TRX680FA5
FOURTRAX
RINCON
Part Number
The information in this publication relates to the Honda TRX680FA,
an ATV (All Terrain Vehicle) designed primarily to travel off-road on
four low-pressure tyres, driven by a mounted rider using the
handlebars for steering control.
This manual should be considered a permanent part of the ATV and
should remain with the ATV when it is resold.
This publication includes the latest production information available
before printing. Honda Motor Co., Ltd. reserves the right to make
changes at any time without notice and without incurring any
obligation.
No part of this publication may be reproduced without written
permission.
© Honda Motor Co., Ltd. 2018
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Honda TRX680FA5
FOURTRAX RINCON
OWNER’S MANUAL
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Introduction
Introduction
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.
Before riding, take time to get acquainted with your ATV and how it
works. To protect your investment, we urge you to take
responsibility for keeping your ATV well maintained. Scheduled
service is a must, of course. But it’s just as important to observe the
break-in guidelines, and perform all pre-ride and other periodic
checks detailed in this manual.
We also recommend that you read this owner’s manual before you
ride. It’s full of facts, instructions, safety information, and helpful
tips. To make it easy to use, the manual contains a detailed list of
topics at the beginning of each section and an index at the back of
the book.
As you read this manual, you will find information that is preceded
by a symbol. This information is intended to help you avoid
damage to your Honda, other property, or the environment.
Whenever you ride, tread lightly. By staying on established trails and
riding only in approved areas, you help protect the environment and
keep off-road riding areas open for the future.
NOTICE
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Introduction
Introduction
If you have any questions, or if you ever need special service or
repairs, remember that your dealer knows your ATV best and is
dedicated to your complete satisfaction.
Happy riding!
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A Few Words About Safety
A Few Words About Safety
A Few Wo rds 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.
Of course, it is not practical or possible to warn you about all hazards
associated with operating or maintaining an ATV. You must use your
own good judgment.
You will find important safety information in a variety of forms,
including:
Safety Labels — on the ATV.
Safety Messages — preceded by a safety alert symbol
2
and one
of three signal words: DANGER, WARNING, or CAUTION.
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A Few Words About Safety
A Few Words About Safety
These signal words mean:
Safety Headings — such as Important Safety Reminders or
Important Safety Precautions.
Safety Section — such as ATV Safety.
Instructions — how to use this ATV correctly and safely.
This entire manual is filled with important safety information —
please read it carefully.
3
DANGER
You WILL be KILLED or
SERIOUSLY HURT if you don't
follow instructions.
3
WARNING
You CAN be KILLED or SERIOUSLY
HURT if you don’t follow
instructions.
3
CAUTION
You CAN be HURT if you don’t
follow instructions.
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Contents
Contents
Conten ts
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 ..................................................................................1
Important safety information you should know, plus a look at the
safety related labels on your ATV.
Instruments & Controls ..............................................................9
The location and function of indicators and controls on your ATV
and operating instructions for various controls and features.
Before Riding ............................................................................43
The importance of wearing a helmet and other protective gear,
how to make sure you and your ATV are ready to ride, and
important information about loading.
Basic Operation & Riding .........................................................59
How to start and stop the engine, shift gears, and brake. Also,
riding precautions.
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Contents
Contents
Servicing Your Honda ..............................................................95
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 ..........................................................................................175
How to store and transport your ATV and how to be an
environmentally responsible rider.
Taking Care of the Unexpected.............................................185
What to do if you have a flat tyre, your engine won’t start, etc.
Technical Information ............................................................207
ID numbers, technical specifications, and other technical facts.
Index........................................................................................218
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ATV Safety
1
ATV Safety
ATV Sa fety
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........................................................ 2
Safety Labels ................................................................................ 5
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ATV Safety
2
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.
The following are a few that we consider to be most important.
Follow the Age Recommendation
The minimum recommended age for this ATV model is 16. Children
under age 16 should never operate this vehicle.
Always Wear a Helmet
It’s a proven fact: helmets significantly reduce the number and
severity of head injuries. So always wear an approved motorcycle
helmet. We also recommend that you wear eye protection, sturdy
boots, gloves, and other protective gear (page 44).
Never Carry a Passenger
Your ATV is designed for one person only. There are no handholds,
footrests, or seat for a second person, so never carry a passenger. A
passenger could interfere with your ability to move around to
maintain your balance and control of the ATV.
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ATV Safety
3
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.
Take Time to Learn & Practice
Even if you have ridden other ATVs, take time to become familiar
with how this ATV works and handles. Practice in a safe area until
you build your skills and get accustomed to the ATV’s size and
weight.
Be Alert for Off-road Hazards
The terrain can present a variety of challenges when you ride off-
road. Continually ”read” the terrain for unexpected turns, drop-offs,
rocks, ruts, and other hazards. Always keep your speed low enough
to allow time to see and react to hazards.
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ATV Safety
4
Important Safety Information
Ride within Your Limits
Pushing limits is another major cause of ATV crashes. Never ride
beyond your personal abilities or faster than conditions warrant.
Remember that alcohol, drugs, fatigue, and inattention can
significantly reduce your ability to make good judgments and ride
safely.
Don’t Drink and Ride
Alcohol and riding don’t mix. Even one drink can reduce your ability
to respond to changing conditions, and your reaction time gets
worse with every additional drink. So don’t drink and ride, and don’t
let your 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. To help avoid
problems, inspect your ATV before every ride and perform all
recommended maintenance.
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ATV Safety
5
Safety Labels
Your ATV comes with several labels containing important safety
information. 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 dealer for
replacements.
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ATV Safety
6
Safety Labels
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ATV Safety
7
Safety Labels
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ATV Safety
8
Safety Labels
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Instruments & Controls
9
Instruments & Controls
(cont’d)
In st rumen ts & C ontrols
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.
Operation Component Locations ................................................ 11
Indicators & Displays................................................................... 14
Multi-function Display.............................................................. 18
Drive Mode Indicator ............................................................... 19
Gear Position Indicator............................................................. 20
Oil Change Indicator................................................................ 21
Odometer/Tripmeter................................................................ 22
Hour meter.............................................................................. 24
Digital Clock ............................................................................ 25
Fuel Gauge .............................................................................. 26
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Instruments & Controls
10
Instruments & Controls
Controls & Features.................................................................... 27
Ignition Switch......................................................................... 27
Shift Lever ............................................................................... 28
Drive Mode Select Switch ........................................................ 29
2WD/4WD Select Switch.......................................................... 30
Start Button............................................................................. 31
Engine Stop Switch.................................................................. 31
Headlight Switch ..................................................................... 32
Headlight Dimmer Switch ........................................................ 32
Horn Button ............................................................................ 32
Recoil Starter ........................................................................... 33
Throttle Lever .......................................................................... 34
Gearshift Switch ...................................................................... 35
Front Brake Lever..................................................................... 36
Rear Brake Lever/Parking Brake Lever ....................................... 36
Rear Brake Pedal...................................................................... 36
Parking Brake .......................................................................... 37
Flag Pole Bracket ..................................................................... 38
Trailer Hitch ............................................................................. 39
Accessory Socket ..................................................................... 40
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Instruments & Controls
11
Operation Component Locations
parking brake
lock lever
ignition switch
2WD/4WD
select switch
throttle lever
headlight switch
headlight dimmer switch
drive mode
select switch
front brake
lever
shift lever
start button
gearshift
switches
engine stop
switch
rear brake lever/parking
brake lever
horn button
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Instruments & Controls
12
Operation Component Locations
rear cargo rack
accessory socket
front cargo rack
recoil starter
rear brake pedal
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Instruments & Controls
13
Operation Component Locations
seat latch
flag pole bracket
trailer hitch
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Instruments & Controls
14
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.
(11)
(9)
(10)
(7) (8)
(2) (1)
(6)(5)(4)
(3)
(1) odometer/tripmeter select button
(2) RESET button
(3) reverse indicator
(4) 4WD indicator
(5) high oil/coolant temperature indicator
(6) neutral indicator
(7) multi-function display
(8) hour select button
(9) minute select button
(10) ADJ button
(11) PGM-FI indicator
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Instruments & Controls
15
Indicators & Displays
Lamp Check
The high oil/coolant temperature indicator, 4WD indicator, neutral
indicator, reverse indicator and PGM-FI indicator comes on for a few
seconds and then go off when you turn the ignition switch ON (q).
The indicators are identified in the table on page 16 with the words:
Lamp Check.
When applicable, the reverse or neutral indicators come on when
you turn the ignition switch ON (q) and remain on until you shift out
of reverse or neutral.
If one of these indicators does not come on when it should, have
your dealer check for problems.
Display Check
When the ignition switch is turned ON (q), the multi-function display
(1) will temporarily show all the modes and digital segments so you
can make sure the liquid crystal display is functioning properly.
The displays are identified in the table on page 17 with the words:
Display Check.
If any part of these displays does not come on when it should, have
your dealer check for problems.
(1)
(1) multi-function display
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Instruments & Controls
16
Indicators & Displays
1Odometer/
tripmeter
select button
Selects display of the odometer or
tripmeter A or tripmeter B
(page 22).
This button also used to reset the
oil change indicator (page 21).
2 RESET
button
Resets the tripmeter to zero (0)
(page 23).
This button also used to reset the
oil change indicator (page 21).
3 Reverse
indicator
Lights when the transmission is in
reverse. Lamp Check.
44WD
indicator
Lights when the drive mode is in
the 4WD mode. The 4WD
indicator blinks if there is a
possible problem with the 2WD/
4WD select system. See your
dealer as soon as possible. Lamp
Check.
5 High oil/
coolant
temperature
indicator
Lights when engine oil and/or
coolant temperature is high
enough to adversely affect the
service life of the engine.
If the high oil/coolant
temperature indicator comes on
while you are riding, immediately
bring the vehicle to a stop, turn
the engine off and let it cool. See
page 197. Lamp Check.
6 Neutral
indicator
Lights when the transmission is in
neutral. Lamp Check.
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Instruments & Controls
17
Indicators & Displays
7Multi-
function
display
The display includes the following
functions. Display Check.
Drive mode
indicator
Shows the driving mode
(page 19).
Gear position
indicator
Shows the gear position
(page 20).
Speedometer Shows riding speed.
Fuel gauge Shows approximate fuel supply
available (page 26).
Oil change
indicator
Lights when specified maintenance
interval for engine oil change is
reached (page 21).
Odometer Shows accumulated mileage
(page 22).
Tripmeter Shows mileage per trip (page 22).
Hour meter
Shows hours and tenths of hours of
engine operation (page 24).
Digital clock Shows the time (hours and
minutes) (page 25).
8 Hour select
button
Advances the hour displayed by
the digital clock (page 25).
9Minute select
button
Advances the minutes displayed
by the digital clock (page 25).
10 ADJ button Used to set the digital clock
(page 25).
11 PGM-FI
indicator
Lights when there is any abnormality
in the PGM-FI (Programmed Fuel
Injection) system. Should also light
for a few seconds and then go off
when the ignition switch is turned ON
and use the start button. If the
indicator comes on at any other time,
reduce speed and take your vehicle to
your dealer as soon as possible.
Lamp
Check
.
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Instruments & Controls
18
Indicators & Displays
The multi-function display (1) includes the following functions:
The digital clock will reset if the battery is disconnected.
Multi-function Display
Drive mode indicator Speedometer Digital clock
Gear position indicator Odometer Hour meter
Oil change indicator Tripmeter Fuel gauge
(8) hour select button
(9) minute select button
(10) ADJ button
(11) hour meter
(12) odometer/tripmeter
(13) digital clock
(14) oil change indicator
(1) multi-function display
(2) RESET button
(3) odometer/tripmeter
select button
(4) gear position indicator
(5) drive mode indicator
(6) speedometer
(7) fuel gauge
(12)(11)
(7)
(9)
(2)
(1)
(6)
(5)
(4)
(3)
(14)(13)
(8) (10)
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Instruments & Controls
19
Indicators & Displays
The drive mode indicator (1) shows the selected drive mode when
the ignition switch is in the ON (q) position.
The drive mode indicator (1) displays ESP when the manual shift
(ESP) mode is selected. The ESP display vanishes when the automatic
shift (AUTO) mode is selected.
Drive Mode Indicator
(1) drive mode indicator
(1)
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Instruments & Controls
20
Indicators & Displays
The gear position indicator (1) shows the gear position when the
ignition switch is in the ON (q) position.
The indicator displays: N for neutral, R for reverse, D for drive, and 1
– 3 for the three forward speed positions in the ESP mode.
“--” will be displayed on the gear position indicator when the
transmission is not shifted into gear properly. Before riding, check
that the gear position is properly displayed on the gear position
indicator.
Gear Position Indicator
(1) gear position indicator
(1)
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Instruments & Controls
21
Indicators & Displays
The oil change indicator (1) 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 both the odometer/tripmeter
select button (2) and RESET button (3) for more than 2 seconds. The
indicator will disappear.
If the oil is changed before the oil change indicator appears, be sure
to reset the oil change indicator after changing the oil. The indicator
will appears for 2 seconds, then disappear. This means the indicator
is reset.
Oil Change Indicator
(1) oil change indicator
(2) odometer/tripmeter select button
(3) RESET button
(1)
(2)
(3)
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Instruments & Controls
22
Indicators & Displays
The odometer/tripmeter display has two functions, odometer (1) and
tripmeter.
The tripmeter has two sub modes, tripmeter A (2) and tripmeter B
(3).
The odometer registers total distance traveled in kilometers while
the ignition switch is ON (q).
The tripmeter shows mileage per trip since you last reset the
tripmeter while the ignition is ON (q).
To change the display from tripmeter A or tripmeter B to odometer,
press and release the odometer/tripmeter select button (4).
Odometer/Tripmeter
(4) (4)
(1)
(2)
(3)
(1) odometer
(2) tripmeter A
(4)
(3) tripmeter B
(4) odometer/tripmeter select button
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Instruments & Controls
23
Indicators & Displays
To reset the tripmeter to zero, press and hold the RESET button (5)
for more than 2 seconds with the display in the tripmeter A or
tripmeter B mode.
(5)
(5) RESET button
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Instruments & Controls
24
Indicators & Displays
The hour meter (1) shows accumulated hours while the ignition is
ON (q). The hour meter provides accurate service period
information for initial and regular maintenance.
Hour meter
(1)
(2)
(1) hour meter (2) hour meter mark
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Instruments & Controls
25
Indicators & Displays
Shows hour and minute while the ignition is ON (q).
To adjust the time, proceed as follows:
1.
Turn the ignition switch ON (q).
2.
To select the adjust mode, push the ADJ button (1) once.
3.
To advance the hour display one unit at a time, press and release
the hour select button (2).
To advance the hour display automatically, press and hold the
hour select button. After 2 seconds, the hour display will begin
advancing.
Release the button when the display reaches the desired hour.
4.
To advance the minute display one unit at a time, press and
release the minute select button (3).
To advance the minute display automatically, press and hold the
minute select button. After 2 seconds, the minute display will
begin advancing. Release the button when the display reaches
the desired minute.
To zero the minute display, press and hold both the hour and
minute select buttons simultaneously for 2 seconds.
5.
Press the ADJ button when the display reaches the desired
minute.
The display will stop flashing.
Digital Clock
(2)
(1) ADJ button
(2) hour select button
(1)
(3) minute select button
(3)
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Instruments & Controls
26
Indicators & Displays
The fuel gauge liquid crystal display (1) shows the approximate fuel
supply available. The fuel tank capacity is:
16.8 ℓ (4.44 US gal , 3.70 Imp gal)
When segment E (2) and low fuel indicator (3) flash, you should refill
the tank as soon as possible. The amount of fuel remaining when the
flashing starts is approximately:
5.3 ℓ (1.40 US gal , 1.17 Imp gal)
All segments will flash, when the fuel gauge function fails. See your
dealer.
Fuel Gauge
(3) low fuel indicator
(2) segment E
(1) fuel gauge
(3) (2)
(1)
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Instruments & Controls
27
Controls & Features
The ignition switch (1) is used for starting and stopping the engine
(page 66). Insert the key and turn it to the right for the ON (q)
position.
Ignition Switch
Key Position Function
ON (q) Electrical circuits on.
OFF (w) No electrical circuits function.
CENTRE OF HANDLEBAR
(1) ignition switch
w OFF
q ON
(1)
ONOFF
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Instruments & Controls
28
Controls & Features
The shift lever (1) has three positions: drive (D), neutral (N), and
reverse (R).
See Shifting Gears (page 71) and Riding in Reverse (page 77).
Shift Lever
LEFT SIDE OF HANDLE COVER
(1)
(1) shift lever
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Instruments & Controls
29
Controls & Features
The drive mode select switch (1) has two positions, AUTO and ESP.
See Shifting Gears page 71.
Drive Mode Select Switch
RIGHT HANDLEBAR
(1)
(1) drive mode select switch
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Instruments & Controls
30
Controls & Features
Your ATV is equipped with a 2WD/4WD select switch (1), which
permits a choice between the “2WD” and “4WD” drive modes.
Select a drive mode that’s suitable for your riding.
The 2WD/4WD select switch is located above the throttle lever. To
select the drive mode, slide the 2WD/4WD select switch to the
desired position.
To check your present drive mode, look at the 4WD indicator (2).
