Honda TRX420TM Owner's Manual
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Honda TRX420TM Owner's Manual

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  • Page 3 Honda TRX420TM/FM FOURTRAX 420/4 4 OWNER’S MANUAL...
  • Page 4 Introduction Congratulations on choosing your Honda ATV. When you own a Honda, you’re part of a worldwide family of satisfied customers people who appreciate Honda’s reputation for building quality into every product. Your Honda was designed as a recreational ATV for off-road use by one rider only.
  • Page 5 Introduction If you have any questions, or if you ever need special service or repairs, remember that your Honda dealer knows your ATV best and is dedicated to your complete satisfaction. Happy riding! Introduction...

  • Page 6: A Few Words About Safety

    A Few Words About Safety Your safety, and the safety of others, is very important. And operating this ATV safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.
  • Page 7 A Few Words About Safety These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions.
  • Page 8 Contents These pages give an overview of the contents of your owner’s manual. The first page of each section lists the topics covered in that section. ATV Safety ..................Important safety information you should know, plus a look at the safety related labels on your ATV.
  • Page 9 Contents Servicing Your Honda ..............Why your ATV needs regular maintenance, what you need to know before servicing your Honda, an owner maintenance schedule, and instructions for specific maintenance and adjustment items. Tips ....................How to store and transport your ATV and how to be an environmentally responsible rider.

  • Page 11: Atv Safety

    ATV Safety This section presents some of the most important information and recommendations to help you ride your ATV safely. Please take a few moments to read these pages. This section also includes information about the location of safety labels on your ATV. Important Safety Information ...............

  • Page 12: Important Safety Information

    Important Safety Information Your ATV can provide many years of service and pleasure if you take responsibility for your own safety and understand the challenges you can meet while riding. There is much that you can do to protect yourself when you ride. You’ll find many helpful recommendations throughout this manual.
  • Page 13 Important Safety Information Ride Off-road Only Your ATV is designed and manufactured for off-road use only. The tyres are not made for pavement, and the ATV does not have turn signals and other features required for use on public roads. If you need to cross a paved or public road, get off and walk your ATV across.
  • Page 14 So don’t drink and ride, and don’t let your friends drink and ride either. Keep Your Honda in Safe Condition It’s important to keep your ATV properly maintained and in safe riding condition. Having a breakdown can be difficult, especially if you are stranded off-road far from your base.

  • Page 15: Safety Labels

    Anyone who rides the vehicle should read and understand this information before riding. The labels should be considered permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your Honda dealer for replacements. ATV Safety...
  • Page 16 Safety Labels (TRX420TM) Engine net power Machine mass (TRX420FM) Engine net power Machine mass ATV Safety...
  • Page 17 Safety Labels ATV Safety...
  • Page 18 Safety Labels (TRX420FM only) ATV Safety...

  • Page 19: Table Of Contents

    Instruments & Controls This section shows the location of all indicators and controls you would normally use before or while riding your ATV. The items listed on this page are described in this section. Instructions for other components are presented in other sections of this manual where they will be most useful.
  • Page 20 Instruments & Controls Controls & Features ................Fuel Valve ..................Ignition Switch .................. 2WD/4WD Select Lever ( TRX420FM only) ........Start Button ..................Engine Stop Switch ................Headlight Switch ................Headlight Dimmer Switch ..............Horn Button ..................Recoil Starter ..................Throttle Lever ...................

  • Page 21: Operation Component Locations

    Operation Component Locations reverse selector knob headlight switch parking brake lock lever horn button rear brake lever/ front brake parking brake lever lever headlight throttle lever dimmer switch ignition switch 2WD/4WD select lever start button (TRX420FM only) engine stop switch Instruments &...
  • Page 22 Operation Component Locations rear cargo rack seat latch front cargo rack recoil starter fuel valve rear brake pedal Instruments & Controls...
  • Page 23 Operation Component Locations flag pole bracket shift lever trailer hitch Instruments & Controls...

  • Page 24: Indicators & Displays

    Indicators & Displays The indicators and displays on your ATV keep you informed, alert you to possible problems, and make your riding safer and more enjoyable. Refer to the indicators frequently. Their functions are described on the following pages. (3) (4) (5) (1) reverse indicator (5) PGM-FI indicator (2) neutral indicator...
  • Page 25 ) and remains on until you shift out of 4WD mode. If one of these indicators does not come on when it should, have your Honda dealer check for problems. Display Check When the ignition switch is turned ON (...
  • Page 26 ON ( ). If the indicator comes on at any other time, reduce speed and take your vehicle to a Honda dealer as soon as possible. Lamp Check. Instruments & Controls...
  • Page 27 Indicators & Displays Multi-function The display includes the following display functions. Display Check. Gear position Shows the gear position (page indicator Oil change Lights when specified maintenance indicator interval for engine oil change is reached (page Speedometer Shows riding speed. Odometer Shows accumulated mileage (page...

  • Page 28: Multi-Function Display

    Indicators & Displays Multi-function Display The multi-function display ( ) includes the following functions: Gear position indicator Oil change indicator Speedometer Odometer Tripmeter Hourmeter (1) multi-function display (4) speedometer (2) gear position indicator (5) odometer/tripmeter/ (3) oil change indicator hourmeter Instruments &...

  • Page 29: Gear Position Indicator

    OFF ( ) position, and then turn it back to the ON ( position again. If the gear position indicator still shows ‘‘ ’’ and blinks, see your Honda dealer. (1) gear position indicator Instruments & Controls...

  • Page 30: Oil Change Indicator

    Indicators & Displays Oil Change Indicator The oil change indicator ( ) appears in the display when the mileage or operating hours on your ATV approaches the oil change interval specified on the maintenance schedule. Reset the indicator after each oil change. To reset the indicator, press and hold the hourmeter/odometer/tripmeter select button ( ) and turn the ignition switch ( ) to ON ( ) for more than 5 seconds.

  • Page 31: Odometer

    Indicators & Displays Odometer When selected, the odometer ( ) registers total distance traveled in kilometers while the ignition is ON ( ). To change the display from tripmeter or hourmeter to odometer, press and release the hourmeter/ odometer/tripmeter select button ( ). (1) odometer (2) hourmeter/odometer/tripmeter select button Tripmeter...

  • Page 32: Hourmeter

    Indicators & Displays Hourmeter When selected, the hourmeter ( ) shows accumulated hours while the ignition is ON ( ). The hourmeter provides accurate service period information for initial and regular maintenance. To change the display from odometer or tripmeter to hourmeter, press and release the hourmeter/odometer/tripmeter select button ( ).

  • Page 33: Fuel Gauge

    Indicators & Displays Fuel Gauge The fuel gauge ( ) shows the approximate fuel supply available. At F (Full), the fuel tank capacity including reserve is: 13.3 (3.51 US gal , 2.93 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 34: Controls & Features

    Controls & Features Fuel Valve RIGHT SIDE (1) fuel valve The manual fuel valve ( ) is located on the right side under the fuel tank. The three-way fuel valve is used to control the flow of fuel from the fuel tank to the fuel pump unit.

  • Page 35: Ignition Switch

    Controls & Features Ignition Switch The ignition switch ( ) is used for starting and stopping the engine (page ). Insert the key and turn it to the right for the ON ( position. The ignition switch is also used to reset the oil change indicator (page Key Position Function...

