Page 1 Honda TRX420TE/FE FOURTRAX 420 ES/4 4 OWNER’S MANUAL...
Page 2 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 3 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! Happy riding! Introduction...
Page 4: 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 5 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 6 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 7 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 9: 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 10: 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 11 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 12 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 13: 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 14 Safety Labels (TRX420TE) (TRX420FE) ATV Safety...
Page 15 Safety Labels (TRX420FE only) ATV Safety...
Page 16 ATV Safety...
Page 17: 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 18 Instruments & Controls Controls & Features ................Fuel Valve ..................Ignition Switch .................. 2WD/4WD Select Lever ( TRX420FE only) ........Start Button ..................Engine Stop Switch ................Headlight Switch ................Headlight Dimmer Switch ..............Horn Button ..................Recoil Starter ..................Throttle Lever ...................
Page 19: Operation Component Locations
Operation Component Locations parking brake reverse selector knob lock lever headlight horn button dimmer switch rear brake lever/ headlight parking switch front brake lever brake lever gearshift start button throttle lever switches engine stop ignition switch switch 2WD/4WD select lever (TRX420FE only) Instruments &...
Page 20 Operation Component Locations rear cargo rack seat latch front cargo rack recoil starter rear brake pedal fuel valve Instruments & Controls...
Page 21 Operation Component Locations flag pole bracket trailer hitch Instruments & Controls...
Page 22: 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. (1) (2) (3) (4) (5) (1) reverse indicator (5) PGM-FI indicator...
Page 23 ) 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 24 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 25 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 26: 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 (3) (4) (5) (6) (7) (8) (10) (11) (1) multi-function display (8) PGM-FI indicator (2) gear position indicator (9) speedometer (3) reverse indicator (10) odometer/tripmeter/...
Page 27: 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 28: 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 2 seconds.
Page 29: 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...
Page 30: 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 31: 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: 13.7 (3.62 US gal , 3.01 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 32: 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 33: 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 resetting the oil change indicator (page Key Position Function ON (...
Page 34: 2Wd/4Wd Select Lever ( Trx420Fe Only)
Controls & Features 2WD/4WD Select Lever ( only) TRX420FE 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 35: Start Button
Controls & Features Start Button LEFT HANDLEBAR (1) start button START (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 36: 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 37: 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 38: 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 39: Gearshift Switch
Controls & Features Gearshift Switch These switches are used to select the next higher or lower gear in the transmission. To operate, press the upshift switch ( ) to engage the next higher gear or press the downshift switch ( ) to engage the next lower gear.
Page 40: 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 press the downshift switch ( ) once.
Page 41: 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 The rear brake lever is used to slow or stop your ATV. To operate, pull the lever.
Page 42: 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 43: 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 44: 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 45: 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 46: 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 47 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 48: 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 49: 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 50: 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 51: 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 52 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 53 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 54 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 55: 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 56: 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 57: 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 58: 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 59: 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 60 Before Riding...
Page 61: 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 62 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 63: 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 64: 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 65: Control Speed
Safe Riding Precautions (1) footpeg 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.
Page 66: 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 67: 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 68: 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 69: Starting Procedure
Starting & Stopping the Engine Starting Procedure This vehicle has a fuel-injected 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 70: 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 71: 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 72: 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 73: Shifting Gears
Shifting Gears UPSHIFTING SEQUENCE DOWNSHIFTING SEQUENCE (1) upshift switch (A) press (2) downshift switch Your ATV has five forward gears: 1, 2, 3, 4, and 5. Two gearshift switches are located next to the left handlebar grip: upshift ( ) and downshift ( To upshift the transmission, press the upshift switch ( ) once.
Page 74 3 km/h (2 mph). If the electric shift system malfunctions, the transmission cannot be shifted by pressing the gearshift switches. See your Honda dealer. (In an emergency, a gear may be selected manually so you may move the vehicle.
Page 75 Shifting Gears Downshift to a lower gear before you feel the engine laboring (lugging) at low rpm. Avoid downshifting to help slow your ATV when engine rpm is high. Downshifting when engine speed is near its allowable maximum may over-rev the engine and cause possible damage. To prevent transmission damage, do not coast or tow the ATV for long distances with the engine off.