2WD mode: the 4WD indicator goes off.
4WD mode: the 4WD indicator goes on.
4WD can only be engaged while the engine is running.
It remains engaged until the 2WD mode is selected or the engine is
stopped.
Upon starting, your ATV will be in the 2WD mode, regardless of the
2WD/4WD select switch position.
2WD/4WD Select Switch
(2) (1)
(1) 2WD/4WD select switch (2) 4WD indicator
4WD mode 2WD mode
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Instruments & Controls
31
Controls & Features
The start button (1) is used for starting the engine. Pushing the
button in starts the engine. See Starting Procedure, page 67.
When the start button is pushed, the starter motor will crank the
engine. The starter motor will not operate if the engine stop switch
is in the OFF (r) position when the start button is pushed.
The engine stop switch (2) is used to stop the engine in an
emergency. To operate, slide the switch to the OFF (r) position. The
switch must be in the RUN (e) position to start the engine, and it
should normally remain in the RUN (e) position even when the
engine is OFF.
If your ATV is stopped with the ignition switch ON (q) and the engine
stop switch OFF (r), the battery will discharge. Turn the ignition
switch OFF (w) to prevent battery discharge.
Start Button
o
Engine Stop Switch
e r
LEFT HANDLEBAR
(1) start button
(2) engine stop switch
o START
e RUN
r OFF
(2)
(1)
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Instruments & Controls
32
Controls & Features
The headlight switch (1) is used to turn the headlight ON (y) or OFF
(t). To operate, turn the switch to ON (y) or OFF (t).
The headlight dimmer switch (2) is used to change between the high
and low beams of the headlight. To operate, turn the switch to HI
(u) for high beam, LO (i) for low beam.
Press the horn button (3) to sound the horn.
Headlight Switch
y t
Headlight Dimmer Switch
u i
Horn Button
(1) headlight switch
(2) headlight dimmer switch
(3) horn button
LEFT HANDLEBAR
y ON
t OFF
u HI
i LO
(1)
(2)
(3)
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Instruments & Controls
33
Controls & Features
The recoil starter (1) is used to start the engine when the battery is
low. See Using the Recoil Starter, page 70.
Recoil Starter
RIGHT SIDE
(1) recoil starter
(1)
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Instruments & Controls
34
Controls & Features
The throttle controls engine rpm (speed). To increase engine rpm,
press the throttle lever (1) with your thumb. To reduce engine rpm,
release pressure on the throttle lever. The throttle will automatically
return to the closed position (engine idle) when you remove your
thumb.
Throttle Lever
RIGHT HANDLEBAR
(1) throttle lever
(A) to open the throttle
(A)
(1)
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Instruments & Controls
35
Controls & Features
Two gearshift switches are used in the manual shift (ESP) mode.
These switches are used to select the next higher or lower gear in the
transmission. To operate, press the upshift switch (1) to engage the
next higher gear or press the downshift switch (2) to engage the
next lower gear.
See Shifting Gears, page 71.
Gearshift Switch
LEFT HANDLEBAR
(1)
(2)
(1) upshift switch (2) downshift switch
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Instruments & Controls
36
Controls & Features
The front brake lever is used to slow or stop your ATV. To operate,
pull the lever. For information on braking techniques, see page 79.
The rear brake lever/parking brake lever is used to slow or stop your
ATV. To operate, pull the lever. For information on braking
techniques, see page 79.
The rear brake pedal is used to slow or stop your ATV. To operate,
depress the pedal. For information on braking techniques, see
page 79.
Front Brake Lever
Rear Brake Lever/Parking Brake Lever
Rear Brake Pedal
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Instruments & Controls
37
Controls & Features
The lock lever (1) on the rear brake lever/parking brake lever (2)
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. See Parking
page 93.
The brakelights are activated by applying the parking brake. When
using the parking brake, be sure to turn the ignition switch OFF (w)
to avoid discharging the battery.
Parking Brake
LEFT HANDLEBAR
(1) lock lever
(2) rear brake lever/parking brake lever
(A) to lock
(1)
(A)
(2)
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Instruments & Controls
38
Controls & Features
Flag poles are optional equipment available from your dealer. To
mount a pole in the bracket (1), follow the instructions that come
with the flag pole kit.
Flag poles are required in some riding areas. Check local regulations
before riding.
Flag Pole Bracket
RIGHT REAR
(1)
(1) flag pole bracket
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Instruments & Controls
39
Controls & Features
The trailer hitch (1) is located on the rear axle housing. To use the
hitch, you’ll need a proper size ball (2) as specified by the trailer
manufacturer.
To attach the ball and properly hook up a trailer, follow the trailer
manufacturer’s instructions, For load limits and operational
guidelines, see page 53.
Trailer Hitch
REAR
(1) trailer hitch (2) ball
(1)
(2)
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Instruments & Controls
40
Controls & Features
The accessory socket (1) is attached to the right side of the meter
cover (2). You can use the accessory socket to power a trouble light,
CB radio, or cell phone, etc.
NOTICE
Do not plug in any heat-generating or high wattage accessory, such
as an automobile cigarette lighter or high-power spotlight, because
it can damage the socket.
To use the accessory socket, turn the ignition switch ON (q), start the
engine. Then turn the headlights OFF (t), and open the accessory
socket cap (3).
Accessory Socket
RIGHT FRONT
(1)
(2)
(3)
(1) accessory socket
(2) meter cover
(3) cap
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Instruments & Controls
41
Controls & Features
Be sure the engine is on and the headlights are turned off before
using the accessory socket, otherwise you may drain the battery.
The accessory socket’s rated capacity is DC 12 V, 120 Watts (10 A)
or less. If you exceed this limit, you may blow a fuse. See If a Fuse
Blows, page 199.
When you are done using an accessory, unplug it, and cover the
socket with the cap.
Be careful not to flood this accessory socket when washing your
ATV.
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Instruments & Controls
42
19 TRX680FA (U)-32HN8A400.book Page 42 Thursday, June 14, 2018 1:25 PM
Before Riding
43
Before Riding
Before Rid ing
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. This section also includes important
information about loading.
Are You Ready to Ride?.............................................................. 44
Protective Apparel ................................................................... 44
Rider Training .......................................................................... 46
Age Recommendation ............................................................. 47
No Passengers ......................................................................... 47
No Alcohol or Drugs ................................................................ 48
Is Your ATV Ready to Ride? ........................................................ 49
Pre-ride Inspection ................................................................... 49
Load Limits & Guidelines............................................................. 53
Loading ................................................................................... 53
Load Limits .............................................................................. 54
Loading Guidelines .................................................................. 55
Accessories & Modifications........................................................ 56
Accessories.............................................................................. 56
Modifications........................................................................... 57
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Before Riding
44
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.
• You are wearing an approved motorcycle helmet (with chin strap
tightened securely), eye protection, and other protective
clothing.
• You don’t have any alcohol or drugs in your system.
For your safety, we strongly recommend that you always wear an
approved motorcycle helmet, eye protection, boots, gloves, trousers,
and a long-sleeved shirt or jacket whenever you ride.
Although complete protection is not possible, wearing proper gear
can reduce the chance of injury when you ride.
Following are suggestions to help you choose the proper gear.
Helmet and Eye Protection
Your helmet is your most important piece of riding gear because it
offers the best protection against head injuries. A helmet should fit
your head comfortably and securely.
Protective Apparel
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Before Riding
45
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.
Additional Riding Gear
In addition to a helmet and eye protection, we also recommend:
• Sturdy off-road motorcycle boots to help protect your feet,
ankles, and lower legs.
• Off-road motorcycle gloves to help protect your hands.
• Riding trousers with knee and hip pads, a riding jersey with
padded elbows, and a chest/shoulder protector.
WARNING
3
WARNING
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 a crash.
Always wear an approved motorcycle helmet
that fits properly and wear eye protection
(goggles or face shield), gloves, boots, long-
sleeved shirt or jacket and trousers.
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Before Riding
46
Are You Ready to Ride?
Developing your riding skills is an on-going process. Even if you have
ridden other ATVs, take time to become familiar with how this ATV
works and handles. Practice riding the ATV in a safe area to build
your skills. Do not ride in rough terrain until you get accustomed to
the ATV’s controls, and feel comfortable with its size and weight.
Rider Training
WARNING
3
WARNING
Operating this ATV without proper
instruction could increase your risk of a crash
which could lead to serious injury or death.
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.
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Before Riding
47
Are You Ready to Ride?
The minimum recommended age for this ATV model is 16. For
safety, never let children under 16 years old operate this vehicle.
This ATV is designed as an operator-only vehicle. The long seat is
designed to allow the rider to change body position, not for carrying
a passenger. Never let a passenger ride on the seat or on the front or
rear cargo racks.
Age Recommendation
WARNING
3
WARNING
A child using an ATV that is not
recommended for their age could lose vehicle
control while riding, resulting in severe injury
or death.
A child under 16 should never operate an ATV
with engine size greater than 90cc.
No Passengers
WARNING
3
WARNING
Carrying a passenger on this ATV greatly
reduces your ability to balance and control
this ATV and could cause a crash and you or
your passenger could be injured or killed.
Never carry a passenger on this ATV.
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Before Riding
48
Are You Ready to Ride?
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. Consult your doctor to be sure it is safe to operate
a vehicle after taking medication.
No Alcohol or Drugs
WARNING
3
WARNING
Operating this ATV after consuming alcohol
or drugs can seriously affect your judgement,
cause you to react more slowly, affect your
balance and perception, and result in serious
injury or death.
Never consume alcohol or drugs before or
while operating this ATV.
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Before Riding
49
(cont’d)
Is Your ATV Ready to Ride?
Before each ride, it’s important to inspect your ATV and make sure
any problem you find is corrected. A pre-ride inspection is a must,
not only for safety, but because having a breakdown, or even a flat
tyre, can be a major inconvenience.
If your ATV has overturned or been involved in a collision, do not ride
the vehicle until it has been inspected by your dealer. There may be
damage or other problems you cannot see.
Check the following items before you get on the ATV:
WARNING
3
WARNING
Improperly maintaining this ATV or failing to
correct a problem before riding can cause a
crash in which you can be seriously hurt or
killed.
Always perform a pre-ride inspection before
every ride and correct any problems.
Pre-ride Inspection
Engine Oil Check the level and add oil if needed
(page 117).
Check for leaks.
Radiator Coolant Check the coolant level and add coolant if
needed (page 127).
Check for leaks.
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Before Riding
50
Is Your ATV Ready to Ride?
Fuel Check the level and add fuel (page 112) 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. Also look for signs of damage or
excessive wear (page 157).
Drivetrain Boots Check for damage (page 163, 164).
Guards Check for damage or looseness (page 160 -
162).
Nuts & Bolts Check the wheels to see that the axle nuts
are tightened. Use a wrench to make sure all
accessible nuts, bolts, and fasteners are
tight.
Underbody & Exhaust
System
Check for, and remove, any dirt, vegetation
or other debris that could be a fire hazard or
interfere with the proper operation of the
vehicle.
Air Cleaner Housing
Drain Tube
Check for deposits in the drain tube. If
necessary, clean the tube (page 135) and
check the air cleaner housing.
Leaks, Loose Parts Walk around your ATV and look for anything
that appears unusual, such as a leak or loose
cable.
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Before Riding
51
Is Your ATV Ready to Ride?
If you are carrying cargo, also check the following:
Check these items after you get on the ATV:
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.
Check the brake pedal, left and right brake
levers independently activate the brakelight.
Loading Limits Make sure you do not exceed the load
limits (page 54).
Cargo Check that all cargo is secure.
Throttle Check the freeplay and adjust if needed.
Press the throttle to make sure it moves
smoothly without sticking, and snaps shut
automatically when it is released, in all
steering positions (page 136).
Brakes Squeeze the front and rear brake levers
and step on the rear brake pedal to check
that the controls operate normally. Press
down on the rear brake pedal several
times, then check for proper brake lever
freeplay (page 150). Make sure there is no
brake fluid leakage.
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Before Riding
52
Is Your ATV Ready to Ride?
Remember, be sure to take care of any problem you find, or have
your dealer correct it before you ride.
Headlight and
Headlight Dimmer Switch
Check for proper function (page 32).
Engine Stop Switch Check for proper function (page 31).
Steering Check that the wheels turn properly as you
steer the handlebar. Move the handlebar
right and left and check that there is no
excessive backlash.
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Before Riding
53
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.
In addition, exceeding the weight limits or carrying an unbalanced
load can seriously affect your ATV’s handling, braking and stability.
Adding accessories or making modifications that change this ATV’s
design and performance can also make it unsafe. Also, the weight of
any accessories will reduce the maximum load the ATV can carry.
More specific information on load limits, accessories, and
modifications follows.
How much weight you put on your ATV, and how you load it, are
important to your safety. If you decide to carry cargo, you should be
aware of the following information.
Loading
WARNING
3
WARNING
Overloading, improper loading, or carrying a
passenger can cause a crash and you can be
seriously hurt or killed.
Follow all load limits and other loading
guidelines in this manual.
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Before Riding
54
Load Limits & Guidelines
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.
Tongue weight can be measured with an ordinary bathroom scale.
Place the scale under the tongue, using either a tongue jack or other
support to keep the trailer level.
The weight of added accessories will reduce the maximum cargo
weight you can carry.
Load Limits
maximum weight capacity 220 kg (485 lb)
(includes the weight of the rider, all cargo, and accessories.)
front cargo rack weight limit
rear cargo rack weight limit
tow weight limit
= 30 kg (66 lb)
= 60 kg (133 lb)
= 385 kg (850 lb)
(Combined weight of the trailer and all cargo in the trailer)
tongue weight = 14 kg (30 lb) recommended
(Weight on the trailer tongue)
tongue and rear cargo weight = 60 kg (133 lb) maximum
(Combined weight on the trailer tongue and on the rear cargo rack)
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Before Riding
55
Load Limits & 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.
• Do not place cargo anywhere on the ATV other than on the front
and rear racks. Otherwise, operating stability may be adversely
affected.
• Never ride with a passenger on the front or rear cargo racks. The
ATV is not designed to carry a passenger.
• Use the trailer hitch to tow another vehicle or trailer. Do not tow
by tying a rope or cable to the rear rack.
• Load cargo on the rear rack as far forward as possible. Make sure
cargo on the front rack does not interfere with handlebar
movement.
• Do not allow cargo to extend beyond the edges of either the
front or rear racks.
• Make sure all cargo is secured before riding.
• Balance cargo weight evenly on both sides.
• Never exceed the maximum weight limit.
• When towing a trailer, take care to maintain balance and
stability. Distribute cargo between the front and rear of the trailer
to obtain the recommended tongue weight.
• When towing a trailer, select the ESP mode (page 74), and
choose the 1st shift position.
• Allow extra room for starting, stopping and turning whenever
you carry cargo or pull a trailer.
• Avoid riding on steep slopes when carrying cargo or pulling a
trailer.
• Never cross a slope when towing a trailer.
Loading Guidelines
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Before Riding
56
Accessories & Modifications
Modifying your ATV or using non-Honda accessories can make your
ATV unsafe.
Before you consider making any modifications or adding an
accessory, be sure to read the following information.
We strongly recommend that you use only Honda Genuine
Accessories that have been specifically designed and tested for your
ATV. Because Honda cannot test all other accessories, you must be
personally responsible for proper selection, installation, and use of
non-Honda accessories.
Check with your 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.
• Make sure the accessory does not interfere with your ability to
shift body position on the seat or operate hand and foot controls.
• Do not add any electrical equipment that will exceed the vehicle’s
electrical system capacity (page 213). A blown fuse can cause a
loss of lights or engine power (page 199).
WARNING
3
WARNING
Improper accessories or modifications can
cause a crash in which you can be seriously
hurt or killed.
Follow all instructions in this owner’s manual
regarding accessories and modifications.
Accessories
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Before Riding
57
Accessories & 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.
Modifications
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Before Riding
58
19 TRX680FA (U)-32HN8A400.book Page 58 Thursday, June 14, 2018 1:25 PM
Basic Operation & Riding
59
Basic Operation & Riding
(cont’d)
Basic O peration & R iding
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 214).
Safe Riding Precautions .............................................................. 61
Off-road Use Only.................................................................... 61
Keep Hands and Feet on Controls............................................ 62
Riding Position & Safety Equipment ......................................... 63
Control Speed ......................................................................... 63
Use Care on Unfamiliar or Rough Terrain ................................. 64
Do Not Perform Stunts............................................................. 65
Starting & Stopping the Engine................................................... 66
Preparation.............................................................................. 66
Starting Procedure ................................................................... 67
Flooded Engine........................................................................ 68
Bank Angle Sensor Ignition Cut-off System.............................. 68
Stalled Engine.......................................................................... 69
How to Stop the Engine........................................................... 69
Using the Recoil Starter............................................................ 70
Shifting Gears............................................................................. 71
Riding in Reverse ........................................................................ 77
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Basic Operation & Riding
60
Basic Operation & Riding
Braking....................................................................................... 79
Riding Your ATV......................................................................... 81
Making Turns .......................................................................... 81
Skidding or Sliding................................................................... 83
Riding Up Hills ......................................................................... 84
Riding Down Hills .................................................................... 88
Crossing or Turning on Hills or Slopes ...................................... 89
Riding Over Obstacles.............................................................. 91
Riding Through Water ............................................................. 92
Parking....................................................................................... 93
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Basic Operation & Riding
61
(cont’d)
Safe Riding Precautions
Before riding your ATV for the first time, please review the ATV
Safety section beginning on page 1, and the Before Riding section
beginning on page 51.