  • Page 36: 2Wd/4Wd Select Lever ( Trx420Fm Only)

    Controls & Features 2WD/4WD Select Lever ( only) TRX420FM Your ATV is equipped with a 2WD/4WD select lever ( ), which permits a choice between the ‘‘2WD’’ and ‘‘4WD’’ drive modes. Select a drive mode that’s suitable for your riding. Keep both hands on the handlebar while machine is in motion and come to a complete stop before using the 2WD/4WD select lever.

  • Page 37: Start Button

    Controls & Features Start Button LEFT HANDLEBAR START (1) start button (2) engine stop switch The start button ( ) is used for starting the engine. Pushing the button in starts the engine. See Starting Procedure, page 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 ) position when the start button is pushed.

  • Page 38: Headlight Switch

    Controls & Features Headlight Switch LEFT HANDLEBAR (1) headlight switch (2) headlight dimmer switch (3) horn button The headlight switch ( ) is used to turn the headlight ON ( ) or OFF ). To operate, turn the switch to ON ( ) or OFF ( Headlight Dimmer Switch The headlight dimmer switch ( ) is used to change between the high...

  • Page 39: Recoil Starter

    Controls & Features Recoil Starter RIGHT SIDE (1) recoil starter The recoil starter ( ) is used to start the engine when the battery is low. Using the Recoil Starter, page Instruments & Controls...

  • Page 40: Throttle Lever

    Controls & Features Throttle Lever RIGHT HANDLEBAR (1) throttle lever (A) to open the throttle The throttle controls engine rpm (speed). To increase engine rpm, press the throttle lever ( ) with your thumb. To reduce engine rpm, release pressure on the throttle lever. The throttle will automatically return to the closed position (engine idle) when you remove your thumb.

  • Page 41: Reverse Selector Knob

    Controls & Features Reverse Selector Knob The reverse selector knob ( ), located on the rear brake lever/parking brake lever ( ), is used to shift into reverse. To operate, with your ATV stopped and the transmission in neutral (make sure the gear position indicator shows ‘‘N’’), push in the knob, squeeze the rear brake lever/ parking brake lever, then depress the shift lever.

  • Page 42: Front Brake Lever

    Controls & Features Front Brake Lever The front brake lever is used to slow or stop your ATV. To operate, pull the lever. For information on braking techniques, see page Rear Brake Lever/Parking Brake Lever The rear brake lever/parking brake lever is used to slow or stop your ATV.

  • Page 43: Parking Brake

    Controls & Features Parking Brake LEFT HANDLEBAR (1) lock lever (A) to lock (2) rear brake lever/ parking brake lever The lock lever ( ) on the rear brake lever/parking brake lever ( ) allows it to be used as a parking brake. To operate, first squeeze the rear brake lever/parking brake lever using your left hand and then lock it with the lock lever using your right hand.

  • Page 44: Flag Pole Bracket

    Flag Pole Bracket RIGHT REAR (1) flag pole bracket Flag poles are optional equipment available from your Honda dealer. To mount a pole in the bracket ( ), follow the instructions that come with the flag pole kit. Flag poles are required in some riding areas. Check local regulations before riding.

  • Page 45: Trailer Hitch

    Controls & Features Trailer Hitch REAR (1) trailer hitch (2) ball The trailer hitch ( ) is located on the rear axle housing. To use the hitch, you’ll need a proper size ball ( ) as specified by the trailer manufacturer.
  • Page 46 Instruments & Controls...

  • Page 47: Before Riding

    Before Riding Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, what items you should check on your ATV, and adjustments to make for your comfort, convenience, or safety.

  • Page 48: Are You Ready To Ride

    Are You Ready to Ride? Before you ride your ATV for the first time, we urge you to: Read this owner’s manual and the labels on your ATV carefully. Make sure you understand all the safety messages. Know how to operate all the controls. Before each ride, be sure: You feel well and are in good physical and mental condition.
  • Page 49 Are You Ready to Ride? An open-face helmet offers some protection, but a full-face helmet offers more. Always wear a face shield or goggles to protect your eyes and help your vision. Operating this ATV without wearing an approved motorcycle helmet, eye protection, and protective clothing could increase your chances of severe injury or death in the event of an accident.

  • Page 50: Rider Training

    Beginning and inexperienced operators should complete the certified training course offered by Honda. They should then regularly practice the skills learned in the course and the operating techniques described in the owner’s manual.

  • Page 51: Age Recommendation

    Are You Ready to Ride? Age Recommendation The minimum recommended age for this ATV model is 16. For safety, never let children under 16 years old operate this vehicle. A child using an ATV that is not recommended for their age could lose vehicle control while riding, resulting in severe injury or death.

  • Page 52: No Alcohol Or Drugs

    Are You Ready to Ride? No Alcohol or Drugs Alcohol, drugs and ATVs don’t mix. Even a small amount of alcohol can impair your ability to operate an ATV safely. Likewise, drugs even if prescribed by a physician can be dangerous while operating an ATV.

  • Page 53: Is Your Atv Ready To Ride

    If your ATV has overturned or been involved in a collision, do not ride the vehicle until it has been inspected by your Honda dealer. There may be damage or other problems you cannot see. Improperly maintaining this ATV or failing to...
  • Page 54 Is Your ATV Ready to Ride? Fuel Check the level and add fuel (page ) if needed. Also make sure the fuel fill cap is securely fastened. Check for leaks. Tyres Use a gauge to check the air pressure. Adjust if needed.
  • Page 55 Is Your ATV Ready to Ride? Cable Check the cable housings for wear. Check the fittings for looseness. Replace or tighten as needed. Lights Make sure the headlight, brakelight and taillight are working properly. If you are carrying cargo, also check the following: Loading Limits Make sure you do not exceed the load limits (page...
  • Page 56 Move the handlebar right and left and check that there is no excessive backlash. Remember, be sure to take care of any problem you find, or have your Honda dealer correct it before you ride. Before Riding...

  • Page 57: Load Limits & Guidelines

    Load Limits & Guidelines Your Honda was designed as a rider-only ATV. It was not designed to carry a passenger. It can carry cargo on the cargo racks, however, carrying cargo anywhere else or carrying a passenger could interfere with your balance and control of the ATV.

  • Page 58: Load Limits

    Load Limits & Guidelines Load Limits Following are the load limits for your ATV: There are limits to how much weight can be carried on your ATV and be pulled in a trailer. The following load limits apply to standard equipment only. Modifying your ATV, using non-standard equipment, or riding on terrain that is not flat and smooth could further reduce these limits.

  • Page 59: Loading Guidelines

    Load Limits & Guidelines Loading Guidelines Carrying cargo or pulling a trailer will affect how your ATV 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: Check that the tyres are properly inflated.

  • Page 60: Accessories & Modifications

    Honda cannot test all other accessories, you must be personally responsible for proper selection, installation, and use of non-Honda accessories. Check with your Honda dealer for assistance and always follow these guidelines: Make sure the accessory does not obscure any lights, reduce ground clearance, limit suspension travel or steering travel, or interfere with operating any controls.