Page 76: 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 77 Riding in Reverse 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. To stop, close the throttle and gradually apply both the front and rear brakes.
Page 78: 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. TRX420FE only: Although the front and rear brakes have separate controls, all four wheels are interconnected when your ATV is in the 4WD mode.
Page 79 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 80: 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 81 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 82: 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 83: 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 84 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 85 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 86 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 87: 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 88: 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 89 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 90: 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 91: 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 92: 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 through riding for the day, turn the fuel valve OFF. If it is necessary to start the engine when your ATV is stopped on a grade in gear, rock the vehicle back and forth to allow shifting the transmission into neutral.
Page 93: 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 94 Servicing Your Honda Service Procedures Fluids & Filters Fuel ....................Engine Oil & Filter ................Gear Case Oil ..................Differential Oil ( TRX420FE only) ........... Coolant ....................Air Cleaner ..................Engine Throttle ....................Clutch System ................... Reverse Lock System ................
Page 95: 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 96: 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 97: 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 genuine Honda parts or other equivalents for repair and replacement.
Page 98: 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 99 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 100: 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 101 HOLDER 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 102: 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 103: Maintenance Component Locations
Maintenance Component Locations rear brake lever/ front brake fluid reservoir parking brake lever front brake lever fuel fill cap throttle lever Servicing Your Honda...
Page 104 Maintenance Component Locations differential oil filler cap (TRX420FE only) differential oil drain bolt (TRX420FE only) coolant reserve tank air cleaner air cleaner housing drain tube front brake caliper rear brakelight switch engine oil filter rear brake pedal Servicing Your Honda...
Page 105 Maintenance Component Locations spark plug owner’s manual air pressure gauge battery fuse box main fuse tool kit clutch spark arrester engine oil drain bolt engine oil filler cap/dipstick gear case oil filler cap gear case oil drain bolt Servicing Your Honda...
Page 106: Tool Kit
The gear change tool ( ) is stored underside of the seat. 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 107: 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 108: 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 109: 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 110: 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 111 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 112 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 genuine Honda replacement part. Servicing Your Honda...
Page 113: 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 114 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 115 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 116 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 117 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 118 Your ATV’s oil filter has very specific performance requirements. Use a new genuine Honda oil filter specified for your model or a filter of equal quality. Using the wrong oil f ilter may result in leaks or premature engine damage.
Page 119 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 120 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 121 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 122: 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 123 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 124: Differential Oil (Trx420Fe Only)
Differential Oil (TRX420FE 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 125 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 126: 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 127 ( ). 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 128 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 129 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 130 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 131 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 132: Air Cleaner
Your ATV’s air cleaner has very specific performance requirements. Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality. Using the wrong air cleaner may result in premature engine damage.
Page 133 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 134 (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 135 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 136 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 137 (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 138: 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 139 If the cable is kinked or chafed, have it replaced. Check the cables for tension or stress in all steering positions. Lubricate the cables with a commercially-available cable lubricant to prevent premature wear and corrosion. Servicing Your Honda...
Page 140: 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 141: 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 142: 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 143 ( ) 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 144 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 145: 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. All others should have valves adjusted by your Honda dealer. Servicing Your Honda...
Page 146: 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 147: 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 148 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 149 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 150 (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 151: Rear Brake Pedal Freeplay