Even if you have ridden other ATVs, take time to become familiar
with how this ATV works and handles. Practice in a safe area until
you build your skills and get accustomed to the ATV’s size and
weight.
Your ATV and its tyres are designed and manufactured for off-road
use only, not for pavement. Riding on pavement can affect handling
and control. You should not ride your ATV on pavement.
When riding off-road, also remember to always obey local off-road
riding laws and regulations. Obtain permission to ride on private
property. Avoid posted areas and obey “no trespassing” signs.
Off-road Use Only
WARNING
3
WARNING
Operating this ATV on paved surfaces may
seriously affect handling and control of the
ATV, and may cause the vehicle to go out of
control.
Never operate the ATV on any paved surfaces,
including sidewalks, driveways, parking lots
and streets.
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Basic Operation & Riding
62
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.
Always keep both hands on the handlebars and both feet on the footpegs
when riding your ATV. This is important to maintain your balance and to
control the vehicle. Removing even one hand from the handlebars or one
foot from the footpegs can reduce your ability to control the ATV or could
cause you to lose your balance and fall off the ATV.
WARNING
3
WARNING
Operating this ATV on public streets, roads or
highways could cause you to collide with
another vehicle.
Never operate this ATV on any public street,
road or highway, even a dirt or gravel one.
Keep Hands and Feet on Controls
WARNING
3
WARNING
Removing hands from handlebars or feet
from footpegs during operation can reduce
your ability to control the ATV or could cause
you to lose your balance and fall off of the
ATV.
Always keep both hands on the handlebars
and both feet on the footpegs of your ATV
during operation.
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Basic Operation & Riding
63
Safe Riding Precautions
Sit on the vehicle as shown below, keeping your hands on the
handlebars and feet on the footpegs.
Riding at excessive speed increases the chance of a crash. 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.
Riding Position & Safety Equipment
Control Speed
WARNING
3
WARNING
Operating this ATV at excessive speeds
increases your chances of losing control of the
ATV, which can result in an accident.
Always go at a speed that is proper for your
vehicle, the terrain, visibility and other
operating conditions, and your experience.
Helmet and eye
protection
Off-road motorcycle
gloves
Long-sleeved apparel
and trousers
Off-road motorcycle
boots
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Basic Operation & Riding
64
Safe Riding Precautions
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.)
Use Care on Unfamiliar or Rough Terrain
WARNING
3
WARNING
Failure to use extra care when operating this
ATV on unfamiliar terrain could result in the
ATV overturning or going out of control.
Go slowly and be extra careful when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions when
operating the ATV.
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Basic Operation & Riding
65
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.
You should always operate your ATV in a safe and reasonable
manner. When riding, always keep all four wheels on the ground.
WARNING
3
WARNING
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
overturn.
Do not operate on excessively rough, slippery
or loose terrain until you have learned and
practiced the skills necessary to control the
ATV on such terrain. Always be especially
cautious on these kinds of terrain.
Do Not Perform Stunts
WARNING
3
WARNING
Attempting wheelies, jumps, and other stunts
increases the chance of an accident, including
an overturn.
Never attempt stunts, such as wheelies or
jumps. Don’t try to show off.
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Basic Operation & Riding
66
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.
WARNING
3
WARNING
Running the engine of your vehicle while in
an enclosed or even partially enclosed area
can cause a rapid build-up of toxic carbon
monoxide gas.
Breathing this colourless, odorless gas can
quickly cause unconsciousness and lead to
death.
Only run your vehicle’s engine when it is
located in a well ventilated area outdoors.
Preparation
(1) ignition switch
(2) neutral indicator
(3) engine stop switch
(2)
(1)
(3)
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Basic Operation & Riding
67
Starting & Stopping the Engine
1.
Before starting, select a level surface and lock the parking brake
(page 37).
2.
Turn the ignition switch (1) ON (q).
Confirm the following:
• The transmission is in neutral, and the neutral indicator (2) is ON.
• The engine stop switch (3) is set to RUN (e).
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).
Snapping the throttle or fast idling for more than 5 minutes may
cause exhaust pipe and muffler discolourations.
Starting Procedure
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Basic Operation & Riding
68
Starting & Stopping the Engine
If the engine fails to start after repeated attempts, it may be flooded
with excess fuel. To clear a flooded engine:
1.
Leave the engine stop switch set to RUN (e).
2.
Open the throttle fully.
3.
Press the start button for 5 seconds (or operate the recoil starter
several times).
4.
Follow the normal starting procedure.
5.
If the engine starts, then open the throttle slightly if idling is
unstable.
If the engine does not start, wait 10 seconds, then follow steps 1
– 4 again.
If the engine still won’t start, refer to If Your Engine Quits or Won’t
Start, page 188.
Your vehicle’s banking (lean angle) sensor system is designed to
automatically stop the engine if the vehicle is overturned.
Before restarting the engine, you must turn the ignition switch to the
OFF (w) position and then back to ON (q). The engine will not restart
until you perform this procedure.
Flooded Engine
Bank Angle Sensor Ignition Cut-off System
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Starting & Stopping the Engine
If the engine stalls, shift into neutral (N) and restart the engine.
If you are unable to shift to neutral (N) from drive (D), you can restart
the engine by squeezing the front brake lever and pressing the start
button while the vehicle is stopped.
Do not press the throttle lever while starting in gear. The engine will
not start if the throttle is fully open (because the electronic control
module cuts off the fuel supply).
Once you have started the engine, release the front brake lever, then
apply throttle gradually.
Normal Engine Stop
To stop the engine, make sure the transmission is in neutral by
checking that the neutral indicator light is on, then turn the ignition
switch OFF (w).
The engine stop switch should normally remain in the RUN (e)
position even when the engine is OFF.
If your ATV is stopped with the engine stop switch OFF (r) and the
ignition switch ON (q), the battery will discharge.
Emergency Engine Stop
To stop the engine in an emergency, use the engine stop switch. To
operate, slide the switch to the OFF (r) position.
Stalled Engine
How to Stop the Engine
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70
Starting & Stopping the Engine
The recoil starter is used to start the engine when the battery is low.
To operate the recoil starter:
1.
Turn the ignition switch to the ON (q) position.
2.
Check that the transmission is in neutral.
3.
Unsnap and remove the right side cover (1).
4.
Grasp the starter grip (2) firmly, then pull it out slowly
approximately 100 mm (4 in).
5.
Pull the grip up briskly and fully.
6.
After the engine starts, allow the starter grip to return slowly.
If the starter grip does not return smoothly, see your dealer.
The engine cannot be started if the battery is disconnected, low or
dead.
If the engine cannot be started with connecting the battery, charge
the battery (page 166).
When the engine cannot be started even if the battery is charged,
see your dealer.
Using the Recoil Starter
RIGHT SIDE
(1) right side cover
(2) recoil starter grip
(1)
(2)
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Shifting Gears
Your ATV has three shift lever positions: neutral (N), drive (D), and
reverse (R).
Neutral (N)
Use neutral when you start and warm up the engine, or if it is
necessary to stop briefly with the engine idling.
Drive (D)
Use this position for normal riding. The following two modes can be
selected in the drive position; automatic shift (AUTO) mode and
manual shift (ESP) mode.
You can select the desired mode with the drive mode select switch
(page 30).
Automatic shift (AUTO) mode:
Use this mode for everyday riding. The transmission automatically
adjusts to keep the engine at the best speed for riding conditions.
The gear position indicator shows “D” and the drive mode indicator
disappears.
Manual shift (ESP) mode:
In this mode, you can shift gears much like a manual transmission,
but without operating a clutch.
You can select three forward shift positions by operating the shift
switches; 1, 2, and 3.
The gear position indicator shows the selected position and the drive
mode indicator shows “ESP.”
When you tow a trailer, select the 1st shift position for proper
performance.
Reverse (R)
Use this position to ride in reverse.
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Shifting Gears
The shift lever (1) is located on the left side of the fuel tank.
To shift the shift lever, bring the ATV to a complete stop.
NOTICE
If the gearshift lever is moved while the vehicle is moving, the
transmission may be damaged.
The drive mode select switch (2) is located on the right handlebar
switches.
To select the drive mode, operate the drive mode select switch.
With the throttle fully closed, the drive mode can be changed during
running.
(1) (2)
(1) shift lever (2) drive mode select switch
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Shifting Gears
AUTO Mode
When the drive mode is at AUTO, shifting the lever to “D” (drive)
provides a 3-speed automatic transmission.
1.
While pulling up the shift lever (1), shift to “D.”
2.
Pull down the shift lever and confirm that the lever is locked and
the gear position indicator (3) is showing “D.”
Shifting to “N” (neutral) or “R” (reverse) is in the same manner as
above. For reverse, refer to the Riding In Reverse (page 77).
(1)
(3)
(1) shift lever
(3) gear position indicator
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74
Shifting Gears
ESP Mode
With the drive mode set at ESP, shifting the lever to “D” allows
manual shifting from 1st to 3rd using the gearshift switches.
Two gearshift switches are located next to the left handlebar grip:
upshift (a) and downshift (s).
To upshift the transmission, press the upshift switch (4) once.
To downshift the transmission, press the downshift switch (5) once.
UPSHIFTING SEQUENCE
(A)
(4)
DOWNSHIFTING SEQUENCE
(4) upshift switch
(5) downshift switch
(A) press
(5)
(A)
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75
Shifting Gears
After starting the engine and letting it warm up, follow these
procedures:
1.
Bring your ATV to a complete stop, select the ESP mode and shift
the shift lever into the “D” position.
NOTICE
If the gearshift lever is moved while the vehicle is moving, the
transmission may be damaged.
2.
Release the parking brake, but continue squeezing the rear brake
lever.
3.
Release the rear brake lever and increase engine speed by
gradually opening the throttle.
4.
When speed increases, release the throttle and upshift to 2nd
position by pressing the upshift switch once.
5.
Repeat this sequence to progressively upshift to 3rd (top)
position.
6.
To downshift, press the downshift switch once. Remember to
close the throttle each time you shift to the next lower position.
Learning when to shift gears in manual shift (ESP) mode comes with
experience. Keep the following tips in mind:
• As a general rule, shift while moving in a straight line.
• Close the throttle completely before shifting. Improper shifting
may damage the engine, transmission, and drivetrain.
• Upshift to a higher gear or reduce throttle before engine rpm
(speed) gets too high. Learn the relationship between engine
sound and the normal shifting points.
• Downshift to a lower gear before you feel the engine laboring
(lugging) at low rpm.
• Avoid downshifting to help slow your ATV when engine rpm is
high. Downshifting when engine speed is near its allowable
maximum may over-rev the engine and possibly cause damage.
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76
Shifting Gears
• To prevent transmission damage, do not coast or tow the ATV for
long distances with the engine off.
Recommended Shift Points
Ride in the highest gear that lets the engine run and accelerate
smoothly. This will give you good fuel economy and effective
emissions control.
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77
(cont’d)
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.
1.
Bring the vehicle to a complete stop, then make sure the
transmission is in neutral.
2.
Depress and hold down the brake pedal.
3.
Be sure there are no obstacles or people in the way.
4.
Shift the shift lever into “R” (reverse) gear.
NOTICE
Your ATV is equipped with a reverse speed limiter, which helps the
vehicle to maintain a safe speed while riding in reverse gear.
NOTICE
If the gearshift lever is moved while the vehicle is moving, the
transmission may be damaged.
5.
Release the rear brake pedal.
6.
Open the throttle gradually and ride slowly. Do not open the
throttle suddenly or make abrupt turns.
WARNING
3
WARNING
Improperly operating in reverse could cause
you to hit an obstacle or person behind you,
resulting in serious injury.
Make sure there are no obstacles or people
behind you before selecting reverse gear.
When it is safe to proceed, go slowly.
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78
Riding in Reverse
7.
To stop, close the throttle and gradually apply both the front and
rear brakes. Do not abruptly apply the rear brake by itself.
8.
To shift out of reverse and into neutral, shift the shift lever into
“N” (neutral) gear.
WARNING
3
WARNING
Applying only the rear brake abruptly when
operating in reverse gear could cause the
front wheels to lift off the ground and the
ATV could overturn backwards.
Carefully apply both the front and rear brakes
when stopping in reverse gear.
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79
Braking
Your ATV is equipped with disc brakes on both front wheels which
are hydraulically activated by operating the right brake lever. The
single disc brake of the rear drivetrain is hydraulically activated by
pressing down on the brake pedal and mechanically activated by
operating the left brake lever.
Although the front and rear brakes have separate controls, all four
wheels are interconnected when your ATV is in the 4WD mode. So
operating any brake control in the 4WD mode will cause braking at
both the front and rear wheels.
As a general rule, the front braking system provides about 70
percent of total stopping power.
For full braking effectiveness, use both the pedal and lever
simultaneously. Using both braking systems will stop your ATV faster
with greater stability.
To slow or stop, apply the brake lever and brake pedal smoothly, while
downshifting to match your speed when your ATV is in the ESP mode.
Gradually increase braking as you feel the brakes slowing your
speed. The increase in engine compression from downshifting will
help slow your vehicle when your ATV is in the ESP mode.
Applying the brakes too hard may cause the wheels to lock and slide,
reducing control of your ATV. If this happens, release the brake
controls, steer straight ahead until you regain control, then reapply
the brakes more gently.
When possible, reduce your speed or complete braking before
entering a turn. Avoid braking or closing the throttle quickly while
turning. Either action may cause one or more wheels to slip and
reduce your control of your ATV.
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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 (in the ESP mode), with intermittent use of
both brakes. Continuous brake application can overheat the brakes
and reduce their effectiveness.
Riding with your foot resting on the brake pedal or your hands on
the brake levers may overheat the brakes, reducing effectiveness.
For information on how to apply the brakes in various riding
situations, see the following section, Riding Your ATV.
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Riding Your ATV
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.
Making Turns
WARNING
3
WARNING
Turning improperly can make the ATV go out
of control, causing a collision or overturn.
• Always follow proper procedures for
turning as described in this owner’s manual.
• Practice turning at low speeds before
attempting to turn at faster speeds.
• Do not turn at excessive speeds.
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Riding Your ATV
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. Leaning into a turn is an
important technique to master in riding an ATV.
To make a sharp turn at low speed:
It helps to shift your body slightly
forward on the seat, and lean inside, as you steer the handlebar.
Shifting weight forward allows the rear wheels to turn easier, and it
also improves front-wheel steering.
To make a turn from a full stop:
Apply the throttle gradually when
you turn and start at the same time. Remember to shift your body
forward to make sharp low-speed turns and whenever you turn
while accelerating from a full stop.
Lean your body to the inside of a turn and forward.
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83
Riding Your ATV
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. To avoid skidding on slippery terrain, keep your
speed low and ride with caution.
If your ATV skids sideways during a turn, steer in the direction of the
skid. Avoid hard braking or accelerating until you have regained
directional control.
Skidding or Sliding
WARNING
3
WARNING
Skidding or sliding improperly may cause you
to lose control of this ATV. You may also
regain traction unexpectedly, which may
cause the ATV to overturn.
Learn to safely control skidding by practicing
at low speeds and on level, smooth terrain.
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84
Riding Your ATV
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.
However, you must be able to decide which hills or hazards might
cause the ATV to overturn. Avoid excessively steep hills.
When climbing hills, you must shift weight toward the front wheels
to help keep them on the ground. To do this, shift your body slightly
forward on the seat and lean forward. For greater weight shift, move
your body farther forward and lean forward.
Riding Up Hills
WARNING
3
WARNING
Operating on excessively steep hills can cause
the vehicle to overturn more easily than
operating on level surfaces or small hills.
Never operate the ATV on hills too steep for
the ATV or for your abilities.
WARNING
3
WARNING
Climbing hills improperly could cause loss of
control or cause the ATV to overturn.
Always follow proper procedures for climbing
hills as described in this owner’s manual.
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85
Riding Your ATV
• 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. Maintain a steady speed as you ascend
the hill.
• Never open the throttle suddenly or make sudden gear changes.
The ATV could flip over backward.
• Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.
Shift weight forward when climbing hills.
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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 happen, the ATV can stall and/or roll backwards.
What to do if the ATV stalls or rolls backwards when climbing a hill:
If you are about to lose all forward speed:
1.
Using the front and rear brakes together, bring the ATV to a stop
with the vehicle pointed straight uphill.
2.
Get off the ATV while you continue holding the brakes.
3.
Shift into neutral, set the parking brake and turn the engine off.
4.
Then assess the situation.
If the ATV starts rolling backwards before you begin braking:
1.
Keep your weight uphill.
2.
Carefully apply the front brakes first, then carefully apply the rear
brake. Do not apply either brake abruptly if you are rolling
backwards, or the vehicle may overturn.
If the ATV continues sliding backwards:
After you’ve applied the brakes, get off and away from the vehicle.
Remember that operating any brake control in the 4WD mode will
cause braking at both the front and rear wheels.