  • Page 61: Modifications

    Accessories & Modifications Modifications We strongly advise you not to remove any original equipment or modify your ATV in any way that would change its design or operation. Such changes could seriously impair your ATV’s handling, stability, and braking, making it unsafe to ride. Removing or modifying your lights, exhaust system, emission control system, or other equipment can also make your ATV illegal.
  • Page 62 Before Riding...

  • Page 63: Basic Operation & Riding

    Basic Operation & Riding This section gives basic riding instructions, including how to start and stop your engine, and how to use the throttle and brakes. It also provides important information on riding with cargo. To protect your new engine and enjoy optimum performance and service life, refer to Break-in Guidelines (page Safe Riding Precautions ................
  • Page 64 Basic Operation & Riding Braking ....................Riding Your ATV ................. Making Turns ..................Skidding or Sliding ................Riding Up Hills ................. Riding Down Hills ................Crossing or Turning on Hills or Slopes ..........Riding Over Obstacles ..............Riding Through Water ..............

  • Page 65: Safe Riding Precautions

    Safe Riding Precautions Before riding your ATV for the first time, please review the ATV Saf ety section beginning on page 1, and the Bef ore Riding section beginning on page Even if you have ridden other ATVs, take time to become familiar with how this ATV works and handles.

  • Page 66: Keep Hands And Feet On Controls

    Safe Riding Precautions You should never ride your ATV 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. In many states it is illegal to operate ATVs on public streets, roads and highways.

  • Page 67: Control Speed

    Safe Riding Precautions 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. Operating this ATV at excessive speeds increases your chances of losing control of the ATV, which can result in an accident.

  • Page 68: Use Care On Unfamiliar Or Rough Terrain

    Safe Riding Precautions Use Care on Unfamiliar or Rough 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 sometimes difficult to see obstructions like hidden rocks, bumps, or holes in time to react.) Failure to use extra care when operating this ATV on unfamiliar terrain could result in the ATV...

  • Page 69: Do Not Perform Stunts

    Safe Riding Precautions Never ride past the limit of visibility. Maintain a safe distance between your ATV and other off-road vehicles. Always exercise caution, and use extra care on rough, slippery and loose terrain. 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...

  • Page 70: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure described below. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your ATV’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

  • Page 71: Starting Procedure

    Starting & Stopping the Engine Starting Procedure This vehicle has a fuel-injected engine with an automatic choke. Follow the procedure indicated below. Any Air Temperature Press the start button with the throttle completely closed. The engine will not start if the throttle is fully open (because the electronic control module cuts off the fuel supply).

  • Page 72: Flooded Engine

    Starting & Stopping the Engine Flooded Engine If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine: Leave the engine stop switch set to RUN ( Open the throttle fully. Press the start button for 5 seconds (or operate the recoil starter several times).

  • Page 73: Stalled Engine

    Starting & Stopping the Engine Stalled Engine You can restart the engine while the vehicle is stopped by squeezing the front brake lever and pressing the start button. Do not press the throttle lever while starting in gear. Your ATV is equipped with a start inhibitor system that will cut off the ignition if the throttle is open while attempting to start in gear.

  • Page 74: Using The Recoil Starter

    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. RIGHT SIDE (1) starter grip...

  • Page 75: Shifting Gears

    Shifting Gears UPSHIFTING SEQUENCE DOWNSHIFTING SEQUENCE Your ATV has five forward gears: 1, 2, 3, 4, and 5. The shift lever is located near the left footpeg. One full stroke of the shift lever shifts the transmission to the next higher or lower gear in the shifting sequence.
  • Page 76 Shifting Gears After starting the engine and letting it warm up, follow these procedures: With the transmission in neutral, release the parking brake, but continue squeezing the rear brake lever. With the throttle closed, raise the shift lever one full stroke to shift into 1st (first) gear.

  • Page 77: Riding In Reverse

    Riding in Reverse If you need to ride in reverse, make sure the area behind you is clear and only operate the ATV at low speed. Improperly operating in reverse could cause you to hit an obstacle or person behind you, resulting in serious injury.
  • Page 78 Riding in Reverse Your ATV may be equipped with a reverse speed limiter, which helps the vehicle to maintain a saf e speed while riding in reverse gear. Release the rear brake lever/parking brake lever. Open the throttle gradually and ride slowly. Do not open the throttle suddenly or make abrupt turns.

  • Page 79: Braking

    Braking Your ATV is equipped with disc brakes on both front wheels which are hydraulically activated by operating the right brake lever. A single drum brake on the rear axle housing is mechanically activated by depressing the brake pedal or operating the left brake lever. TRX420FM only: Although the front and rear brakes have separate controls, all four wheels are interconnected when your ATV is in the 4WD mode.
  • Page 80 Braking 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 compression braking by downshifting, with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduce their effectiveness.

  • Page 81: Riding Your Atv

    Riding Your ATV Making Turns Learn how to turn your ATV properly. Practice the techniques outlined in this section on level ground and at low speeds until you are confident in making turns. Turning improperly can make the ATV go out of control, causing a collision or overturn.
  • Page 82 Riding Your ATV Lean your body to the inside of a turn and forward. To make a turn on level ground: Steer the handlebar and lean your body toward the inside of the turn. Leaning helps balance the vehicle, and it feels more comfortable.

  • Page 83: Skidding Or Sliding

    Riding Your ATV Skidding or Sliding 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 84: Riding Up Hills

    Riding Your ATV Riding Up Hills The ATV’s ability to safely climb hills largely depends on the rider’s skill and judgment. Begin by practicing on smooth, gentle slopes. As you gain experience, you’ll learn the hazards and your own limitations. You may then proceed to ride on more difficult terrain.
  • Page 85 Riding Your ATV Shift weight forward when climbing hills. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. To climb a hill, take a running start in an appropriate gear and speed for the conditions.
  • Page 86 Riding Your ATV Stalling the ATV and/or Rolling Backwards: If you incorrectly estimate climbing capability or terrain conditions, the ATV may not have enough power or traction to continue uphill. If this happens, the ATV can stall and/or roll backwards. Stalling, rolling backwards or improperly dismounting while climbing a hill could result in the ATV overturning.
  • Page 87 Riding Your ATV What to do after the ATV has stalled or rolled backwards: If the hill is too steep or too slippery, or if you have any doubt whether you can safely walk the ATV back down the hill, leave the vehicle where it is and get help.

  • Page 88: Riding Down Hills

    Riding Your ATV Riding Down Hills It’s usually advisable to descend hills with the ATV pointed straight downhill. Avoid angles that would cause the vehicle to lean sharply to one side. Going down a hill improperly could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this owner’s manual.

  • Page 89: Crossing Or Turning On Hills Or Slopes

    Riding Your ATV When you’ve selected a safe downhill path, shift into a lower gear, shift your weight back with your arms extended and braced against the handlebar, then go down slowly with the throttle closed. Use mainly the rear brake to control speed. Avoid using either the front brake or rear brake hard or abruptly when riding down hills.
  • Page 90 Riding Your ATV Crossing Hills or 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 centre of the seat and lean toward the uphill side.

  • Page 91: Riding Over Obstacles

    Riding Your ATV Riding Over Obstacles Before operating in a new area, check for 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.

