYING LOADS ... Dumping loads..Load carrying capacity..Load carrying safety ... Side rails and side plates..Tie-down hooks ... Using the front stopper plate ... COMPONENT IDENTIFICATION CONTROLS Carrier bed release lever ... Drive clutch levers ... Engine switch ...