WARNING
3
WARNING
Stalling, rolling backwards or improperly
dismounting while climbing a hill could result
in the ATV overturning.
Always follow proper procedures for climbing
a hill as described in this owner’s manual.
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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. If possible, block the wheels so the
vehicle doesn’t roll backwards.
If the hill is not too steep and you have good footing, you may be
able to walk the ATV back down the hill. Make sure your intended
path is clear in case you lose control of the ATV.
1.
Stand with your body facing downhill, beside the vehicle so you
can reach the rear brake lever with your right hand.
2.
Be sure your legs are clear of the wheels.
3.
Check your footing.
4.
Slowly and carefully back the ATV down the hill using the rear
brake lever to control speed.
5.
If you lose control of the ATV, for your safety, get away from the
vehicle.
Be sure your legs are
clear of the wheels.
Body position for
backing down a hill.
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88
Riding Your ATV
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.
As you approach a downhill, stop and survey the terrain below.
Never ride past the limit of your visibility. Never go down a hill at
high speed.
Riding Down Hills
WARNING
3
WARNING
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.
On downhills, shift your weight back.
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89
Riding Your ATV
(cont’d)
When you’ve selected a safe downhill path, shift into a lower gear (in
the ESP mode), 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.
Remember that operating any brake control in the 4WD mode will
cause braking at both the front and rear wheels.
Remember, braking effectiveness is reduced on any hill with a loose
surface.
Riding on hills or slopes is different from riding on level terrain. Be
careful when riding on any hill. Make sure that you practice on
gentle, smooth slopes before attempting to ride on steeper or more
difficult terrain.
Crossing or Turning on Hills or Slopes
WARNING
3
WARNING
Improperly crossing hills or turning on hills
could cause loss of control or cause the ATV to
overturn.
Always follow proper procedures for crossing
or turning on slopes as described in this
owner’s manual. Avoid crossing steep hills if
possible.
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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.
• On a slippery or loose surface, you may also need to steer slightly
uphill to maintain a straight course across the slope.
• Avoid crossing hills that are excessively steep, slippery or rough.
Making Turns on Slopes
• Compared to riding on level ground, you may need to shift more
weight and lean more when making turns on slopes.
• Do not make turns on any slopes until you have first mastered the
techniques for making turns on level terrain.
Shift weight uphill when crossing slopes.
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91
Riding Your ATV
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.
Riding Over Obstacles
WARNING
3
WARNING
Improperly operating over obstacles could
cause loss of control or a collision and could
cause the ATV to overturn.
When you go over obstacles, always follow
proper procedures as described in this
owner’s manual.
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92
Riding Your ATV
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.
1.
Choose a path where both banks have gradual slopes.
2.
Proceed through the water at a slow, steady speed.
3.
Watch out for submerged obstacles and slippery rocks.
4.
Avoid getting the spark plug or air cleaner wet, as this would
cause the engine to stop.
5.
After leaving the water, always test both the front and rear
brakes.
• Riding through water can make the brakes less effective than
normal, and may reduce stopping ability.
• If necessary, apply the brakes repeatedly until they dry out and
operate normally.
Riding Through Water
WARNING
3
WARNING
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.
Never operate this ATV in fast-flowing water
or in water deeper than that specified in this
owner’s manual.
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93
Parking
1.
Look for level parking area. Make sure the ground surface is firm.
2.
After bringing your ATV to a stop, hold the brakes while you shift
into neutral.
3.
Set the parking brake.
4.
Turn the ignition switch OFF (w).
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.
The brakelights are activated by applying the parking brake. When
using the parking brake, be sure to turn the ignition switch OFF (w)
to avoid discharging the battery.
Parking on a Steep Incline or a Loose or Slippery Surface
If you must park your ATV on a steep incline or loose or slippery
surface, use the following procedure:
1.
While holding the brakes, set the parking brake.
2.
Turn the ignition switch OFF (w) and release the brakes.
3.
If the ATV begins to move, either while sitting on it or after you
dismount, find a better parking location.
4.
If rocks or other objects are available, you can block the wheels
as shown for additional security.
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94
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Servicing Your Honda
95
Servicing Your Honda
(cont’d)
Servicing Yo ur Honda
To help keep your ATV in good shape, this section includes a
Maintenance Schedule for required service and step-by-step
instructions for specific maintenance tasks. You’ll also find important
safety precautions, information on fuels and oils, and tips for
keeping your Honda looking good.
For information about replacing fuses, see page 199.
Before You Service Your Honda
The Importance of Maintenance................................................. 97
Maintenance Safety.................................................................... 98
Important Safety Precautions ................................................... 99
Maintenance Schedule ............................................................. 100
Maintenance Record................................................................. 104
Service Preparations
Maintenance Component Locations ......................................... 105
Tool Kit .................................................................................... 108
Owner’s Manual Storage .......................................................... 109
Seat Removal............................................................................ 110
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Servicing Your Honda
96
Servicing Your Honda
Service Procedures
Fluids & Filters
Fuel.......................................................................................... 111
Engine Oil & Filter..................................................................... 114
Rear Final Gear Oil.................................................................... 122
Front Final Gear Oil................................................................... 124
Coolant.................................................................................... 126
Air Cleaner............................................................................... 131
Engine
Throttle .................................................................................... 136
Spark Plugs............................................................................... 138
Valves....................................................................................... 142
Spark Arrester .......................................................................... 143
Chassis
Brakes ...................................................................................... 145
Tyres ........................................................................................ 153
Guards ..................................................................................... 160
Drivetrain Boots........................................................................ 163
Electrical
Battery ..................................................................................... 165
Appearance Care...................................................................... 170
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97
Before You Service Your Honda
The Importance of Maintenance
A well-maintained ATV is essential for safe, economical, and trouble-
free riding. It will also help reduce air pollution. Careful pre-ride
inspections and good maintenance are especially important because
your ATV is designed to be ridden over rough off-road terrain.
To help you properly care for your ATV, this section of the manual
provides a Maintenance Schedule. The service intervals in this
schedule are based on average riding conditions.
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 dealer
inspects all major parts, even if you are able to make some repairs.
WARNING
3
WARNING
Improperly maintaining this ATV or failing to
correct a problem before you ride can cause a
crash in which you can be seriously hurt or
killed.
Always follow the inspection and
maintenance recommendations and
schedules in this owner’s manual.
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Servicing Your Honda
98
Maintenance Safety
This section includes instructions on how to perform some important
maintenance tasks. If you have basic mechanical skills, you can
perform many of these tasks with the tools provided with your ATV.
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.
Some of the most important safety precautions follow. However, we
cannot warn you of every conceivable hazard that can arise in
performing maintenance. Only you can decide whether or not you
should perform a given task.
WARNING
3
WARNING
Failure to properly follow maintenance
instructions and precautions can cause you to
be seriously hurt or killed.
Always follow the procedures and
precautions in this owner’s manual.
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Servicing Your Honda
99
Maintenance Safety
• Make sure the engine is off before you begin any maintenance or
repairs. This will help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure
there is adequate ventilation whenever you operate the engine.
Burns from hot ATV parts. Let the engine and exhaust system
cool before touching.
Injury from moving parts. Do not run the engine unless
instructed to do so.
• Read the instructions before you begin, and make sure you have
the tools and skills required.
• To reduce the possibility of a fire or explosion, be careful when
working around petrol. Use only non-flammable solvent, not
petrol, to clean parts. 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.
Important Safety Precautions
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Servicing Your Honda
100
Maintenance Schedule
The required Maintenance Schedule that follows specifies how often
you should have your ATV serviced, and what things need attention.
It is essential to have your ATV serviced as scheduled to maintain
safe, dependable performance and proper emission control.
The service intervals in this Maintenance Schedule are based on
average riding conditions. Some items will need more frequent
service if you ride in unusually wet or dusty areas or at full throttle.
Consult your dealer for recommendations applicable to your
individual needs and use.
Some items in the Maintenance Schedule can be performed with
basic mechanical skills and hand tools. Procedures for these items
are provided in this manual. Other items involve more extensive
procedures and may require special training, tools, and equipment.
We recommend that you have your dealer perform these tasks
unless you have advanced mechanical skills and the required tools
and equipment. Procedures for such items in this schedule are
provided in an official Honda Shop Manual available for purchase.
If you do not feel capable of performing a given task or need
assistance, remember that your Honda dealer knows your ATV best
and is fully equipped to maintain and repair it. If you decide to do
your own maintenance, use only Honda Genuine Parts or their
equivalents for repair or replacement to ensure the best quality and
reliability.
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101
Maintenance Schedule
Perform the pre-ride inspection (page 49) and owner maintenance
on this section at each scheduled maintenance period.
Each item on the maintenance schedule requires some mechanical
knowledge. Certain items (particularly those marked
*
and
**
) may
require more technical information and tools. Consult your dealer.
Summary of Maintenance Schedule Notes & Procedures:
NOTES:
1.
Service more frequently when riding in dusty areas, sand or
snow.
2.
Service more frequently after riding in very wet or muddy
conditions.
3.
Replace every 2 years. Replacement requires mechanical skill.
* Should be serviced by your 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 dealer.
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102
Maintenance Schedule
Maintenance Procedures:
I: inspect and clean, adjust, lubricate, or replace, if necessary
C: clean
A: adjust
L: lubricate
R: replace
* Should be serviced by your dealer, unless you have the proper tools and service data, and are
mechanically qualified. Refer to the official Honda Shop Manual.
FREQUENCY
WHICHEVER
COMES FIRST
INITIAL REGULAR
Refer to
page
MAINT. MAINT. INTERVAL
km 150 1000 2000
mi 100 600 1200
MONTH
1612
ITEMS NOTE HOURS 20 100 200
* FUEL LINE I —
* THROTTLE OPERATION I 136
AIR CLEANER
NOTE 1
CC131
AIR CLEANER HOUSING
DRAIN TUBE
NOTE 2
II135
SPARK PLUG I I 138
* VALVE CLEARANCE I I I 142
ENGINE OIL INITIAL=
150 km (100 mi), 20
operating hours or 1
month: R
114
ENGINE OIL FILTER REGULAR=
Every 1,000 km (600 mi),
100 operating hours or 12
months: R
* ENGINE IDLE SPEED I I I —
RADIATOR COOLANT
NOTE 3
II126
* COOLING SYSTEM
NOTE 2
II—
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Servicing Your Honda
103
Maintenance Schedule
* Should be serviced by your 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 dealer.
FREQUENCY
WHICHEVER
COMES FIRST
INITIAL REGULAR
Refer to
page
MAINT. MAINT. INTERVAL
km 150 1000 2000
mi 100 600 1200
MONTH
1612
ITEMS NOTE HOURS 20 100 200
DRIVETRAIN BOOTS I I 163,164
FRONT/REAR FINAL GEAR
OIL
(R: EVERY
2 YEARS)
I 122,124
* BRAKE FLUID
NOTE 3
II145
* BRAKE PADS WEAR
NOTE 1, 2
I148
* BRAKELIGHT SWITCH I I I 152
BRAKE SYSTEM I I I 145
GUARDS I I 160
* SUSPENSION I I —
* SPARK ARRESTER C C 143
* NUTS, BOLTS, FASTENERS I I —
** WHEELS/TYRES I I I 153
** TIE-ROD AND JOINT
BOOTS
III—
** STEERING SHAFT HOLDER
BEARINGS
I—
** STEERING SYSTEM I —
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Servicing Your Honda
104
Maintenance Record
Keeping an accurate maintenance record will help ensure that your
ATV is properly maintained. Retain detailed receipts to verify the
maintenance was performed. If the ATV is sold, these receipts should
be transferred with the ATV to the new owner. Make sure whoever
performs the maintenance completes this record. All scheduled
maintenance, including the 150 km (100 mile) or 1 month or 20
hours initial maintenance, is considered a normal owner operating
cost and will be charged for by your dealer. Use the space under
Notes to record anything you want to remind yourself about or
mention to your dealer.
km (Miles) or
months or hours
ODO or
HOUR
Date Performed
By:
Notes
150 (100) or
1 or 20
1,000 (600) or
6 or 100
2,000 (1,200) or
12 or 200
3,000 (1,800) or
18 or 300
4,000 (2,400) or
24 or 400
5,000 (3,000) or
30 or 500
6,000 (3,600) or
36 or 600
7,000 (4,200) or
42 or 700
8,000 (4,800) or
48 or 800
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Servicing Your Honda
105
Servic e Preparati ons
Maintenance Component
Locations
front brake fluid reservoir
front brake lever
throttle lever
fuel fill cap
rear brake lever/parking
brake lever
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Servicing Your Honda
106
Maintenance Component
Locations
battery
fuse box
main fuse 1
main fuse 2
other fuses
air cleaner
rear brake fluid
reservoir
front brake caliper
air cleaner
housing
drain tube
front brake
caliper
rear brakelight
switch
rear brake pedal
engine oil filter
coolant
reserve
tank
front final gear oil
drain bolt
front final gear oil fill cap
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Servicing Your Honda
107
Maintenance Component
Locations
owner’s manual
storage compartment
air pressure gauge
spark plugs
tool kit
spark arrester
engine oil dipstick
engine oil fill cap
engine oil drain bolt
rear final gear
oil drain bolt
rear final gear
oil fill cap
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108
Tool Kit
The tool kit (1) is stored in the tool kit compartment (2) under the
seat. After using the tools, be sure to use the rubber band (3) to
fasten the tool kit securely.
To access the tool kit, remove the seat (see page 110), and then
remove the rubber band.
The tools in the kit are sufficient to perform routine maintenance
and simple repairs. Any extensive work requiring additional tools
should be performed by your dealer.
The tool kit includes the following items:
* standard/Phillips screwdriver
* screwdriver handle
* 10 × 12 mm open end wrench
* 14 mm box end wrench
* 17 mm box end wrench
* 5 mm Hex wrench
* spark plug wrench and handlebar
* pliers
* tool bag
UNDER SEAT
(2)
(3)
(1)
(1) tool kit
(2) tool kit compartment
(3) rubber band
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109
Owner’s Manual Storage
Your ATV provides storage for the owner’s manual so you’ll have it
with you for easy reference. Store your owner’s manual (1) in the
storage compartment (2) at the left side of the front fender.
To open the compartment, turn left the quick screw (3) and remove
the lid (4).
The owner’s manual and air pressure gauge (5) should be stored in
the plastic bag (6) and fastened with the rubber band (7).
Be careful not to flood this area when washing your ATV.
(3)
(2)
LEFT
(1) owner’s manual
(2) storage compartment
(3) quick screw
(4) lid
(5) air pressure gauge
(6) plastic bag
(7) rubber band
(1)
(5)
(6)
(7)
(4)
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Servicing Your Honda
110
Seat Removal
Refer to Safety Precautions on page 99.
The seat must be removed for the air cleaner, spark plugs and fuse
maintenance, and access to the tool kit.
Removal
1.
Pull the seat latch (1) at the rear of the seat.
2.
Slide the seat (2) back and lift it.
Installation
1.
Insert the front prongs (3) into the hooks (4) and press the studs
(5) into the grommets on the rear fender.
2.
Press down on the seat until it locks.
(1) seat latch
(2) seat
(3) front prongs
(4) hooks
(5) studs
(4)
(1)
(3) (3)
(2)
(5)
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Servicing Your Honda
111
Servic e Procedur esFluids & Filters
Fuel
Refer to Safety Precautions on page 99.
Use only unleaded fuel in your Honda. If you ride your Honda in a
country where leaded fuel might be available, take precautions to
use only unleaded fuel.
Your engine is designed to use any unleaded petrol that has a pump
octane number (R + M)/2 of 86 or higher, or a research octane
number of 91 or higher. Petrol pumps at service stations normally
display the pump octane number. For information on the use of
Petrol Containing Alcohol, see page 215
Use of lower octane petrol can cause persistent “pinging” or “spark
knock” (a loud rapping noise) which, if severe, can lead to engine
damage. Light pinging experienced while operating under a heavy
load, such as climbing a hill, is no cause for concern.
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 dealer.
Never use stale or contaminated petrol or an oil/petrol mixture.
Avoid getting dirt, dust, or water in the fuel tank.
Fuel Recommendation
type unleaded
research octane number 91 (or higher)
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112
Fuel
Fuel tank capacity:
16.8 ℓ (4.44 US gal , 3.70 Imp gal)
The tank should be refilled as soon as possible when the E segment
in the fuel gauge flashes.
Refer to Safety Precautions on page 99.
Fuel Capacity
Refueling Procedure
(3)
(1)
(2)
(3) fuel fill cap
(4) filler neck
(1) breather tube
(2) handlebar cover hole
(4)
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113
Fuel
1.
Pull the breather tube (1) out of the handlebar cover hole (2).
2.
To open the fuel fill cap (3), turn it counterclockwise.
3.
Add fuel until the level reaches the bottom of the filler neck (4).
Avoid over filling the tank. There should be no fuel in the filler
neck.
4.
After refueling, turn the fuel fill cap clockwise until it clicks.
5.
Insert the breather tube into the handlebar cover hole.
If you replace the fuel fill cap, use only a Honda Genuine
replacement part.
WARNING
3
WARNING
Petrol is highly flammable and explosive. You
can be burned or seriously injured when
handling fuel.