  • Page 92: Riding Through Water

    Riding Your ATV Riding Through Water Your ATV is designed to travel through water up to approximately 254 mm (10 inches) deep. Before crossing a stream, make sure the water is not too deep or flowing too fast. The ATV tyres have some ability to float. Operating this ATV through deep or fast-flowing water may cause a loss of traction and loss of control, which could lead to an accident.

  • Page 93: Parking

    Parking Look for level parking area. Make sure the ground surface is firm. After bringing your ATV to a stop, hold the brakes while you shift into neutral. Set the parking brake. Turn the ignition switch OFF ( If you’re finished riding for the day, turn the fuel valve OFF. If it is necessary to start the engine when your ATV in gear and is stopped on a grade, rock the vehicle back and forth to allow shifting the transmission into neutral.
  • Page 94 Basic Operation & Riding...

  • Page 95: Servicing Your Honda

    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 Bef ore You Service Your Honda The Importance of Maintenance ............Maintenance Safety ................
  • Page 96 Servicing Your Honda Service Procedures Fluids & Filters Fuel ....................Engine Oil & Filter ................Gear Case Oil ..................Differential Oil ( TRX420FM only) ........... Coolant ....................Air Cleaner ..................Engine Throttle ....................Clutch System ................... Reverse Lock System ................

  • Page 97: The Importance Of Maintenance

    Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair. If your ATV overturns or is involved in a crash, be sure your Honda dealer inspects all major parts, even if you are able to make some repairs.

  • Page 98: Maintenance Safety

    Other tasks that are more difficult and require special tools are best performed by professionals. Removing the wheels should normally be handled only by a Honda technician or other qualified mechanic. Instructions are included in this manual only to assist in emergency service.

  • Page 99: Important Safety Precautions

    Keep cigarettes, sparks, and flames away from all fuel- related parts. Remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new Honda Genuine Parts or other equivalents for repair and replacement.

  • Page 100: Maintenance Schedule

    Other items involve more extensive procedures and may require special training, tools, and equipment. We recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools and equipment.
  • Page 101 Certain items (particularly those marked and ) may require more technical information and tools. Consult your Honda dealer. Should be serviced by your Honda dealer, unless you have the proper tools and service data, and are mechanically qualified. Refer to the official Honda Shop Manual.

  • Page 102: Maintenance Procedures

    ENGINE OIL FILTER RADIATOR COOLANT NOTE 3 COOLING SYSTEM NOTE 2 Should be serviced by your Honda dealer, unless you have the proper tools and service data, and are mechanically qualified. Refer to the official Honda Shop Manual. Servicing Your Honda...

  • Page 103: Servicing Your Honda

    BEARINGS STEERING SYSTEM Should be serviced by your Honda dealer, unless you have the proper tools and service data, and are mechanically qualified. Refer to the official Honda Shop Manual. In the interest of safety, we recommend these items be serviced only by your Honda dealer.

  • Page 104: Maintenance Record

    (Miles) or ODO or Date Performed Notes hours HOUR 150 (100) or 1,000 (600) or 2,000 (1,200) or 3,000 (1,800) or 4,000 (2,400) or 5,000 (3,000) or 6,000 (3,600) or 7,000 (4,200) or 8,000 (4,800) or Servicing Your Honda...

  • Page 105: Maintenance Component Locations

    Maintenance Component Locations front brake fluid reservoir rear brake lever/ parking brake lever front brake lever throttle lever fuel fill cap Servicing Your Honda...
  • Page 106 Maintenance Component Locations differential oil filler cap (TRX420FM only) differential oil drain bolt (TRX420FM only) coolant reserve tank air cleaner air cleaner housing drain tube front brake caliper rear brakelight switch rear brake pedal engine oil filter Servicing Your Honda...
  • Page 107 Maintenance Component Locations owner’s manual air pressure gauge spark plug battery fuse box main fuse tool kit clutch spark arrester engine oil filler cap/dipstick engine oil drain bolt gear case oil filler cap gear case oil drain bolt Servicing Your Honda...

  • Page 108: Tool Kit

    To open the compartment, unhook the rubber strap ( ). 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 Honda dealer. The tool kit includes the following items: standard/Phillips screwdriver...

  • Page 109: Owner's Manual Storage

    ( ). To remove the seat, see page Be careful not to flood this area when washing your ATV. SEAT UNDERSIDE (1) owner’s manual (3) air pressure gauge (2) seat (4) plastic document bag Servicing Your Honda...

  • Page 110: Seat Removal

    Slide the seat ( ) back and lift it. Installation Insert the front prongs ( ) into the hooks ( ) on the frame and press the studs ( ) into the grommets ( ). Press down on the seat until locks. Servicing Your Honda...

  • Page 111: Clip Removal

    Press down on the center pin to release the lock. Pull the clip out of the hole. Installation Push the bottom of the pin. Insert the clip into the hole. Lightly press down on the center pin to lock the clip. Servicing Your Honda...

  • Page 112: Fuel

    If pinging or spark knock occurs at a steady engine speed under normal load, change brands of petrol. If pinging or spark knock persists, consult your Honda dealer. Never use stale or contaminated petrol or an oil/petrol mixture. Avoid getting dirt, dust, or water in the fuel tank.
  • Page 113 ON position after refueling to avoid running out of fuel with no reserve. Refueling Procedure Refer to Saf ety Precautions on page (1) fuel fill cap (3) handlebar cover hole (2) breather tube (4) filler neck Servicing Your Honda...
  • Page 114 After refueling, turn the fuel fill cap clockwise until it clicks. Insert the breather tube into the handlebar cover hole. If the fuel valve was set to RES, turn the fuel valve ON. If you replace the fuel fill cap, use only a Honda Genuine replacement part. Servicing Your Honda...

  • Page 115: Engine Oil & Filter

    Change the engine oil as specified in the maintenance schedule on page . When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule. Servicing Your Honda...
  • Page 116 SE, SF or SG viscosity (weight) SAE 10W-40 suggested oil Honda 4-stroke oil or an equivalent Motor oils intended for Service SE, SF or SG will show this designation on the container. Your ATV does not need oil additives. Use the recommended oil.
  • Page 117 There are two classes: MA and MB. Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification. (1) code number of the sales company of the oil (2) oil classification Servicing Your Honda...
  • Page 118 Start the engine in a well-ventilated area and let it idle for 3 5 minutes. Stop the engine and wait 2 3 minutes. Remove the seat (page Unsnap and remove the left side cover ( ). LEFT SIDE (1) left side cover Servicing Your Honda...
  • Page 119 Reinstall the oil filler cap/dipstick. Install the left side cover. Install the seat. Running the engine with an improper oil level can cause serious engine damage. LEFT SIDE (2) oil filler cap/dipstick (3) upper level mark (4) lower level mark Servicing Your Honda...
  • Page 120 Your ATV’s oil filter has very specific performance requirements. Use a new Honda Genuine oil filter specified for your model or a filter of equal quality. Using the wrong oil f ilter may result in leaks or engine damage.
  • Page 121 Engine Oil & Filter Install a New Engine Oil Filter: Remove the seat (page Unsnap and remove the right side cover ( ). RIGHT SIDE (1) right side cover (cont’d) Servicing Your Honda...
  • Page 122 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 123 If necessary, add more oil but do not overfill. Check that there are no oil leaks. Install the left side cover. Install the seat. If a torque wrench is not used for installation, see your Honda dealer as soon as possible to verify proper assembly. Servicing Your Honda...