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 152 Turn the brake pedal adjusting nut ( ), located on the brake operating rod at the rear of the frame. Make sure the cutout on the adjusting nut is properly seated on the brake arm pin ( ). Servicing Your Honda...
Page 153: Rear Brake Lever Freeplay
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 154 ( ). Other Inspections Check that the brake lever and brake pedal assemblies are positioned properly and the securing bolts are tight. Make sure that the brake cables, brake arm, spring, and fasteners are in good condition. Servicing Your Honda...
Page 155 ( ). 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 156: Brakelight Switch Adjustment
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 157 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 158: 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 159: Air Pressure
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 a new cap. Servicing Your Honda...
Page 160 The recommended ‘‘cold’’ tyre pressures are: FRONT REAR RECOMMENDED 25 kPa 25 kPa PRESSURE (0.25 kgf/cm , (0.25 kgf/cm , 3.6 psi) 3.6 psi) RECOMMENDED 25 kPa 25 kPa PRESSURE (0.25 kgf/cm , (0.25 kgf/cm , 3.6 psi) 3.6 psi) Servicing Your Honda...
Page 161 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 162 ( ). For best performance, you should replace a tyre before the tread depth at the centre reaches the following limits: front 4 mm (0.16 in) rear 4 mm (0.16 in) Servicing Your Honda...
Page 163 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 164 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 165: Engine Guard & Skid Plate
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 166: Driveshaft Boots (Trx420Fe Only)
Driveshaft Boots (TRX420FE 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 167: Propeller Shaft Boots & Yoke Joint Boot
(1) rubber propeller shaft boots (TRX420FE 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 168: Battery
–– or at least disconnect the battery cables (negative cable first). If you plan to store your ATV, see Battery Storage, page If your battery seems weak and/or is leaking electrolyte (causing slow starting or other electrical problems), see your Honda dealer. Servicing Your Honda...
Page 169 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 170 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. Servicing Your Honda...
Page 171 Slow charge the battery (see following section) once every 30 days. Installation Reinstall in the reverse order of removal. Be sure to connect the positive ( ) terminal first, then the negative ( ) terminal. Check all bolts and other fasteners are secure. Servicing Your Honda...
Page 172 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 173: 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 174 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 175 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 176 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 177: 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 178: 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 179: 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 180: 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 181 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 182: 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 183: 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 184 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 185: 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 186: 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 187: 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 188: 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 189 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 190: 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 191 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 192 Check the high coolant temperature If the High temperature indicator. Refer to 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 193: If The Shift Switches Do Not Function
If the Shift Switches Do Not Function If one or both shift switches do not function, see the following instructions. If proper function cannot be restored, see your Honda dealer. When the engine is running: Stop the ATV. Turn the ignition switch to the ‘‘OFF’’ ( ) position.
Page 194: Emergency Gear Selection & Operation
If the shift switches do not operate, use the following procedure to manually select a gear so you may drive the vehicle to a location where it can be loaded and transported to a Honda dealer. Turn the ignition switch to the ‘‘ON’’ ( ) position.
Page 195 Emergency Gear Selection & Operation How to Shift Gears Manually: (A) downshift (counterclockwise) (B) upshift (clockwise) With the ATV unoccupied, align the hexagonal hole of the gear change tool with the hexagonal end of the secondary spindle which is located on the front crankcase. To downshift, turn the gear change tool counterclockwise ( ).
Page 196: 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 197 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. Raise the front (or rear) wheels off the ground and place a support block under the vehicle.
Page 198 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 199: 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 200 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 201: 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 202 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 ( ) and shift motor fuse ( ), remove the fuse box cover ( ).
Page 203 If a Fuse Blows Circuit Fuse Access (6) circuit fuses (7) 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 204 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 205: 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 206: If You Lose Your Key
If you don’t know your key number, call the dealer you purchased your Honda from. They may have it listed in their records. If they don’t, transport your ATV to them or the nearest Honda dealer.
Page 207: 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 208: 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 209: 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 210: Vehicle Identification
Vehicle Identification Serial Numbers The VIN and engine serial numbers 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. VIN. FRONT (1) VIN The engine number ( ) is stamped on the upper side of the rear...
Page 211 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 212: Specifications