• Stop the engine and keep heat, sparks and
flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
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Servicing Your Honda
114
Engine Oil & Filter
Engine oil quality is a major factor that affects both the performance
and the service life of the engine.
Using the proper oil (page 115) and filter, and regularly checking,
adding, and changing oil will help extend your engine’s life. Even the
best oil wears out. Changing oil helps get rid of dirt and deposits in
the engine. Operating the engine with old or dirty oil can damage
your engine. Running the engine with insufficient oil can cause
serious damage to the engine and transmission.
Change the engine oil as specified in the maintenance schedule on
page 102. When running in very dusty conditions, oil changes
should be performed more frequently than specified in the
maintenance schedule.
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Servicing Your Honda
115
Engine Oil & Filter
*
Suggested oils are equal in performance to SJ oils that are not
labeled as energy conserving or resource conserving on the
circular API service label.
• Your ATV does not need oil additives. Use the recommended oil.
• Do not use oils with graphite or molybdenum additives. They may
adversely affect clutch operation.
• Do not use API SH or higher oils displaying a circular API “energy
conserving” or “resource conserving” service label on the
container. They may affect lubrication and clutch performance.
• Do not use non-detergent, vegetable, or castor based racing oils.
Oil Recommendation
API classification
*
SG or higher except oils labeled as
energy conserving or resource
conserving on the circular API
service label
viscosity (weight) SAE 10W–30
JASO T 903
standard
MA
NOT RECOMMENDED RECOMMENDED
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Servicing Your Honda
116
Engine Oil & Filter
Other viscosities shown in the following chart may be used when the
average temperature in your riding area is within the indicated
range.
JASO T 903 standard
The JASO T 903 standard is an index for engine oils for 4-stroke
motorcycle engines.
There are two classes: MA and MB.
Oil conforming to the standard is labeled on the oil container. For
example, the following label shows the MA classification.
(1)
(2)
(1) oil code
(2) oil classification
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117
Engine Oil & Filter
(cont’d)
Refer to Safety Precautions on page 99.
Check the engine oil level each day before operating your ATV and
add if needed.
Before riding your ATV, check the engine oil level.
1.
Park your ATV on a firm, level surface.
2.
Start the engine in a well-ventilated area and let it idle for 3–5
minutes. Stop the engine and wait 2–3 minutes.
3.
Remove the dipstick (1) from the front crankcase cover and wipe
it clean.
4.
Insert the dipstick without screwing it in, then remove the
dipstick and check the oil level. The oil level should be between
the upper level mark (2) and the lower level mark (3) on the
dipstick.
Checking & Adding Oil
LEFT SIDE
(1) dipstick
(2) upper level mark
(3) lower level mark
(2)
(3)
(1)
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118
Engine Oil & Filter
5.
If required, remove the oil fill cap lid (4) and oil fill cap (5) and add
the specified oil into the fill cap hole, up to the upper level mark
on the dipstick. Do not overfill.
6.
Reinstall the oil fill cap, oil fill cap lid and dipstick.
NOTICE
Running the engine with an improper oil level can cause serious
engine damage.
LEFT SIDE
(4) oil fill cap lid (5) oil fill cap
(5)
(4)
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119
Engine Oil & Filter
(cont’d)
Refer to Safety Precautions on page 99.
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.
NOTICE
Using the wrong oil filter may result in leaks or engine damage.
This procedure requires mechanical skill and professional tools such
as a torque wrench and oil filter wrench, as well as a means for
disposing of the drained fluid (page 180). If you do not have the
skills or the tools, see your dealer.
Drain the Engine Oil:
1.
With the ATV on level ground, remove the oil fill cap from the left
side of crankcase.
2.
Place an oil drain pan under the crankcase and remove the
engine oil drain bolt (1).
Changing Engine Oil & Filter
UNDER ENGINE
(1) engine oil drain bolt
(1)
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120
Engine Oil & Filter
Install a New Engine Oil Filter:
3.
Remove the oil filter bolt (2) and oil filter cover (3).
Let the remaining oil drain out.
4.
Remove the oil filter (4) from the cover.
5.
Remove the spring and washer. Do not discard the washer with
the old oil filter.
6.
Discard the oil filter.
7.
Coat new O-rings (5) with oil and install them into the grooves in
the oil filter cover and oil filter bolt. Then insert a new oil filter to
the oil filter cover.
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.
8.
Install the oil filter cover and tighten the oil filter bolt. Make sure
the oil filter bolt is tightened securely to the specified torque.
Oil filter bolt torque:
18 N·m (1.8 kgf·m , 13 lbf·ft)
NOTICE
Improper installation of the oil filter can cause serious engine damage.
(5)
(4)
(2) oil filter bolt
(3) oil filter cover
(2)
(3)
(4) oil filter
(5) O-rings
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121
Engine Oil & Filter
9.
Pour the drained oil into a suitable container and dispose of it in
an approved manner (page 184).
NOTICE
Improper disposal of drained fluids is harmful to the environment.
Add Engine Oil:
10.
Install a new sealing washer (6) onto the drain bolt.
11.
Apply a thin coat of oil to a new O-ring (7) with oil and install into
the groove in the oil drain bolt.
12.
Reinstall the engine oil drain bolt and tighten it to the specified
torque:
25 N·m (2.5 kgf·m , 18 lbf·ft)
13.
Fill the crankcase with the recommended grade oil
approximately:
2.9 ℓ (3.1 US qt , 2.6 Imp qt)
14.
Reinstall the oil fill cap.
15.
Start the engine, let it idle for 3–5 minutes.
16.
Stop the engine and wait 2–3 minutes and check the oil level.
Make sure the oil is between the upper and lower level marks on
the dipstick. If necessary, add more oil but do not overfill.
17.
Reinstall the oil fill cap and dipstick.
18.
Check that there are no oil leaks.
If a torque wrench is not used for installation, see your dealer as
soon as possible to verify proper assembly.
(6)
(7)
(6) drain bolt sealing washer (7) O-ring
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122
Rear Final Gear Oil
Refer to Safety Precautions on page 99.
Change the oil with the rear final gear at normal operating
temperature to assure complete and rapid draining.
Oil Recommendation
type hypoid gear oil
viscosity (weight) SAE 80W-90
suggested oil Honda shaft drive oil or equivalent
Changing Oil
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Servicing Your Honda
123
Rear Final Gear Oil
1.
Park the ATV on level ground.
2.
Place an oil drain pan under the oil drain bolt (1).
3.
Remove the oil fill cap (2), O-ring, drain bolt and sealing washer.
4.
After the oil has completely drained, reinstall the drain bolt with
a new sealing washer and tighten it to the specified torque:
12 N·m (1.2 kgf·m , 9 lbf·ft)
5.
Pour the drained oil into a suitable container and dispose of it in
an approved manner (page 184).
NOTICE
Improper disposal of drained fluids is harmful to the environment.
6.
Fill the rear final gear case with the recommended oil.
80 cm
3
(2.7 US oz , 2.8 Imp oz)
7. Make sure the oil level is at the lower edge of the inspection hole (3).
8.
Coat a new O-ring with grease and install it into the fill cap
groove and tighten it to the specified torque:
12 N·m (1.2 kgf·m , 9 lbf·ft)
REAR
(3)
(2) (1)
(1) oil drain bolt
(2) oil fill cap
(3) lower edge of the inspection hole
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124
Front Final Gear Oil
Refer to Safety Precautions on page 99.
Change the oil with the front final gear at normal operating
temperature to assure complete and rapid draining.
Oil Recommendation
type hypoid gear oil
viscosity (weight) SAE 80W-90
suggested oil Honda shaft drive oil or equivalent
Changing Oil
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Servicing Your Honda
125
Front Final Gear Oil
1.
Park the ATV on level ground.
2.
Place an oil drain pan under the oil drain bolt (1).
3.
Remove the oil fill cap (2), O-ring, drain bolt and sealing washer.
4.
After the oil has completely drained, reinstall the drain bolt with
a new sealing washer and tighten it to the specified torque:
12 N·m (1.2 kgf·m , 9 lbf·ft)
5.
Pour the drained oil into a suitable container and dispose of it in
an approved manner (page 184).
NOTICE
Improper disposal of drained fluids is harmful to the environment.
6.
Fill the front final gear case with the recommended oil.
180 cm
3
(6.1 US oz , 6.3 Imp oz)
Make sure the oil level is at the lower edge of the inspection hole (3).
7.
Coat a new O-ring with grease and install it into the fill cap
groove and tighten it to the specified torque.
12 N·m (1.2 kgf·m , 9 lbf·ft)
FRONT
(1) oil drain bolt
(2) oil fill cap
(3) lower edge of the inspection hole
(3)
(2)
(1)
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126
Coolant
Your ATV’s liquid cooling system dissipates engine heat through the
coolant jacket that surrounds the cylinder and cylinder head.
Maintaining the coolant will allow the cooling system to work
properly and prevent freezing, overheating, and corrosion.
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.
Use only distilled water as a part of the coolant solution. Water that
is high in mineral content or salt may be harmful to the aluminum
engine.
NOTICE
Using coolant with silicate inhibitors may cause premature wear of
water pump seals or blockage of radiator passages. Using tap water
may cause engine damage.
The factory provides a 50/50 solution of antifreeze and water in this
ATV. This coolant solution is recommended for most operating
temperatures and provides good corrosion protection.
Decreasing the concentration of antifreeze to less than 40% will not
provide proper corrosion protection.
Coolant Recommendation
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127
Coolant
(cont’d)
Increasing the concentration of antifreeze is not recommended
because it decreases cooling system performance. Higher
concentrations of antifreeze (up to 60%) should only be used to
provide additional protection against freezing. Check the cooling
system frequently during freezing weather.
Refer to Safety Precautions on page 99.
Check the engine coolant level each day before operating your ATV
and add if needed.
1.
Make sure the vehicle is on level ground.
2.
With the engine at normal operating temperature, check the
coolant level in the reserve tank (1). It should be between the
UPPER (2) and LOWER (3) level marks.
If the reserve tank is empty, or if coolant loss is excessive, check
for leaks and see your dealer for repair.
Checking & Adding Coolant
RIGHT FRONT
(1) reserve tank
(2) UPPER level mark
(3) LOWER level mark
(1)
(2)
(3)
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128
Coolant
3.
Remove the steering cover (4) and reserve tank cap (5).
Always add coolant to the reserve tank. Do not attempt to add
coolant by removing the radiator cap.
4.
Add coolant to the reserve tank as required to bring the coolant
level to the UPPER level mark.
5.
After adding coolant, install the reserve tank cap and steering
cover.
FRONT
(4) steering cover (5) reserve tank cap
(4)
(5)
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129
Coolant
Refer to Safety Precautions on page 99.
Coolant should be replaced by your dealer, unless you have the
proper tools and service data, and are mechanically qualified. Refer
to the official Honda Shop Manual.
To properly dispose of drained coolant, refer to You & the
Environment, page 184.
NOTICE
Improper disposal of drained fluids is harmful to the environment.
Coolant Replacement
WARNING
3
WARNING
Removing the radiator cap while the engine is
hot can cause the coolant to spray out,
seriously scalding you.
Always let the engine and radiator cool down
before removing the radiator cap.
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130
Coolant
Refer to Safety Precautions on page 99.
Check the air passages for clogging or damage. Remove insects,
mud, or any obstruction with low water pressure. Have the radiator
checked by your dealer if the air flow is restricted over more than
20% of the radiator surface.
Clean the radiator core after riding the ATV in mud.
To clean the radiator core, oil cooler and radiator cover plate:
1.
Unhook the tabs (1).
2.
Remove the radiator cover plate (2).
3.
Wash the radiator core (3), oil cooler (4) and radiator cover plate.
NOTICE
Do not apply pressured water directly to the radiator core and oil
cooler. The pressured water can damage the radiator core.
Radiator Core
FRONT
(1) tabs
(2) radiator cover plate
(3) radiator core
(4) oil cooler
(1)
(2) (3)
(4)
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Air Cleaner
Refer to Safety Precautions on page 99.
Proper air cleaner maintenance is very important for off-road
vehicles.
A dirty, water-soaked, worn-out, or defective air cleaner will allow
dirt, dust, mud, and other impurities to pass into the engine.
Service the air cleaner more frequently if you ride in unusually wet or
dusty areas. Your dealer can help you determine the correct service
interval for your riding conditions.
Your ATV’s air cleaner has very specific performance requirements.
Use a new Honda Genuine air cleaner specified for your model or an
air cleaner of equal quality.
NOTICE
Using the wrong air cleaner may result in premature engine wear.
Proper air cleaner maintenance can prevent premature engine wear
or damage, expensive repairs, low engine power, poor gas mileage,
and spark plug fouling.
NOTICE
Improper or lack of proper air cleaner maintenance can cause poor
performance and premature engine wear.
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Air Cleaner
1.
Remove the seat by pulling the seat latch (1) up.
2.
Unlatch the retainer clips (2).
3.
Remove the air cleaner housing cover (3).
Cleaning
UNDER SEAT
(1)
(1) seat latch
(2) retainer clips
(3) air cleaner housing cover
(2)
(3)
(2)
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Air Cleaner
(cont’d)
4.
Remove the element holder (4).
5.
Loosen the screw (5) and remove the air cleaner assembly (6)
from the air cleaner housing.
6.
Unscrew the clamp (7).
7.
Remove the air cleaner (8) from the air cleaner body (9).
8.
Gently wash the air cleaner in clean, non-flammable (high flash
point) solvent such as kerosene – not petrol. After cleaning,
gently squeeze out the remaining solvent. Avoid twisting or
wringing the air cleaner. This can tear the foam.
9.
Inspect for tears or cracks in the foam or seams of the air cleaner.
Replace the air cleaner if it is damaged.
UNDER SEAT
(4) element holder
(5) screw
(6) air cleaner assembly
(7) clamp
(8) air cleaner
(9) air cleaner body
(4)
(8)
(9)
(7)
(5)
(6)
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Air Cleaner
10.
Allow the air cleaner to dry thoroughly before applying oil. A wet
air cleaner will not fully absorb the oil.
11.
Pour clean air filter oil over the entire surface of the air cleaner.
Use both hands to evenly spread the oil into the air cleaner.
Gently squeeze out any excess oil. (To keep your hands dry, place
the air cleaner in a clean plastic bag before spreading the oil into
the air cleaner.)
12.
Install the air cleaner on the air cleaner body.
13.
Apply a thin coat of grease to the sealing surface of the air
cleaner assembly.
14.
Install the clamp.
15.
Insert the air cleaner assembly into the air cleaner housing.
16.
Install the element holder.
17.
Fasten the screw.
18.
Reassemble by reversing the disassembly sequence.
• Install the air cleaner housing cover with the FRONT mark (10)
facing forward and fit the tab (11) at the element holder.
UNDER SEAT
(11)
(10)
(11) tab
(10) FRONT mark
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135
Air Cleaner
The air cleaner housing drain tube should be serviced in accordance
with the Maintenance Schedule. (Riding through water may require
more frequent inspection.) If deposits can be seen in the drain tube,
the tube must be cleaned before starting the vehicle.
1.
Remove the drain tube (1) by removing the clip (2) under the air
cleaner housing (3).
2.
Drain the deposits.
3.
Reinstall the drain tube, securing it with the clip.
Air Cleaner Housing Drain Tube
REAR
(1) drain tube
(2) clip
(3) air cleaner housing
(3)
(2)
(1)
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Engine
Throttle
Refer to Safety Precautions on page 99.
Inspection
Check freeplay at the throttle lever (1).
Freeplay:
3 – 8 mm (0.1 – 0.3 in)
Adjustment
1.
Slide the rubber sleeve (2) back to expose the throttle cable
adjuster (3).
2.
Loosen the lock nut (4).
3.
Turn the adjuster to obtain the correct freeplay.
4.
Tighten the lock nut and reinstall the sleeve.
5.
After adjustment, check for smooth operation of the throttle
lever from fully closed to fully open in all steering positions.
Throttle Freeplay
RIGHT HANDLEBAR
(1) throttle lever
(2) rubber sleeve
(3) throttle cable adjuster
(4) lock nut
(A) decrease freeplay
(B) increase freeplay
3 – 8 mm
(0.1 – 0.3 in)
(3)
(4)
(2) (1)
(B)
(A)
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Throttle
Refer to Safety Precautions on page 99.
1.
Check that the throttle assembly is positioned properly and the
securing bolts are tight.
2.
Check for smooth operation of the throttle lever from fully open
to fully closed in all steering positions. If there is a problem, see
your dealer.
3.
Inspect the condition of the throttle cables from the throttle lever
down to the throttle body. If the cable is kinked or chafed, have
it replaced.
4.
Check the cables for tension or stress in all steering positions.
5.
Lubricate the cables with a commercially available cable lubricant
to prevent premature wear and corrosion.
Throttle Inspection
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Spark Plugs
Use only the recommended type of spark plug in the recommended
heat range.
NOTICE
Using spark plugs with an improper heat range can cause engine
damage.
Refer to Safety Precautions on page 99.
1.
Remove the seat (page 110).
2.
Remove the pin (1) by a Phillips screwdriver and pull the clip (2)
out of the hole.
3. Loosen the band screw (3) and remove the resonance chamber (4).
4.
Unhook the rubber cover (5).