  • Page 124: Gear Case Oil

    Gear Case Oil Oil Recommendation type hypoid gear oil viscosity (weight) SAE 80 Changing Oil Refer to Saf ety Precautions on page Change the oil with the gear case at normal operating temperature to assure complete and rapid draining. Servicing Your Honda...
  • Page 125 Remove the oil level check bolt ( ). Make sure the oil level reaches the oil level check hole ( ). Install the oil filler cap and oil level check bolt. REAR (1) oil drain plug (3) oil level check bolt (2) oil filler cap (4) oil level check hole Servicing Your Honda...

  • Page 126: Differential Oil (Trx420Fm Only)

    Differential Oil (TRX420FM only) Oil Recommendation type hypoid gear oil viscosity (weight) SAE 80 Changing Oil Refer to Saf ety Precautions on page Change the oil with the differential at normal operating temperature to assure complete and rapid draining. Servicing Your Honda...
  • Page 127 Make sure the oil level is at the lower edge of the oil filler inspection hole ( ). Install the oil filler cap. FRONT (1) oil drain plug (3) oil filler inspection hole (2) oil filler cap Servicing Your Honda...

  • Page 128: Coolant

    Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion. Coolant Recommendation Use Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. Check the antifreeze container label.
  • Page 129 ( ). It should be between the UPPER ( ) and LOWER ( ) level marks. If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your Honda dealer for repair. (cont’d) Servicing Your Honda...
  • Page 130 Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark. REAR (4) rubber strap (6) reserve tank cap (5) rear fender cover After adding coolant, install the reserve tank cap and rear fender cover. Fasten the rubber strap. Install the seat. Servicing Your Honda...
  • Page 131 Refer to Saf ety Precautions on page Coolant should be replaced by your Honda dealer, unless you have the proper tools and service data, and are mechanically qualified. Refer to the official Honda Shop Manual. Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you.
  • Page 132 Check the air passages for clogging or damage. Remove insects, mud, or any obstruction with low water pressure. Have the radiator checked by your Honda dealer if the air flow is restricted over more than 20% of the radiator surface.
  • Page 133 Coolant Remove the radiator grill plate ( ). Wash the radiator core ( ) and radiator grill plate. Install the removed parts in reverse order of removal. FRONT (7) radiator grill plate (8) radiator core Servicing Your Honda...

  • Page 134: Air Cleaner

    Your ATV’s air cleaner has very specific performance requirements. Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality. Using the wrong air cleaner may result in premature engine wear.
  • Page 135 Air Cleaner Cleaning Remove the seat (page UNDER SEAT (1) retainer clips (2) air cleaner housing cover Unlatch the retainer clips ( ). Remove the air cleaner housing cover ( ). (cont’d) Servicing Your Honda...
  • Page 136 (To keep your hands dry, place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner.) UNDER SEAT (3) screw (6) air cleaner (4) air cleaner assembly (7) air cleaner body (5) clamp Servicing Your Honda...
  • Page 137 Install the air cleaner housing cover with the FRONT mark ( facing forward and fit the cut out of the tab ( ) at the end of the air cleaner. UNDER SEAT (8) FRONT mark (9) tab Servicing Your Honda...
  • Page 138 Air Cleaner Dust Cover UNDER SEAT (1) dust cover (2) breather joint Do not push the dust cover ( ) too far into the breather joint ( ). If the dust cover is dirty, clean it. Servicing Your Honda...
  • Page 139 (3) air cleaner housing (2) clip Remove the drain tube ( ) by removing the clip ( ) under the air cleaner housing ( ). Drain the deposits. Reinstall the drain tube, securing it with the clip. Servicing Your Honda...

  • Page 140: Throttle

    Loosen the lock nut ( ). Turn the adjuster to obtain the correct freeplay. Tighten the lock nut and reinstall the sleeve. After adjustment, check for smooth operation of the throttle lever from fully closed to fully open in all steering positions. Servicing Your Honda...

  • Page 141: Throttle Inspection

    If the cable is kinked or chafed, have it replaced. Check the throttle cable for tension or stress in all steering positions. Lubricate the throttle cable with a commercially available cable lubricant to prevent premature wear and corrosion. Servicing Your Honda...

  • Page 142: Clutch System

    Install the removed parts in reverse order of removal. If you cannot get proper adjustment, or the clutch does not work properly, the clutch friction discs may be worn. See your Honda dealer or refer to official Honda Shop Manual.

  • Page 143: Reverse Lock System

    After adjustment, tighten the lock nut securely. Return the dust cover and rubber 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. Servicing Your Honda...

  • Page 144: Spark Plug

    Saf ety Precautions on page Remove the seat (page ) and left side cover (page Remove the left tank side cover ( ) by removing the bolts ( ). LEFT SIDE (1) left tank side cover (2) bolts Servicing Your Honda...
  • Page 145 ( ) should not be eroded. If the electrodes and insulator tip appear unusually fouled or burned, we suggest that you contact your Honda dealer. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped.
  • Page 146 If a plug is too tight, the threads may be damaged. Connect the spark plug cap. Take care to avoid pinching any cables or wires. Install the remaining parts in the reverse order of removal. Servicing Your Honda...

  • Page 147: Valves

    For those who are mechanically proficient and have the proper tools, instructions on adjusting valve clearances are given in the official Honda Shop Manual. Otherwise, the valves should be adjusted by your Honda dealer. Servicing Your Honda...

  • Page 148: Spark Arrester

    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. Stop the engine and allow the exhaust pipe to cool. Reinstall the bolt securely. Servicing Your Honda...

  • Page 149: Brakes

    Worn pads should be replaced. If the pads are not worn beyond the recommended limit, there is probably air in the brake system. See your Honda dealer to have the air bled from the system. Mechanical Drum Rear Brake If the rear brake lever/parking brake lever or brake pedal freeplay does...
  • Page 150 Do not add or replace brake fluid, except in an emergency. If you do add fluid, have your Honda dealer check the system as soon as possible. Brake f luid can damage plastic and painted surf aces. Handle with care.
  • Page 151 Other Inspections Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. If the hoses are worn or cracked, have them replaced by your Honda dealer. Servicing Your Honda...
  • Page 152 (2) edge of reference mark Check the wear indicator ( ). If the wear indicator aligns with the edge of the reference mark ( ), both pads must be replaced, see your Honda dealer for this replacement. Always inspect both pads in both the right and left front brake calipers.
  • Page 153 Measure the distance the rear brake pedal ( ) moves before the brake starts to take hold. Freeplay, measurement at the tip of the end of the pedal, should be: 15 20 mm (0.6 0.8 in) If necessary, adjust to the specified range. Servicing Your Honda...
  • Page 154 ( ). Adjust the freeplay of the rear brake pedal. Push the brake arm ( ) then check the clearance between the brake arm and the brake arm pin. (4) brake arm Servicing Your Honda...
  • Page 155 Measure the distance the rear brake lever/parking brake lever ( ) moves before the brake starts to take hold. Freeplay (measurement at the tip of the end of the brake lever) should be: 15 20 mm (0.6 0.8 in) If necessary, adjust to the specified range. Servicing Your Honda...
  • Page 156 ( ). Adjust the freeplay of the rear brake lever/parking brake lever. Push the brake arm ( ) then check the clearance between the brake arm and the brake arm pin. (4) brake arm Servicing Your Honda...
  • Page 157 ( ). Replace the brake shoe if the arrow aligns with the reference mark ( ) on the brake panel upon full application of the brake. If replacement is necessary, see your Honda dealer. Servicing Your Honda...
  • Page 158 Adjustment is done by turning the adjusting nut ( ). Turn the nut in direction ( ) if the switch operates too late and in direction ( ) if the switch operates too soon. RIGHT REAR (1) rear brakelight switch (2) adjusting nut Servicing Your Honda...
  • Page 159 Make sure the engine is OFF and the parking brake is set. Remove the rear brake drain bolt ( ) from the bottom of the rear brake panel. If any water drains, the brake seals must be replaced by your Honda dealer as soon as possible. Servicing Your Honda...