3.1 (3.3 US qt , 2.7 Imp qt) after draining: 2.7 (2.9 US qt , 2.4 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 213 Specifications Capacities passenger capacity operator only 220 kg (485 lbs) maximum weight capacity rider, all cargo and accessories Engine Specifications displacement 420 cm (25.6 cu-in) bore & stroke 86.5 71.5 mm (3.41 2.81 in) compression ratio 9.8 : 1 spark plug BKR5E-11 (NGK) (standard) K16PR-U11 (DENSO)
Page 214 Vibration on seat Not exceed 0.5 m/s (EN 1032, ISO 5008) 6.2 m/s Vibration on handlegrip (EN 1033, EN 709) Chassis & Suspension caster 6.34 ...TRX420TE ...TRX420FE trail 25.1 mm (0.99 in) ...TRX420TE 9.5 mm (0.37 in) ...TRX420FE AT24 8-12 MAXXIS M977...
Page 215 Specifications Electrical battery 12 V 12 Ah 0.343 kW/5,000 min (rpm) generator Lights headlight 12 V 30/30 W brake/tail light neutral indicator reverse indicator high coolant temperature indicator PGM-FI indicator 4WD indicator (TRX420FE only) Fuses main 30 A shift motor 30 A other 15 A...
Page 216: 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 217: 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 218 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 219 Table of Contents Controls & Features ................Fuel Valve ..................Ignition Switch .................. 2WD/4WD Select Lever ( TRX420FE only) ........Start Button ..................Engine Stop Switch ................Headlight Switch ................Headlight Dimmer Switch ..............Horn Button ..................Recoil Starter ..................Throttle Lever ...................
Page 220 Table of Contents BEFORE RIDING (cont’d) Accessories & Modifications ..............Accessories ..................Modifications ..................BASIC OPERATION & RIDING ............ . 53 Safe Riding Precautions ................ Off-Road Use Only ................Keep Hands and Feet on Controls ............. Control Speed ..................Use Care on Unfamiliar or Rough Terrain ........
Page 221 Table of Contents SERVICING YOUR HONDA ............85 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 222 ....................169 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 223: Table Of Contents
Table of Contents TECHNICAL INFORMATION ............201 Vehicle Identification ................ Specifications ..................Break-in Guidelines ................Petrol Containing Alcohol ..............TABLE OF CONTENTS ..............210 INDEX ....................216 Table of Contents...
Page 224: Index
Index accessories .................... . 50 age recommendation ................41 air cleaner, dust cover ..................128 filter ....................125 housing drain tube ................129 air pressure, gauge ....................99 tyre ....................152 apparel, protective .................
Page 225 Index braking ....................70 break-in guidelines ................208 button, horn ....................28 hourmeter/odometer/tripmeter select ......14, 17, 20, 21, 22 capacity, fuel ..................103 care, appearance ................. . 165 cargo, loading and operational guidelines ........... .
Page 226 Index differential oil (TRX420FE only) ............116 dimmer switch, headlight ..............28 dipstick ....................109 display check ..................15 display, multi-function ................18 driveshaft boots (TRX420FE only) ............ . 158 engine, flooded ....................62 guard ....................
Page 227 Index final gear case oil ................114 flag pole bracket ..................35 flat tyre ....................188 flooded engine ..................62 fuel, fill cap ................... . 103 gauge ....................23 recommendation ................102 refueling ..................
Page 228 Index gap, spark plug ..................135 gasohol ....................209 gear case oil ..................114 gear shifting ..................65 gearshift switch ..................65 headlight dimmer switch ............... 28 headlight switch ..................28 hills, crossing or turning on slopes ............
Page 229 Index identification, vehicle ................202 ignition switch ..................25 indicators, gear position indicator ..............18, 19 high coolant temperature indicator ........14, 16, 191 neutral indicator ................14, 16 oil change indicator ..............18, 20 PGM-FI indicator ...............
Page 230 Index labels, safety ................... lamp check ................... . 14 lever, 2WD/4WD select (TRX420FE only) ......... . 26 limit, weight ..................48 load limits ....................48 loading guidelines ................. 49 lubrication, differential oil (TRX420FE only) ........... 116 engine oil ..................
Page 231 Index neutral indicator ................14, 16 numbers, serial ..................202 obstacles, riding over ................82 odometer ....................21 oil, differential (TRX420FE only) ............116 engine ....................105 gear case ..................114 operation component locations .............
Page 232 Index parking ....................84 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 233 Index riding, basic operations ................. 53 clothing ....................38 precautions ..................55 preparing for .................. . 170 over obstacles ..................82 safety ....................safety precautions ................55 through water ..................83 safety, important precautions ...............
Page 234 Index starting, engine ....................60 troubleshooting ................182 stop switch, engine ................27 stopping engine ..................63 storage, ....................174 owner’s manual ................. 99 switch, downshift ..................31, 65 engine stop ..................27 headlight ...................
Page 235 Index throttle, cable ....................131 lever .................. . 30, 130, 131 tyres, air pressure ..................152 flat ....................188 replacing ..................156 repairing ..................155 thread conditions ..............153, 154 tool kit ....................98 trailer hitch ...................
Page 236 Index valve, fuel ....................24 valve clearance ..................137 vehicle identification no. (VIN) ............202 warning labels ..................washing your ATV ................166 water, riding through ..................83 draining from brakes ............... 149 weight limit ..................

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Trx420fe Fourtrax 420 es/4 4

Honda TRX420TE Owner's Manual

Instruments & Controls

Before Riding

Basic Operation & Riding

Servicing Your Honda/Bef Ore You Service Your Honda the Importance of Maintenance

Taking Care of the Unexpected

Technical Information

Table of Contents

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Summary of Contents for Honda TRX420TE

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