Spark Plug Recommendation
standard spark plug CPR6EB-9 (NGK)
Spark Plug Inspection & Replacement
UNDER SEAT
(2)
(1)
(1) pin (4) resonance chamber
(2) clip (5) rubber cover
(4)
(3)
(3) band screw
(5)
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Spark Plugs
(cont’d)
5.
Remove the oil fill cap lid (page 118).
6.
Remove the bolts A (6), collars (7), bolts B (8) and left engine side
cover (9).
7.
Clean any dirt from around the spark plug bases.
8.
Disconnect the top spark plug cap (10) and side spark plug cap
(11). Take care to avoid damaging the spark plug wires when
disconnecting the caps.
9.
Using a spark plug wrench provided in the tool kit, remove the
spark plugs.
(7)
(6)
(6) bolts A (8) bolts B
(7) collars (9) left engine side cover
(9)
(8)
LEFT SIDE
(10)
(10) top spark plug cap (11) side spark plug cap
(11)
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Spark Plugs
10.
Inspect the electrodes and centre porcelain for deposits,
corrosion, or carbon fouling. If the corrosion or deposits are
heavy, replace the plug. Clean a carbon or wet-fouled plug with
a plug cleaner, if available, or a wire brush. Inspect the spark plug
electrodes for wear. The centre electrode (12) should have a flat
tip and sharp edges, and the side electrode (13) should not be
eroded. If the electrodes and insulator tip appear unusually
fouled or burned, we suggest that you contact your Honda
dealer.
11.
Discard the spark plug if there is apparent wear or if the insulator
is cracked or chipped.
12.
Using a wire-type feeler gauge, check the spark plug gap (14). If
adjustment is necessary, bend the side electrode carefully.
The gap should be:
0.80 to 0.90 mm (0.031 to 0.035 in)
(12) centre electrode
(14)
(14) spark plug gap
(13) side electrode
0.80 to 0.90 mm
(0.031 to 0.035 in)
(13)
(12)
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Spark Plugs
13.
With the plug washer attached, thread the spark plug in by hand
to prevent cross-threading.
14.
Tighten the spark plug:
• If the old plug is good:
1/8 turn after it seats.
• If installing a new plug, tighten it twice to prevent loosening:
a) First, tighten the plug:
b) Then loosen the plug.
c) Next, tighten the plug again:
1/8 turn after it seats.
NOTICE
An improperly tightened spark plug can damage the engine. If a
plug is too loose, the piston may be damaged. If a plug is too tight,
the threads may be damaged.
15.
Reinstall the top spark plug cap and side spark plug cap. Take
care to avoid pinching any cables or wires.
16.
Install the remaining parts in the reverse order of removal.
1/2 turn after it seats.
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Valves
Refer to Safety Precautions on page 99.
Valve clearance should be:
Excessive clearance will cause noise. Insufficient clearance will cause
loss of power and possibly damage the valves.
For those who are mechanically proficient and have the proper tools,
instructions on adjusting valve clearances are given in the official
Honda Shop Manual. Otherwise, the valves should be adjusted by
your dealer.
Valve Inspection
intake: 0.15 mm (0.006 in)
exhaust: 0.32 mm (0.013 in)
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143
Spark Arrester
Refer to Safety Precautions on page 99.
The exhaust system must be periodically purged of accumulated
carbon.
To purge the system:
1.
Allow the engine and muffler to cool.
2.
Remove the bolts (1), the spark arrester (2) and the gasket (3)
from the muffler (4).
REAR
(1) (2) (3) (4)
(1) bolts
(2) spark arrester (4) muffler
(3) gasket
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Spark Arrester
3.
Use a brush to remove carbon deposits from the spark arrester
screen (5). Be careful to avoid damaging the spark arrester
screen. The spark arrester must be free of breaks and holes.
Replace, if necessary. Check the gasket. Replace, if necessary.
4.
Install the spark arrester and the gasket in the muffler and tighten
the bolts to the specified torque:
12 N·m (1.2 kgf·m , 9 lbf·ft)
(5) spark arrester screen
(5)
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145
Cha ssis
Brakes
The hydraulic disc brakes (front) and a single hydraulic/mechanical
disc brake (rear) on your ATV dissipate the heat generated by the
friction of the brake pads on the disc as the wheels are slowed.
As the brake pads wear, the brake fluid level will drop. A leak in the
system will also cause the level to drop.
There are no adjustments to perform, but fluid level and pad wear
must be inspected periodically. The system must be inspected
frequently to ensure there are no fluid leaks.
If the brake lever or brake pedal freeplay does not feel within the
normal range while riding, check the brake pads for wear
(page 148).
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 dealer to have the air bled from the system.
The recommended brake fluid is DOT 4 Brake Fluid, or any brake
fluid of equal quality and performance. Use fresh brake fluid from a
sealed container. Be sure to read the label before opening the sealed
container. An opened container may be contaminated or may have
absorbed moisture from the air.
Brake Fluid Recommendation
brake fluid DOT 4 Brake Fluid
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Brakes
Refer to Safety Precautions on page 99.
Front Brake Fluid Level
If your inspection indicates a low fluid level, have your dealer add the
recommended fluid.
Do not add or replace brake fluid, except in an emergency. If you do
add fluid, have your dealer check the system as soon as possible.
NOTICE
Brake fluid can damage plastic and painted surfaces. Handle with
care.
With the ATV in an upright position, check the fluid level.
It should be above the LOWER level mark (1). If the level is at or
below the LOWER level mark, check the brake pads for wear
(page 148).
Worn brake pads should be replaced. If the pads are not worn, have
your brake system inspected for leaks.
Fluid Level Inspection
(1)
RIGHT HANDLEBAR
(1) LOWER level mark
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Brakes
Wipe up spills immediately. Avoid brake fluid contact with skin or
eyes. If it comes in contact with your eyes, wash them out with clean
water and immediately call a doctor. If it comes in contact with your
skin, wash with clean water and, if necessary, call a doctor.
Rear Brake Fluid Level
Remove the right side cover.
With the ATV in an upright position, check the fluid level.
It should be between the UPPER (1) and LOWER (2) level mark. If the
level is at or below the LOWER level mark, check the brake pads for
wear (page 148).
Worn brake pads should be replaced. If the pads are not worn, have
your brake system inspected for leaks.
• 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 dealer.
Other Inspections
(1)
RIGHT SIDE
(2)
(2) LOWER level mark(1) UPPER level mark
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Brakes
Refer to Safety Precautions on page 99.
Brake pad wear will depend upon the severity of usage and riding
conditions. The pads will wear faster in wet or muddy conditions.
Inspect the pads visually during all regular service intervals to
determine the pad wear.
Check the wear indicator (1). Remove the front wheels (page 195). If
the wear indicator aligns with the reference mark (2), both pads
must be replaced, see your dealer for this replacement.
Always inspect both pads in both the right and left front brake
calipers.
Brake Pad Wear
FRONT
(Left side similar)
(1) wear indicator (2) reference mark
(2)
(1)
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Brakes
Check the wear indicator. If the wear indicator (1) aligns with the
reference mark (2), replace both pads as a set, see your dealer for
this service.
REAR
(1) wear indicator (2) reference mark
(2)
(1)
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Brakes
Inspection
1.
Press down on the rear brake pedal several times.
2.
Measure the distance the rear brake lever/parking brake lever (1)
moves before the brake starts to take hold. Freeplay
(measurement at the tip of the end of the brake lever) should be:
25 – 30 mm (1 – 1.2 in)
3.
If necessary, adjust to the specified range.
Rear Brake Lever Freeplay
LEFT HANDLEBAR
(1) rear brake lever/parking brake lever
25 – 30 mm
(1 – 1.2 in)
(1)
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Brakes
Adjustment
Turn the brake lever adjusting nut (2), located on the brake
operating rod at the brake caliper. Make sure the cutout on the
adjusting nut is properly seated on the brake arm pin (3).
• 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.
Other Inspection
RIGHT REAR
(2) brake lever adjusting nut
(3) brake arm pin
(A)
(B)
(3)
(2)
(A) increase freeplay
(B) decrease freeplay
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152
Brakes
Refer to Safety Precautions on page 99.
Rear Brake Only:
Check the operation of the rear brakelight switch (1) at the right side
behind the engine from time to time. Adjustment is done by turning
the adjusting nut (2). Turn the nut in direction (A) if the switch
operates too late and in direction (B) if the switch operates too soon.
Brakelight Switch Adjustment
RIGHT SIDE
(1) brakelight switch
(2) adjusting nut
(1)
(2)
(A)
(B)
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153
Tyres
To safely operate your ATV, your tyres must be the proper type and
size, in good condition with adequate tread, and correctly inflated.
This ATV is equipped with low pressure tubeless tyres. Although the
tyres are designed specifically for off-road use, they are not immune
to punctures. 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.
WARNING
3
WARNING
Using tyres that are excessively worn or
improperly inflated can cause a crash in which
you can be seriously hurt or killed.
Follow all instructions in this owner’s manual
regarding tyre inflation and maintenance.
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Tyres
Refer to Safety Precautions on page 99.
Properly inflated tyres provide the best combination of handling,
tread life, and riding comfort. Generally, underinflated tyres wear
unevenly, adversely affect handling, and are more likely to fail from
being overheated. Overinflated tyres make your ATV ride harshly, are
more prone to damage from surface hazards, and wear unevenly.
Make sure the valve stem caps are secure. If necessary, install new
caps.
Air Pressure
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155
Tyres
Always check air pressure when your tyres are “cold.” If you check
air pressure when your tyres are “warm” – even if your ATV has only
been ridden for a few miles – the readings will be higher. If you let
air out of warm tyres to match the recommended cold tyre
pressures, the tyres will be underinflated. Be sure to check tyre
pressure at the riding site, since changes in altitude can affect air
pressure.
The recommended “cold” tyre pressures are:
FRONT REAR
NO CARGO
RECOMMENDED
PRESSURE
30 kPa
(4.4 psi)
25 kPa
(3.6 psi)
WITH CARGO
RECOMMENDED
PRESSURE
30 kPa
(4.4 psi)
25 kPa
(3.6 psi)
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Tyres
A manually operated tyre pump should be used rather than the high
pressure system found in service stations. This will minimize the
possibility of tyre damage from overinflation. If you use a high
pressure system at a service station, add air in small amounts and
check the pressure increase frequently to prevent possible tyre
damage from overinflation.
Refer to Safety Precautions on page 99.
Whenever you check the tyre pressures, you should also look for:
• Bumps or bulges in the side of the tyre or the tread. Replace any
tyre that has a bump or bulge.
• Cuts, slits, or cracks in the tyres. Replace the tyre if you can see
fabric or cord.
• Nails or other foreign objects embedded in the side of the tyre or
tread.
• Excessive tread wear.
WARNING
3
WARNING
Operating this ATV with improper tyres, or
with uneven tyre pressure may cause loss of
control, and you could be seriously injured or
killed.
• Always use the size and type tyres specified
in this owner’s manual for this vehicle.
• Always maintain proper tyre pressure as
described in this owner’s manual.
Inspection
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Tyres
Also, if you hit a pothole or other hard object while riding, stop as
soon as you safely can and carefully inspect the tyres for damage.
Tread Wear
To check the condition of a tyre tread, measure the groove depth (1)
in the centre of the tyre, or check the wear indicator (2).
For best performance, you should replace a tyre before the tread
depth at the centre reaches the following limits:
front 4 mm (0.16 in)
rear 4 mm (0.16 in)
Front
Rear
4 mm
(0.16 in)
NEW
Replace
(2)
Replace
NEW
(3)
4 mm
(0.16 in)
(2)
(1) groove depth
(2) wear indicator
(3) wear indicator location mark
(1)
(1)
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Tyres
Refer to Safety Precautions on page 99.
A tyre that is repaired, either temporarily or permanently, will have
lower speed and performance limits than a new or undamaged tyre.
A temporary repair can sometimes be made in an emergency
situation. However, since a temporary repair may not hold, you must
ride very slowly, preferably without any cargo, and have the tyre
replaced or permanently repaired as soon as possible. (For more
information on temporary repairs, see If You Have a Flat Tyre,
page 193.)
A permanent repair, such as an internal plug patch, can be made if
a tyre has only a small puncture in the tread area. However you may
not be able to safely carry as much weight. 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 dealer.
Tyre Repair
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Tyres
Refer to Safety Precautions on page 99.
The tyres that came on your ATV were designed to match the
performance capabilities of your ATV and provide the best
combination of handling, braking, and comfort.
It is best to replace all four tyres, however if that is not possible, you
must replace the tyres in pairs (front or rear) with tyres of the same
size and type as the originals. Never replace just one tyre.
The recommended tyres for your ATV are:
When you replace a tyre, remember:
Have the tyre replaced by your dealer if possible.
If you have a tyre professionally repaired at a non-Honda facility, we
recommend that you have the work checked by your dealer.
Tyre Replacement
WARNING
3
WARNING
Installing improper tyres on your ATV can
affect handling and stability. This can cause a
crash in which you can be seriously hurt or
killed.
Always use the size and type of tyres
recommended in this owner’s manual.
front AT25 × 8-1211 MAXXIS M975
rear AT25 × 10-1211 MAXXIS M978
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Guards
Refer to Safety Precautions on page 99.
The engine guard (1) protects the engine crankcase.
The skid plate (2) protects the frame. Check the guard and plate for
cracks, damage or looseness at intervals shown in the 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.
Skid Plate & Engine Guard
(1)
(1) engine guard
(2)
(2) skid plate
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161
Guards
Refer to Safety Precautions on page 99.
Check the front boot guards (1) and front driveshaft guards (2) for
cracks, damage or looseness.
Tighten any loose fasteners. Replace the front boot guards and front
driveshaft guards as required.
Front Boot Guards & Front Driveshaft Guards
(1) front boot guards
(1)
(2) front driveshaft guards
(2) (2)
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162
Guards
Refer to Safety Precautions on page 99.
Check the rear boot guards (1) for cracks, damage or looseness.
Tighten any loose fasteners. Replace the rear boot guards as
required.
Rear Boot Guards
(1) rear boot guards
(1)
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163
Drivetrain Boots
Refer to Safety Precautions on page 99.
Check the rubber driveshaft boots (1) for cuts, damage or leaking
grease. If necessary, have your dealer replace them.
Front Driveshaft Boots & Rear Driveshaft Boots
FRONT
REAR
(1) rubber driveshaft boots
(1)
(1)
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164
Drivetrain Boots
Refer to Safety Precautions on page 99.
Check the rubber propeller shaft boots (1) and rubber yoke joint
boot (2) for cuts, damage or leaking grease. If necessary, have your
dealer replace them.
Propeller Shaft Boots & Yoke Joint Boot
(1) rubber propeller shaft boots
(2) rubber yoke joint boot
(1) (2) (1)
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165
Electr ical
Battery
Your ATV has a maintenance-free type battery. You do not have to
check the battery electrolyte level or add distilled water as you would
with a conventional-type battery.
NOTICE
Your battery is a maintenance-free type and can be permanently
damaged if the cap strip is removed.
Electrical accessories use current from the battery, even when the
ignition is OFF. Limited operation also allows the battery to
discharge. If you have electrical accessories on your ATV or do not
ride frequently, we recommend that you charge the battery
frequently (see Battery Charging, page 169).
If you do not expect to ride your ATV for at least two weeks, we
recommend you remove the battery, or at least disconnect the
battery cables (negative cable first).
If you plan to store your ATV, see Battery Storage, page 166.
If your battery seems weak and/or is leaking electrolyte (causing slow
starting or other electrical problems), see your dealer.
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Battery
Refer to Safety Precautions on page 99.
If you plan to store your ATV, we recommend you remove the
battery and store it where it can be charged at least every 30 days to
maintain its service life.
If you do not remove the battery, we recommend disconnecting the
battery cables (negative cable first).
You will get the best storage results from removing the battery and
slow charging it every 30 days (see Battery Charging, page 169).
Before you remove the battery, be sure to read all the information
that follows, as well as the information on the battery label.
Battery Storage
WARNING
3
WARNING
The battery gives off explosive hydrogen gas
during normal operation.
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.
19 TRX680FA (U)-32HN8A400.book Page 166 Thursday, June 14, 2018 1:25 PM
Servicing Your Honda
167
Battery
(cont’d)
The battery is located under the rear fender.
Removal
1.
Make sure the ignition switch is OFF (w).
2.
Remove the battery cover (1) by removing the bolts (2).
3.
Release the rings and remove the rubber band (3).
4.
Disconnect the negative (–) terminal lead (4) from the battery (5)
first, then disconnect the positive (+) terminal lead (6).
5.
Remove the battery from battery box (7).
REAR FENDER
(4) (6)
(2)
(7) (5) (3) (1)
(1) battery cover
(3) rubber band
(2) bolts
(4) negative (-) terminal lead
(5) battery
(6) positive (+) terminal lead
(7) battery box
19 TRX680FA (U)-32HN8A400.book Page 167 Thursday, June 14, 2018 1:25 PM
Servicing Your Honda
168
Battery
6.
Charge the battery (see following section).
7.
Store your battery in an easy-to-reach location off the floor, in an
area protected from freezing temperature and direct sunlight.
8.
Clean the battery box after removing the battery for storage. Dry
the battery box and, if paint is missing, re-paint the area.