  • Page 160: Tyres

    Always select your riding area with care. The following pages give detailed information on how and when to check your air pressure, how to inspect your tyres for wear and damage, and our recommendations for tyre repair and replacement. Servicing Your Honda...
  • Page 161 Overinflated tyres make your ATV ride harshly, are more prone to damage from surface hazards, and wear unevenly. Make sure the air valve caps are secure. If necessary, install new caps. Servicing Your Honda...
  • Page 162 Be sure to check tyre pressure at the riding site, since changes in altitude can affect air pressure. The recommended ‘‘cold’’ tyre pressures are: tyre pressure, front 25.0 kPa (3.6 psi) front & rear (cold) rear 25.0 kPa (3.6 psi) Servicing Your Honda...
  • Page 163 Cuts, slits, or cracks in the tyres. Replace the tyre if you can see fabric or cord. Nails or other foreign objects embedded in the side of the tyre or tread. Excessive tread wear. Servicing Your Honda...
  • Page 164 ( ). For best performance, you should replace a tyre before the tread depth at the centre reaches the following limits: 4 mm (0.16 in) front rear 4 mm (0.16 in) Servicing Your Honda...
  • Page 165 If you choose to have a tyre repaired, be sure the repair work is performed by a professional. If you have a tyre professionally repaired at a non-Honda facility, we recommend that you have the work checked by your Honda dealer.
  • Page 166 When you replace a tyre, remember: Have the tyre replaced by your Honda dealer if possible. If you have a tyre professionally replaced at a non-Honda facility, we recommended that you have the work checked by your Honda dealer. Servicing Your Honda...

  • Page 167: Guards

    Maintenance Schedule. Have the engine guard and skid plate replaced if they are cracked or damaged. If the guard and plate bolts are loose, tighten them securely. Servicing Your Honda...
  • Page 168 (2) front driveshaft guards Check the front boot guards ( ) and front driveshaft guards ( ) for cracks, damage or looseness. Tighten any loose fasteners. Replace the front boot guards and front driveshaft guards as required. Servicing Your Honda...

  • Page 169: Drivetrain Boots

    (1) rubber propeller shaft boots (TRX420FM only) (2) rubber yoke joint boot Check the rubber propeller shaft boots ( ) and rubber yoke joint boot ( ) for damage or leaking grease. If necessary, have your Honda dealer replace them. Servicing Your Honda...
  • Page 170 Drivetrain Boots Driveshaft Boots (TRX420FM only) Refer to Saf ety Precautions on page FRONT (1) rubber driveshaft boots Check the rubber driveshaft boots ( ) for damage or leaking grease. If necessary, have your Honda dealer replace them. Servicing Your Honda...

  • Page 171: Battery

    Battery Storage, page If your battery seems weak and/or is leaking electrolyte (causing slow starting or other electrical problems), see your Honda dealer. This symbol on the battery means that this product must not be treated as household waste. An improperly disposed of battery can be harmf ul to the environment and human health.
  • Page 172 A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you. Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance. Servicing Your Honda...
  • Page 173 Release the rings and remove the rubber band ( ). Disconnect the negative ( ) terminal lead ( ) from the battery ( ) first, then disconnect the positive ( ) terminal lead ( ). Remove the battery. (cont’d) Servicing Your Honda...
  • Page 174 Reinstall in the reverse order of removal. Be sure to connect the positive ( ) terminal first, then the negative ( ) terminal. Make sure all bolts and other fasteners are secure. 40 mm (1.6 in) (5)battery band Servicing Your Honda...

  • Page 175: Battery Charging

    However, do not intentionally leave the charger connected longer than the time period recommended in the charger’s instructions. Avoid using an automotive-type battery charger. An automotive charger can overheat an ATV battery and cause premature damage. Servicing Your Honda...

  • Page 176: Appearance Care

    Appearance Care Frequent cleaning and polishing will keep your Honda looking newer longer. Frequent cleaning also identifies you as an owner who values his ATV. A clean ATV is also easier to inspect and service. General Recommendations Refer to Saf ety Precautions...
  • Page 177 As a precaution, ride your ATV at a slow speed and apply the brakes several times. This will help dry the brakes and restore normal braking performance. If the inside of the headlight lens appears clouded immediately after washing, it should clear after a few minutes of riding. Servicing Your Honda...
  • Page 178 Brake dust. necessary, rub with a sponge. Rinse and dry. Apply a spray cleaner/polish and wipe with a non-abrasive cloth. Dull, corroded chrome Apply a high quality chrome/ or aluminum. aluminum polish and wipe with a non-abrasive cloth. Servicing Your Honda...
  • Page 179 After washing your ATV, consider using a commercially available spray cleaner/polish or quality liquid or paste wax to finish the job. Use only a non-abrasive polish or wax made specifically for motorcycles or automobiles. Apply the polish or wax according to the instructions on the container. Servicing Your Honda...
  • Page 180 Servicing Your Honda...

  • Page 181: Tips

    Tips Here’s helpful advice on how to prepare for an off-road adventure, how to transport and store your Honda, and how to be an environmentally responsible ATV owner. Preparing for a Ride ................What to Take to the Riding Area ..........

  • Page 182: Preparing For A Ride

    Preparing for a Ride A safe and enjoyable ride begins with good planning and preparation. Always ride with at least one other person in case you have trouble, and let someone know where you’re going and when you expect to return. Before riding in an unfamiliar area, find out in advance if you need special permits, get maps so you can study the terrain, and talk to other riders who know the area.

  • Page 183: What To Take On The Trail

    Preparing for a Ride What to Take on the Trail What you take with you during a ride depends on the kind of terrain, how long 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.

  • Page 184: Transporting Your Honda

    Transporting Your Honda Do not tow your ATV behind a car or other vehicle. When you transport your ATV, we recommend that you carry the vehicle in its normal operating position (on all four wheels). Do not incline the vehicle upright on its rear end. This can damage the vehicle, and leaking petrol could be a hazard.
  • Page 185 Transporting Your Honda Secure the vehicle with tie-down straps in the areas shown. Suitable tie-down straps are available from your Honda dealer. Ordinary rope is not recommended because it can stretch under load. Using tie-down straps in any other areas can damage your ATV.

  • Page 186: Storing Your Honda

    Storing Your Honda If you won’t be riding for an extended period, such as during the winter, thoroughly inspect your ATV and correct any problem before storing it. That way, needed repairs won’t be forgotten and it will be easier to get your ATV running again.

  • Page 187: Preparation For Storage

    Storing Your Honda Preparation for Storage Refer to Saf ety Precautions on page Change the engine oil and filter (page Make sure the cooling system is filled with a 50/50% antifreeze solution (page Fill the fuel tank. Make sure the fuel fill cap is properly installed.
  • Page 188 Storing Your Honda Remove the battery and charge it fully. Store it in an area protected from freezing temperatures and direct sunlight. Slow charge the battery (page ) once a month. The battery gives off explosive hydrogen gas during normal operation.

  • Page 189: Removal From Storage

    (page If your ATV has been stored for more than two months ask your Honda dealer to drain and replace the fuel. Charge the battery (page ) as required. Install the battery. Perform a pre-ride inspection (page ), then test-ride your ATV at low speeds.

  • Page 190: You & The Environment

    You & the Environment Owning and riding an ATV can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport of off-road riding. Following are tips on how you can be an environmentally responsible ATV owner.

  • Page 191: Taking Care Of The Unexpected

    Taking Care of the Unexpected With all the challenges you can encounter off-road, there’s a chance that sometime something may go wrong. This section gives practical advice to help you deal with a wide range of problems. Take time to read this section before you ride.

  • Page 192: Taking Care Of The Unexpected

    Taking Care of the Unexpected General Guidelines Keeping your ATV well-maintained is the best way to reduce the possibility of having a problem while riding. However, problems can arise even with well-maintained machines. Remember to take along your owner’s manual, the tool kit that came with your ATV, and any other items (such as tyre repair supplies and additional tools) that might help you solve a problem on your own.
  • Page 193 Taking Care of the Unexpected Should you ever have a problem while riding, please follow these guidelines: Always put personal safety first. Take time to assess the situation and your options before deciding what to do. If the problem is relatively minor and you have the tools, supplies, and skills to make a temporary repair, be sure to have permanent repairs made as soon as possible.

  • Page 194: If Your Engine Quits Or Won't Start

    If you have a problem starting the engine or experience poor engine performance the following information may help you. If you can’t correct the problem, see your Honda dealer. If your ATV won’t start, listen as you press the start button. If you don’t hear the starter motor turning, refer to the Starter motor doesn’t operate...
  • Page 195 If charging doesn’t help, see your Honda dealer. faulty starter motor If all possible causes are negative, the starter motor may be faulty. See your Honda dealer. SYMPTOM: Starter motor works, but the engine won’t start. POSSIBLE CAUSE WHAT TO DO out of fuel Fill the fuel tank.
  • Page 196 Check the high coolant temperature temperature indicator. Refer to If the High Coolant T emperature Indicator Lights, page runs erratically, See your Honda dealer. misfires blubbers (rich fuel See your Honda dealer. mixture) sooty exhaust (rich See your Honda dealer. fuel mixture)

  • Page 197: If You Have A Flat Tyre

    Follow the instructions provided with the repair kit to make a temporary repair. As soon as possible, have the tyre permanently repaired by your Honda dealer. Any tyre that cannot be repaired should be replaced. Whenever the ATV 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 198 If You Have a Flat Tyre Emergency Wheel Removal/Installation Refer to Saf ety Precautions on page (1) wheel nuts (2) wheel rim Removal Park your ATV on a firm, level surface. Loosen but do not remove the wheel nuts ( ). Raise the front (or rear) wheels off the ground and place a support block under the vehicle.
  • Page 199 64 N·m (6.5 kgf·m , 47 lbf·ft) If a torque wrench was not used for installation, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capability.

  • Page 200: If The High Coolant Temperature Indicator Lights

    If the High Coolant Temperature Indicator Lights Normally, the high coolant temperature indicator will only light momentarily when you turn the ignition ON ( ). Occasionally, it may flicker at or near idling speed. High coolant temperature may be caused by restriction of air flow to the radiator (such as mud caked on the radiator), extended idling, an oil leak, a coolant leak, a low oil level, a low coolant level, or extended operation under adverse conditions.
  • Page 201 If there’s a mild coolant leak, you can ride for awhile, carefully watching the indicator. Be prepared to stop and add more coolant or water. If the leak is bad, transport your ATV to a Honda dealer (page Taking Care of the Unexpected...

  • Page 202: If A Fuse Blows

    If a Fuse Blows All of the electrical circuits on your ATV have fuses to protect them from damage caused by excess current flow (short circuit or overload). If something electrical on your ATV stops working, the first thing you should check for is a blown fuse ( ).
  • Page 203 If a Fuse Blows Main Fuse Access To prevent an accidental short circuit, turn the ignition switch OFF ) before checking or replacing the fuses. Remove the seat (page Remove the rear fender cover (page To access the main fuse ( ), remove the fuse box cover ( ). UNDER REAR FENDER COVER (2) main fuse (4) spare main fuse...
  • Page 204 If a Fuse Blows Circuit Fuse Access (5) circuit fuses (6) spare fuses To check or replace a circuit fuse ( ), pull the old fuse out of its retaining clips. If the fuse is blown, replace it with a spare fuse ( ) of the same rating. If you do not have a replacement fuse with the proper rating for the circuit, install one with a lower rating.
  • Page 205 If the replacement fuse of the same rating burns out in a short time, there is probably a serious electrical problem on your ATV. Leave the blown fuse in that circuit and have your ATV checked by your Honda dealer.

  • Page 206: If You Crash

    Sometimes, crash damage is hidden or not immediately apparent. When you get home, thoroughly check your ATV and correct any problems you find. Also, be sure to have your Honda dealer check the frame and suspension after any serious crash.

  • Page 207: If You Lose Your Key

    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 nearest Honda dealer.

  • Page 208: If The Battery Is Low (Or Dead)

    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’t charge the battery or it appears unable to hold a charge, contact your Honda dealer. Taking Care of the Unexpected...

  • Page 209: If A Component Fails

    If a Component Fails The brake levers or pedal, control cables, and other components can be damaged as you ride in dense brush or over rocky terrain. Making a trailside repair depends on how serious the damage is and what tools and supplies you have with you.
  • Page 210 Taking Care of the Unexpected...

  • Page 211: Technical Information

    Technical Information This section contains dimensions, capacities, and other technical data, plus information on government requirements and how to break-in your ATV. Vehicle Identification ................ Specifications ..................Break-in Guidelines ................Petrol Containing Alcohol ..............Technical Information...

  • Page 212: Vehicle Identification

    Vehicle Identification Serial Numbers The VIN, engine serial number, and key number may be required when ordering replacement parts. Record the numbers here for your reference. The VIN ( ) is stamped on the front of the frame. FRONT (1) VIN The engine number ( ) is stamped on the upper side of the rear crankcase.
  • Page 213 Vehicle Identification Colour Label & Code The colour label ( ) is attached to the frame under the seat. Remove the seat (page ) to check the label. The colour code is helpful when ordering replacement parts. Record the colour and code here for your reference. COLOUR CODE UNDER SEAT...