9.
Slow charge the battery (see following section) once every 30
days.
Installation
1.
Reinstall in the reverse order of removal.
Be sure to connect the positive (+) terminal first, then the
negative (–) terminal.
2.
Make sure all bolts and other fasteners are secure.
19 TRX680FA (U)-32HN8A400.book Page 168 Thursday, June 14, 2018 1:25 PM
Servicing Your Honda
169
Battery
Refer to Safety Precautions on page 99.
Be sure to read the information that came with your battery charger
and follow the instructions on the battery. Improper charging may
damage the battery.
We recommend using a charger (1) designed specifically for your
Honda, which can be purchased from your dealer. These units can
be left connected for long periods without risking damage to the
battery. 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.
Battery Charging
(1) charger
(1)
19 TRX680FA (U)-32HN8A400.book Page 169 Thursday, June 14, 2018 1:25 PM
Servicing Your Honda
170
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.
Refer to Safety Precautions on page 99.
• To clean your ATV, you may use:
– water
– a mild, neutral detergent and water
– a mild spray and wipe cleaner/polisher
– a mild spray and rinse cleaner/degreaser and water
• Avoid products that contain harsh detergents or chemical
solvents that could damage the metal, paint, and plastic on your
ATV.
• If your ATV is still warm from recent operation, give the engine
and exhaust system time to cool off.
• Park in a shady area. Washing your ATV in bright sunlight may
cause the finish to fade because water droplets intensify the sun’s
brightness.
• Spotting is also more likely because surface water can dry before
you have time to wipe it off.
• Clean your ATV regularly to protect surface finishes.
• We recommend the use of a low pressure garden hose to wash
your ATV. High pressure washers (like those at coin-operated car
washers) can damage certain parts of your ATV.
NOTICE
High pressure water (or air) can damage certain parts of your ATV.
Water entering the muffler may damage the oxygen sensor.
• After cleaning, inspect for damage, wear, and leaks (fuel, oil,
coolant and brake fluid).
General Recommendations
19 TRX680FA (U)-32HN8A400.book Page 170 Thursday, June 14, 2018 1:25 PM
Servicing Your Honda
171
Appearance Care
Refer to Safety Precautions on page 99.
1.
Cover or plug the exhaust outlet prior to washing your ATV.
2.
Rinse your ATV thoroughly with cool water to remove loose dirt.
3.
Fill a bucket with cool water. Mix in a mild, neutral detergent,
such as dish washing liquid or a product made especially for
washing motorcycles or automobiles.
4.
Wash your ATV with a sponge or soft towel. As you wash, check
for heavy grime. If necessary, use a mild cleaner/degreaser to
remove the grime.
5.
After washing, rinse your ATV thoroughly with plenty of clean
water to remove any residue. Detergent residue can corrode alloy
parts.
6.
Dry your ATV with a chamois or a soft towel. Leaving water on
the surface to air dry can cause dulling and water spots. As you
dry, inspect for chips and scratches.
7.
Remove the cover or the plug from exhaust outlet. Then, start the
engine and let it idle for several minutes. The engine heat will
help dry moist areas.
8.
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.
The headlight’s inside lens may fog temporarily after washing or
while riding in the rain. This does not impact the headlight
function.
Any condensation inside the headlight should dissipate after a
few minutes of running the engine with the headlight(s) on.
However, if you see a large amount of water or ice accumulated
inside the lens(es), have your vehicle inspected by your dealer.
Washing Your ATV with a Mild Detergent
19 TRX680FA (U)-32HN8A400.book Page 171 Thursday, June 14, 2018 1:25 PM
Servicing Your Honda
172
Appearance Care
Refer to Safety Precautions on page 99.
Avoid using spray cleaner products on the tyres or suspension
components.
Suggestions for using spray cleaner(s) follow:
Spray Cleaning Your ATV
ATV condition Recommended Cleaning
Dust and fingerprint
smudges.
Apply a spray cleaner/polish
and wipe paint, chrome, glass,
and clear plastic.
Light road grimes. Spray any difficult-to-reach or
very dirty areas with a spray
cleaner/degreaser.
Rinse and dry.
Apply a spray cleaner/polish
and wipe with a non-abrasive
cloth.
Heavy grime. Oil leaks.
Brake dust.
Use a spray cleaner/degreaser.
If necessary, rub with a
sponge.
Rinse and dry.
Apply a spray cleaner/polish
and wipe with a non-abrasive
cloth.
Dull, corroded chrome
or aluminum.
Apply a high quality chrome/
aluminum polish and wipe
with a non-abrasive cloth.
19 TRX680FA (U)-32HN8A400.book Page 172 Thursday, June 14, 2018 1:25 PM
Servicing Your Honda
173
Appearance Care
Refer to Safety Precautions on page 99.
Aluminum may corrode from contact with dirt, mud, or road salt.
Clean the wheels after riding through any of these substances. Use
a wet sponge and mild detergent. Avoid stiff brushes, steel wool, or
cleaners containing abrasives or chemical compounds.
After washing, rinse with plenty of water and dry with a clean cloth.
Then apply a mild, commercially available spray cleaner/polish or
wax.
For stained or dull-looking wheels, use a quality chrome/aluminum
polish to restore the finish.
Refer to Safety Precautions on page 99.
The exhaust pipe and muffler are stainless steel but may become
stained by mud or dust.
To remove mud or dust, use a wet sponge and a liquid kitchen
abrasive, then rinse well with clean water. Dry with chamois or a soft
towel.
If necessary, remove heat stains by using a commercially available
fine texture compound. Then rinse by the same manner as removing
mud or dust.
Aluminum Wheel Maintenance
Exhaust Pipe and Muffler Maintenance
19 TRX680FA (U)-32HN8A400.book Page 173 Thursday, June 14, 2018 1:25 PM
Servicing Your Honda
174
Appearance Care
Refer to Safety Precautions on page 99.
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.
Finishing Touches
19 TRX680FA (U)-32HN8A400.book Page 174 Thursday, June 14, 2018 1:25 PM
Tips
175
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.................................................................. 176
What to Take to the Riding Area............................................ 176
What to Take on the Trail ...................................................... 177
Transporting Your Honda ......................................................... 178
Storing Your Honda.................................................................. 180
Preparation for Storage ............................................................ 181
Removal from Storage .............................................................. 183
You & the Environment ............................................................ 184
19 TRX680FA (U)-32HN8A400.book Page 175 Thursday, June 14, 2018 1:25 PM
Tips
176
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.
Along with your ATV and riding gear, you should take along some
tools and supplies in case you have a problem. For some of the
difficulties you might encounter, see Taking Care of the Unexpected,
which begins on page 193.
We recommend that you always take water, food, a first aid kit, and
your owner’s manual. Other items you should consider loading on
your truck or trailer include:
• a tool kit
• tyre repair supplies and tools, and tyres
• extra parts, control levers, cables, and spark plugs
• wire, duct tape, and rope
• extra petrol
For safety, all refueling should be done at a gas station on the way
to the riding area or at your base camp.
What to Take to the Riding Area
19 TRX680FA (U)-32HN8A400.book Page 176 Thursday, June 14, 2018 1:25 PM
Tips
177
Preparing for a Ride
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.
If you decide to take some tools, spare parts, or other supplies on the
trail, be sure you can carry them safely and know how to use them.
Also, be sure to follow the loading guidelines and weight limit
(page 54).
What to Take on the Trail
19 TRX680FA (U)-32HN8A400.book Page 177 Thursday, June 14, 2018 1:25 PM
Tips
178
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.
Follow these procedures:
1.
Set the parking brake.
19 TRX680FA (U)-32HN8A400.book Page 178 Thursday, June 14, 2018 1:25 PM
Tips
179
Transporting Your Honda
2.
Secure the vehicle with tie-down straps in the areas shown.
• Suitable tie-down straps are available from your dealer.
• Ordinary rope is not recommended because it can stretch
under load.
• Using tie-down straps in any other areas can damage your ATV.
3.
Rock the vehicle back and forth to make sure the tie-down straps
are tight and the vehicle is secure.
(1)
(2)
(1) front cargo rack
(2) rear cargo rack
(3) trailer hitch
(3)
19 TRX680FA (U)-32HN8A400.book Page 179 Thursday, June 14, 2018 1:25 PM
Tips
180
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.
We suggest you perform the following procedures to keep your ATV
in top condition. These storage procedures will reduce the
deterioration that can occur during storage.
19 TRX680FA (U)-32HN8A400.book Page 180 Thursday, June 14, 2018 1:25 PM
Tips
181
Storing Your Honda
(cont’d)
Refer to Safety Precautions on page 99.
This procedure requires a means for draining and disposing of
drained fuel (page 184).
1.
Change the engine oil and filter (page 119).
2.
Make sure the cooling system is filled with a 50/50% antifreeze
solution (page 126).
3.
Fill the fuel tank. Make sure the fuel fill cap is properly installed.
Preparation for Storage
19 TRX680FA (U)-32HN8A400.book Page 181 Thursday, June 14, 2018 1:25 PM
Tips
182
Storing Your Honda
4.
To prevent rusting in the cylinders, perform the following:
• Remove the spark plug caps from the spark plugs.
• Remove the spark plugs.
Do not connect the spark plugs to the spark plug caps.
• Pour a tablespoon (15 – 20 cm
3
) of clean engine oil into the
cylinder and cover the spark plug holes with a piece of cloth.
• With the engine stop switch in the RUN (e) position, press the
start button several times to crank the engine and distribute
the oil.
• Reinstall the spark plugs and spark plug caps.
5.
Remove the battery and charge it fully. Store it in an area
protected from freezing temperatures and direct sunlight. Slow
charge the battery (page 169) once a month.
6.
Wash and dry your ATV. Wax all painted surfaces.
7.
Inflate the tyres to their recommended pressures (page 154).
8.
Store your ATV in an unheated area, free of dampness, away
from sunlight, with a minimum of daily temperature variation.
9.
Place your ATV on blocks to lift all tyres off the floor.
10.
Cover your ATV with a porous material. Avoid using plastic or
similar non-breathing, coated materials that restrict air flow and
allow heat and moisture to accumulate.
WARNING
3
WARNING
The battery gives off explosive hydrogen gas
during normal operation.
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.
19 TRX680FA (U)-32HN8A400.book Page 182 Thursday, June 14, 2018 1:25 PM
Tips
183
Storing Your Honda
Refer to Safety Precautions on page 99.
1.
Uncover and clean your ATV.
2.
If your ATV has been stored for more than four months – change
the engine oil (page 119).
3.
If your ATV has been stored for more than two months – ask your
dealer to drain and replace the fuel.
4.
Charge the battery (page 169) as required. Install the battery.
5.
Perform a pre-ride inspection (page 49), then test-ride your ATV
at low speeds.
Removal from Storage
19 TRX680FA (U)-32HN8A400.book Page 183 Thursday, June 14, 2018 1:25 PM
Tips
184
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.
• Tread Lightly. Stay on existing roads and trails, avoid surfaces
that are easily damaged, and ride only in areas approved for off-
road vehicles.
• Keep the Noise Down. Loud vehicles can be offensive. Ride as
quietly as possible, don’t remove your spark arrester, and don’t
modify the muffler or any other part of your air intake and
exhaust systems. Such modifications not only increase noise, they
also reduce engine performance and may be illegal.
• Choose Sensible Cleaners. Use a biodegradable detergent
when you wash your ATV. Avoid aerosol spray cleaners that
contain chlorofluorocarbons (CFCs) which damage the
atmosphere’s protective ozone layer. Don’t throw cleaning
solvents away; see the following guidelines for proper disposal.
• Recycle Wastes. It’s illegal and thoughtless to put used engine
oil in the trash, down a drain, or on the ground. Used oil, petrol,
and cleaning solvents contain poisons that can hurt refuse
workers and contaminate our drinking water, lakes, rivers, and
oceans. Before changing your oil, make sure you have the proper
containers. Put oil and other toxic wastes in separate sealed
containers and take them to a recycling centre. Call your local or
state office of public works or environmental services to find a
recycling centre in your area, and to get instructions on how to
dispose of non-recyclable wastes.
19 TRX680FA (U)-32HN8A400.book Page 184 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
185
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. Also review the tips in Preparing for
a Ride (page 176).
General Guidelines ................................................................... 186
If Your Engine Quits or Won’t Start .......................................... 188
If the Transmission Is Not Functioning Properly ......................... 191
If You Have a Flat Tyre.............................................................. 193
If the High Oil/Coolant Temperature Indicator Lights................. 197
If a Fuse Blows.......................................................................... 199
If You Crash ............................................................................. 203
If You Lose Your Key ................................................................ 204
If the Battery Is Low (or Dead)................................................... 205
If a Component Fails................................................................. 206
19 TRX680FA (U)-32HN8A400.book Page 185 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
186
Taking Care of the Unexpected
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.
If something goes wrong during a ride, the first thing to do is stop as
soon as you safely can. Do not continue riding if you have a flat tyre,
or you hear an unusual noise, or your ATV just doesn’t feel right. If
you continue riding, you could cause more damage and endanger
your own safety.
After stopping, take time to assess the situation. Carefully inspect
your ATV to identify the problem, then consider your options before
you decide what to do.
If a problem is relatively minor and you have the tools, supplies, and
skills to make a permanent repair, you may be able to fix it on the
trail and continue riding. Or, you may be able to make a temporary
repair that allows you to slowly ride back to your base where you can
make a permanent repair or get help.
When a problem is more serious – or you don’t have the tools,
supplies, experience, or time to deal with it – you need to choose the
safest way to get yourself and your ATV back to base. For example,
if you are close enough, you (or you and another person) might be
able to push it back.
General Guidelines
19 TRX680FA (U)-32HN8A400.book Page 186 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
187
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.
• Do not continue riding if you are hurt or your ATV is not in safe
riding condition.
Additional recommendations for specific problems follow.
19 TRX680FA (U)-32HN8A400.book Page 187 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
188
If Your Engine Quits or Won’t
Start
Proper operation and maintenance can prevent starting and engine
performance problems. In many cases, the cause of the problem may
be a simple operational oversight.
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 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 symptom. If you can hear the starter motor working
normally, refer to the Starter motor works, but the engine won’t
start symptom.
19 TRX680FA (U)-32HN8A400.book Page 188 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
189
If Your Engine Quits or Won’t
Start
SYMPTOM: Starter motor doesn’t operate.
POSSIBLE CAUSE WHAT TO DO
ignition switch OFF Turn the ignition switch ON.
engine stop switch OFF Slide the engine stop switch to
RUN.
transmission not in
neutral
Shift into neutral.
blown fuse Replace with a new fuse of the
same rating (page 199).
battery terminal loose Tighten the battery terminal.
low (or dead) battery Charge the battery (page 169).
If charging doesn’t help, see
your dealer.
faulty starter motor If all possible causes are
negative, the starter motor
may be faulty. See your dealer.
SYMPTOM: Starter motor works, but the engine won’t
start.
POSSIBLE CAUSE WHAT TO DO
out of fuel Fill the fuel tank.
flooded engine See Flooded Engine (page 68).
loose or unconnected
spark plug caps
Install the spark plug caps
securely. If the engine still
won’t start, see your dealer.
loose battery cables Tighten the battery terminal
bolts.
weak battery Charge the battery (page 169).
If charging doesn’t help, see
your dealer.
19 TRX680FA (U)-32HN8A400.book Page 189 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
190
If Your Engine Quits or Won’t
Start
SYMPTOM: Engine starts, but runs poorly.
POSSIBLE CAUSE WHAT TO DO
high oil/coolant
temperature
Check the high oil/coolant
temperature indicator. Refer
to If the High Oil/Coolant
Temperature Indicator Lights,
page 197.
runs erratically, misfires May damage catalytic
converter. See your dealer.
blubbers (rich fuel
mixture)
See your dealer.
sooty exhaust (rich fuel
mixture)
See your dealer.
detonates or pings
under load
If applicable, switch to the
recommended octane petrol
(page 111) or change your
brand of petrol. If the problem
persists, see your dealer.
afterfires (backfires) May damage catalytic
converter. See your dealer.
pre-ignition (runs on
after ignition switched
OFF)
May damage catalytic
converter. See your dealer.
SYMPTOM: Engine starts, but runs poorly or dies when
hot.
POSSIBLE CAUSE WHAT TO DO
poor or inadequate
fuel flow due to
clogged fuel filter
See your dealer.
(ensure clean fuel supply)
19 TRX680FA (U)-32HN8A400.book Page 190 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
191
(cont’d)
If the Transmission Is Not
Functioning Properly
Manual Shift (ESP) Mode:
If one or both shift switches do not function, stop riding your ATV in
the ESP mode. Switch to riding in the AUTO (automatic shift) mode.
Have your ATV inspected and repaired by your dealer.
Automatic Shift (Auto) Mode:
When the automatic transmission is not shifting properly, the gear
position indicator will show “--” and blink.
See your dealer to check and restore the automatic transmission.
If the gear position indicator shows “--” and blinks while riding,
perform the following:
1.
Stop the ATV.
2.
Turn the ignition switch to the “OFF” (w) position.
3.
After the engine stops, turn the ignition switch to the “ON” (q)
position.
4.
Check the gear position indicator.
When the “--” is blinking on the gear position indicator:
Restart the engine; drive the vehicle to a location where it can be
loaded and transported to your dealer.