  • Page 214: Specifications

    & oil filter change: 2.8 (3.0 US qt , 2.5 Imp qt) engine oil API Service Classification SE, SF or recommendation Honda 4-stroke oil or an equivalent cooling system High quality ethylene glycol recommendation antifreeze containing corrosion protection inhibitors specifically...
  • Page 215 Specifications Capacities passenger capacity operator only maximum weight 220 kg (485 lbs) capacity rider, all cargo and accessories Engine Specifications displacement 420.2 cm (25.63 cu-in) bore & stroke 86.5 71.5 mm (3.41 2.81 in) compression ratio 9.9 : 1 spark plug BKR5E-11 (NGK) (standard) K16PR-U11 (DENSO)
  • Page 216 Not exceed 0.5 m/s (EN 1032, ISO 5008) Vibration on handlegrip 6.0 m/s (ISO 5349:2001, EN 709) Chassis & Suspension caster 6.34° …TRX420TM 3° …TRX420FM trail 25.1 mm (0.99 in) …TRX420TM 9.0 mm (0.35 in) …TRX420FM tyre size, front AT24...
  • Page 217 Specifications Electrical battery 12 V 12 Ah generator 0.359 kW/5,000 min (rpm) Lights headlight 12 V 30/30 W brake/tail light neutral indicator reverse indicator high coolant temperature indicator PGM-FI indicator 4WD indicator (TRX420FM only) Fuses main 30 A other 15 A, 10 A Torque Specification engine oil drain bolt 25 N·m (2.5 kgf·m , 18 lbf·ft)

  • Page 218: Break-In Guidelines

    Break-in Guidelines 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, rapid acceleration, and constant rpm operation. Technical Information...

  • Page 219: Petrol Containing Alcohol

    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 220: Table Of Contents

    Table of Contents The following presents the contents of each section of your owner’s manual. ATV SAFETY ..................Important Safety Information ............... Safety Labels ..................INSTRUMENTS & CONTROLS ............Operation Component Locations ............Indicators & Displays ................Multi-function Display ..............Gear Position Indicator ..............
  • Page 221 Table of Contents Controls & Features ................Fuel Valve ..................Ignition Switch .................. 2WD/4WD Select Lever ( TRX420FM only) ........Start Button ..................Engine Stop Switch ................Headlight Switch ................Headlight Dimmer Switch ..............Horn Button ..................Recoil Starter ..................Throttle Lever ...................
  • Page 222 Table of Contents BEFORE RIDING (cont’d) Accessories & Modifications ..............Accessories ..................Modifications ..................BASIC OPERATION & RIDING ............. Safe Riding Precautions ................ Off-road Use Only ................Keep Hands and Feet on Controls ............. Control Speed ..................Use Care on Unfamiliar or Rough Terrain ........
  • Page 223 Table of Contents SERVICING YOUR HONDA ............Bef ore You Service Your Honda The Importance of Maintenance ............Maintenance Safety ................Important Safety Precautions ............Maintenance Schedule ................Maintenance Record ................Service Preparations Maintenance Component Locations ............Tool Kit ....................
  • Page 224 TIPS ....................Preparing for a Ride ................What to Take to the Riding Area ..........What to Take on the Trail ............. Transporting Your Honda ..............Storing Your Honda ................Preparation for Storage ..............Removal from Storage ..............You & the Environment ..............
  • Page 225 Table of Contents TECHNICAL INFORMATION ............ Vehicle Identification ................ Specifications ..................Break-in Guidelines ................Petrol Containing Alcohol ..............TABLE OF CONTENTS ..............INDEX ....................MANUFACTURER AND AUTHORISED REPRESENTATIVE FOR EU MARKET ........Table of Contents...

  • Page 226: Index

    Index accessories .................... . 50 age recommendation ................41 air cleaner, dust cover ..................128 filter ....................124 housing drain tube ................129 air pressure, gauge ....................99 tyre ....................151 apparel, protective .................
  • Page 227 Index break-in guidelines ................208 button, horn ....................28 hourmeter/odometer/tripmeter select ......14, 17, 20, 21, 22 capacity, fuel ..................103 care, appearance ................. . 166 cargo, loading and operational guidelines ........... . 49 weight limit ..................
  • Page 228 Index differential oil (TRX420FM only) ............116 dimmer switch, headlight ..............28 dipstick ....................109 display check ..................15 display, multi-function ................18 driveshaft boots (TRX420FM only) ........... 160 drivetrain boots ..................162 engine, flooded .....................
  • Page 229 Index final gear case oil ................114 flag pole bracket ..................34 flat tyre ....................187 flooded engine ..................62 fuel, fill cap ................... . 103 gauge ....................23 recommendation ................102 refueling ..................
  • Page 230 Index headlight dimmer switch ............... 28 headlight switch ..................28 hills, crossing or turning on slopes ............. 79 riding down hills ................78 riding up hills ..................74 stopping on hills ................76 horn button ...................
  • Page 231 Index key, lost ....................197 number ................... 197 kit, tool ....................98 labels, safety ................... lamp check ................... . 14 lever, 2WD/4WD select (TRX420FM only) ......... 26 limit, weight ..................48 load limits ....................48 loading guidelines ................
  • Page 232 Index maximum weight limit ................48 modifications ..................51 multi-function display ................18 neutral indicator ................14, 16 numbers, serial ..................202 obstacles, riding over ................81 odometer ..................17, 18, 21 oil, differential (TRX420FM only) ............
  • Page 233 Index parking ....................83 passenger, no carrying ................41 pavement, no riding on ................55 petrol ....................102 petrol containing alcohol ..............209 pinging, engine ..................102 plug, spark ................... 134 pre-ride inspection ................
  • Page 234 Index rear final gear case oil ................ . 114 recoil starter ................... 29 removal, seat ..................100 reverse, assist cable ..................133 assist lever ..................133 gear, shifting into ................67 indicator ..................14, 16 riding in ....................
  • Page 235 Index safety, important precautions ............... . 89 labels ....................riding precautions ................55 schedule, maintenance ................90 seat removal ..................100 select lever, 2WD/4WD ............... . 26 serial numbers ..................202 shifting gears ..................65 skid plate ....................
  • Page 236 Index starting, engine ....................60 troubleshooting ................184 stop switch, engine ................27 stopping engine ..................63 storage, ....................176 owner’s manual ................. 99 switch, engine stop ..................27 headlight ................... . 28 headlight dimmer ................
  • Page 237 Index throttle, cable ....................131 lever .................. . 30, 130, 131 tyres, air pressure ..................151 flat ....................187 repairing ..................155 replacing ..................156 tread conditions ............... 153, 154 tool kit ....................98 trailer hitch ...................
  • Page 238 Index valve, fuel ....................24 valve clearance ..................137 vehicle identification no. (VIN) ............202 warning labels ..................washing your ATV ................168 water, draining from brakes ............... 149 riding through ..................82 weight limit ..................

  • Page 239: Manufacturer And Authorised Representative For Eu Market

    Manufacturer and Authorised Representative for EU Market Manufacturer Authorised Representative for EU Market Honda of South Carolina Honda Motor Europe Ltd. Mfg., Inc. Aalst Office 1111 Honda way Wijngaardveld 1 Timmonsville, (Noord V), B-9300 Aalst South Carolina 29161, Belgium U.S.A.

This manual is also suitable for:

Trx420fmFourtraxFourtrax rancher 420/4x4

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