When the display on the gear position indicator returns to normal:
You may drive the vehicle as usual after restarting the engine.
However, we urge you to have your ATV inspected by your dealer.
19 TRX680FA (U)-32HN8A400.book Page 191 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
192
If the Transmission Is Not
Functioning Properly
Although “--” is not blinking in the gear position indicator, the
vehicle does not move:
If your ATV won’t move, it is possible the transmission is locked. Use
the following procedure to unlock the transmission.
1.
Shift the shift lever in neutral (N) position.
2.
Apply the parking brake.
3.
Turn the ignition switch to the “OFF” (w) position.
4.
Loosen the screw (1) and release the lock plate (2).
5.
Turn the emergency valve (3) all the way in. With the engine
running, your ATV will move forward slowly at idle.
6.
See your dealer as soon as possible.
LEFT SIDE
(2)
(3)
(1)
(1) screw
(2) lock plate
(3) emergency valve
19 TRX680FA (U)-32HN8A400.book Page 192 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
193
(cont’d)
If You Have a Flat Tyre
How you handle a flat tyre on the trail depends on how serious the
tyre damage is, and what tools and supplies you have with you.
If you have a slow leak or a minor puncture, use the plug method to
make a temporary repair. (The plug method is applied from the
outside of the tyre and is the same as that for conventional tubeless
tyres.)
A plug-type repair kit, available at most auto parts stores or service
stations, provides a plug, an installation tool, tyre cement, and an
instruction sheet. Follow the instructions provided with the repair kit
to make a temporary repair.
As soon as possible, have the tyre permanently repaired by your
dealer. Any tyre that cannot be repaired should be replaced.
Whenever the ATV is to be operated far from service facilities or
available transportation, we recommend that you carry a tyre pump
and a repair kit with the vehicle.
19 TRX680FA (U)-32HN8A400.book Page 193 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
194
If You Have a Flat Tyre
If the leak is more serious, or a temporary repair doesn’t hold, the
tyre must be replaced. The tyre will also need to be replaced if it is
damaged (page 158). Replacing a tyre involves removing and re-
installing the wheel (page 195).
If you are unable to repair a flat tyre on the trail, you will need to
send for help. We strongly recommend that you do not try to ride
with a flat tyre. The ATV will be hard to handle, and if the tyre comes
off the rim, it may lock up the wheel and cause you to crash.
19 TRX680FA (U)-32HN8A400.book Page 194 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
195
If You Have a Flat Tyre
Refer to Safety Precautions on page 99.
Removal
1.
Park your ATV on a firm, level surface.
2.
Loosen – but do not remove – the wheel nuts (1).
3.
Raise the front (or rear) wheels off the ground and place a
support block under the vehicle.
4.
Remove the wheel nuts.
5.
Remove the wheel.
• Avoid getting grease, oil, or dirt on the disc or pad surfaces
when removing and installing each wheel. Any contamination
can cause poor brake performance or rapid pad wear after
reassembly.
Emergency Wheel Removal/Installation
(1) wheel nuts (2) wheel rim
(1)
(2)
(1)
19 TRX680FA (U)-32HN8A400.book Page 195 Thursday, June 14, 2018 1:25 PM
Taking Care of the Unexpected
196
If You Have a Flat Tyre
Installation
1.
Position the wheel.
2.
Position the wheel nuts so that the tapered sides face the wheel
rim (2).
3.
Hand-tighten the wheel nuts on the wheel, then lower the ATV
to the ground before tightening the nuts in a crisscross (rather
than circular) pattern to the specified torque:
64 N·m (6.5 kgf·m , 47 lbf·ft)
If a torque wrench was not used for installation, see your dealer as
soon as possible to verify proper assembly. Improper assembly may
lead to loss of braking capability.
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Taking Care of the Unexpected
197
(cont’d)
If the High Oil/Coolant
Temperature Indicator Lights
Normally, the high oil/coolant temperature indicator will only light
momentarily when you turn the ignition ON (q). Occasionally, it may
flicker at or near idling speed.
High oil/coolant temperature may be caused by restriction of air flow
to the radiator (such as mud caked on the radiator or oil cooler),
extended idling, an oil leak, a coolant leak, a low oil level, a low
coolant level, or extended operation under adverse conditions.
If the indicator comes on while you’re riding, don’t ignore it. Pull
safely to a stop. Stop the engine as soon as it’s safe to do so, and let
it cool.
NOTICE
Continuing to ride with low oil pressure or an overheated engine can
cause serious engine damage.
• A steaming engine indicates a coolant leak. Shut the engine off
and wait until the steaming stops. Look for a leak, but don’t
touch the engine or radiator system. Let everything cool off first.
• Check for any restriction of air flow to the radiator or oil cooler.
• If there’s no obvious problem, leave the engine on so the fan and
coolant circulating system can continue working. Monitor the
high coolant temperature indicator. The indicator may turn off
after a brief stop with no load on the engine.
• Check the radiator fan.
If the fan is not working, turn the engine off. Open the fuse box
(page 199) and check the radiator fan fuse. If the fuse is blown,
replace it with the proper (same rating) spare fuse. Start the
engine. If the high coolant temperature indicator comes on and
stays on, turn the engine off.
If the radiator fan is working, visually check the coolant level in
the reserve tank, located under the rear fender. It isn’t necessary
to touch the radiator system.
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Taking Care of the Unexpected
198
If the High Oil/Coolant
Temperature Indicator Lights
• If the reserve tank is low or empty, don’t ride without adding
coolant (page 127). After adding coolant, turn the engine on and
check the high coolant temperature indicator.
If the indicator doesn’t turn off, do not ride. The engine needs
repair.
Transport your ATV to your dealer.
If the temperature drops to normal, check the coolant level. If it
has gone down, add more coolant.
• Check for an oil leak.
• Check the oil level. If necessary, add the recommended oil
(page 115) to the upper level mark. If you must leave your ATV to
get oil, secure it as much as possible.
• Start the engine, and check that the high oil/coolant temperature
indicator goes off.
If you are able to resume riding, continue to monitor the high
coolant temperature indicator frequently.
If there is an oil leak – do not ride the ATV until the leak is repaired
by your dealer.
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 your dealer.
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Taking Care of the Unexpected
199
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 (1).
Check all the fuses before looking elsewhere for another possible
cause of the problem. Replace any blown fuses and check
component operation.
The main fuse and the circuit fuses are located under the seat.
Recommended Fuses
main fuse 1 30 A
main fuse 2 30 A
other fuses 15 A × 2, 10 A × 3
(1)
(1) blown fuse
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Taking Care of the Unexpected
200
If a Fuse Blows
Main Fuse Access
1.
To prevent an accidental short circuit, turn the ignition switch
OFF (w) before checking or replacing the fuses.
2.
Remove the seat (page 110).
3.
To access the main fuse (2) (3), remove the fuse box cover (4).
4.
Pull the main fuse out.
If it is blown, install the spare main fuse (5).
(2) main fuse 1 (4) fuse box cover
(5) spare main fuse
UNDER SEAT
(3) main fuse 2
(4)
(2)(3)
(5)
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Taking Care of the Unexpected
201
If a Fuse Blows
Circuit Fuse Access
5.
To check or replace a circuit fuse (6), pull the old fuse out of its
retaining clips.
If the fuse is blown, replace it with a spare fuse (7) 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.
NOTICE
Replacing a fuse with one that has a higher rating greatly increases
the chance of damage to the electrical system.
6.
Install the fuse box cover.
7.
Install the seat.
(6) circuit fuses (7) spare fuses
(6)
(7)
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Taking Care of the Unexpected
202
If a Fuse Blows
If you do not have a spare fuse and you cannot ride the ATV without
fixing the problem, take a fuse of the same rating or a lower rating
from one of the other circuits that you can do without temporarily.
If you replace a blown fuse with a spare fuse that has a lower rating,
replace the fuse with the correct rating as soon as you can. Also
remember to replace any spare fuses that were installed.
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 dealer.
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Taking Care of the Unexpected
203
If You Crash
Personal safety is your first priority after a crash. If you or anyone else
has been injured, take time to assess the severity of the injuries and
whether it is safe to continue riding. If you cannot ride safely, send
someone for help. Do not ride if you will risk further injury.
If you decide you are capable of riding safely, carefully inspect your
ATV for damage and determine if it is safe to ride. Check the
tightness of critical nuts and bolts securing such parts as the
handlebar, control levers, brakes, and wheels.
If there is minor damage, or you are unsure about possible damage
but decide to try riding the ATV back to your base, ride slowly and
cautiously.
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 dealer check the frame
and suspension after any serious crash.
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Taking Care of the Unexpected
204
If You Lose Your Key
Be sure to record your key number (1) at the following space. You’ll
need this number to have a duplicate key made.
If you lose your key and aren’t carrying a duplicate, either get your
spare or have one made. If you don’t know your key number, call the
dealer where you purchased your Honda ATV. They may have it
listed in their records. If they don’t, transport your ATV to them or
the nearest dealer. The dealer will probably have to remove the
ignition switch assembly to find the key number so they can make a
key for you.
KEY NO. __________________________________________________
(1) key number
(1)
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Taking Care of the Unexpected
205
If the Battery Is Low (or Dead)
Your ATV will operate even if the battery is low (or dead), as long as
the engine is running. If the engine is not running, it may be started
using the recoil starter.
1.
Shift the shift lever in neutral position.
2.
Apply the parking brake.
3.
Turn the ignition switch to the “ON” (q) position.
4.
Use the recoil starter (page 70) to start the engine.
Jump starting is not recommended, especially if you use an
automobile battery. The greater amperage of an automobile battery
when the car engine is running can damage your ATV’s electrical
system.
Bump starting is also not recommended.
If you can’t charge the battery or it appears unable to hold a charge,
contact your dealer.
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Taking Care of the Unexpected
206
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.
• If any component of the brake system is damaged, you may be
able to ride carefully back to your base using the other brake
components for slowing or stopping.
• If you damage a throttle cable or other critical component, your
ATV may be unsafe to ride. Carefully assess the damage and
make any repairs that you can. But if there is any doubt, it’s best
to be conservative and safe.
19 TRX680FA (U)-32HN8A400.book Page 206 Thursday, June 14, 2018 1:25 PM
Technical Information
207
Technical Information
Tech nical I nformat ion
This section contains dimensions, capacities, and other technical
data, plus information on government requirements and how to
break-in your ATV.
Vehicle Identification ................................................................ 208
Specifications ........................................................................... 210
Break-in Guidelines................................................................... 214
Petrol Containing Alcohol......................................................... 215
Catalytic Converter................................................................... 216
19 TRX680FA (U)-32HN8A400.book Page 207 Thursday, June 14, 2018 1:25 PM
Technical Information
208
Vehicle Identification
The VIN, engine serial number, and key number may be required
when ordering replacement parts. Record the numbers here for your
reference.
The VIN (1) is stamped on the front of the frame.
VIN ______________________________________________________
The engine number (2) is stamped on the upper side of the rear
crankcase.
ENGINE No. _______________________________________________
Serial Numbers
FRONT
(1) VIN
(1)
RIGHT SIDE
(2) engine number
(2)
19 TRX680FA (U)-32HN8A400.book Page 208 Thursday, June 14, 2018 1:25 PM
Technical Information
209
Vehicle Identification
The colour label (1) is attached to the frame under the seat.
Remove the seat (page 110) to check the label.
The colour code is helpful when ordering replacement parts. Record
the colour and code here for your reference.
COLOUR__________________________________________________
CODE ____________________________________________________
Colour Label & Code
UNDER SEAT
(1) colour label
(1)
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Technical Information
210
Specifications
Dimensions
overall length 2,117 mm (83.3 in)
overall width 1,235 mm (48.6 in)
overall height 1,206 mm (47.5 in)
wheelbase 1,284 mm (50.6 in)
ground clearance 232 mm (9.1 in)
Fuel & Lubricants
fuel
recommendation
unleaded petrol, research octane
number of 91 or higher
fuel tank capacity 16.8 ℓ (4.44 US gal , 3.70 Imp gal)
engine oil
capacity
after disassembly:
4.1 ℓ (4.3 US qt , 3.6 Imp qt)
after draining:
2.7 ℓ (2.9 US qt , 2.4 Imp qt)
after draining & oil filter change:
2.9 ℓ (3.1 US qt , 2.6 Imp qt)
engine oil API Service Classification SG or
higher except oils labeled as energy
conserving or resource conserving
on the circular API service label, SAE
10W-30, JASO T 903 standard MA,
Honda 4-stroke oil or an equivalent
cooling system
recommendation
High quality ethylene glycol
antifreeze containing corrosion
protection inhibitors specifically
recommended for use in aluminum
engines
cooling system
capacity
2.0 ℓ (2.1 US qt , 1.8 Imp qt)
19 TRX680FA (U)-32HN8A400.book Page 210 Thursday, June 14, 2018 1:25 PM
Technical Information
211
Specifications
Capacities
passenger capacity
operator only
maximum weight
capacity
220 kg (485 lb)
rider, all cargo and accessories
Engine Specifications
displacement 675 cm
3
(41.2 cu-in)
bore & stroke 102.0 × 82.6 mm (4.02 × 3.25 in)
compression ratio 9.2 : 1
spark plug
(standard)
CPR6EB-9 (NGK)
spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)
valve clearance
(cold)
intake: 0.15 mm (0.006 in)
exhaust: 0.32 mm (0.013 in)
idle speed 1,400 ± 100 min
-1
(rpm)
NO ADJUSTMENT
Power Transmission
primary reduction 1.333
secondary reduction forward 2.000
reverse 2.375
final reduction front 3.231
rear 3.154
transmission ratio 1st 2.052
2nd 1.375
3rd 0.933
reverse 2.138
final drive shaft
19 TRX680FA (U)-32HN8A400.book Page 211 Thursday, June 14, 2018 1:25 PM
Technical Information
212
Specifications
Chassis & Suspension
caster 2°
trail 7 mm (0.3 in)
tyre size, front AT25 × 8-1211
MAXXIS M975
tyre size, rear AT25 × 10-1211
MAXXIS M978
tyre pressure,
front & rear (cold)
front 30 kPa (4.4 psi)
rear 25 kPa (3.6 psi)
Electrical
battery YTX20L – BS
12 V –18 Ah (10 HR)
generator 0.409 kW/5,000 min
-1
(rpm)
Lights
headlight 12 V 40/40 W × 2
brakelight/taillight
12 V 21/5 W × 2
neutral indicator LED
reverse indicator LED
high oil/coolant
temperature
indicator
LED
PGM-FI indicator LED
4WD indicator LED
Fuses
main 1 30 A
main 2 30 A
other 15 A × 2, 10 A × 3
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Technical Information
213
Specifications
Torque Specification
engine oil drain bolt 25 N·m (2.5 kgf·m , 18 lbf·ft)
engine oil filter bolt 18 N·m (1.8 kgf·m , 13 lbf·ft)
rear final gear case oil
drain bolt
12 N·m (1.2 kgf·m , 9 lbf·ft)
rear final gear case oil
fill cap
12 N·m (1.2 kgf·m , 9 lbf·ft)
front final gear case
oil drain bolt
12 N·m (1.2 kgf·m , 9 lbf·ft)
front final gear case
oil fill cap
12 N·m (1.2 kgf·m , 9 lbf·ft)
spark arrester bolt 12 N·m (1.2 kgf·m , 9 lbf·ft)
wheel nuts 64 N·m (6.5 kgf·m , 47 lbf·ft)
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Technical Information
214
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 and rapid acceleration.
19 TRX680FA (U)-32HN8A400.book Page 214 Thursday, June 14, 2018 1:25 PM
Technical Information
215
Petrol Containing Alcohol
If you decide to use a petrol containing alcohol (gasohol), be sure its
octane rating is at least as high as that recommended above.
There are two types of gasohol: One contains ethanol, and the other
contains methanol. Do not use gasohol that contains more than
10% ethanol. Do not use gasohol that contains methanol (methyl or
wood alcohol) unless it also contains cosolvents and corrosion
inhibitors for methanol. Never use petrol containing more than 5%
methanol, even if it has cosolvents and corrosion inhibitors.
Engine performance problems resulting from the use of fuels that
contain alcohol are not covered under the warranty. Honda cannot
endorse the use of fuels containing methanol since evidence of their
suitability is not yet complete.
Before buying fuel from an unfamiliar station, try to find out if the
fuel contains alcohol. If it does, confirm the type and percentage of
alcohol used. If you notice any undesirable operating symptoms
while using a petrol that contains alcohol, or one that you think
contains alcohol, switch to a petrol that you know does not contain
alcohol.
19 TRX680FA (U)-32HN8A400.book Page 215 Thursday, June 14, 2018 1:25 PM
Technical Information
216
Catalytic Converter
This ATV is equipped with a three-way catalytic converter.
The catalytic converter contains precious metals that serve as
catalysts, promoting chemical reactions to convert the exhaust
gasses without affecting the metals.
The catalytic converter acts on HC, CO, and NOx. A replacement unit
must be an original Honda part or its equivalent.
The catalytic converter must operate at a high temperature for the
chemical reactions to take place. It can set fire to any combustible
materials that come near it. Park your ATV away from high grasses,
dry leaves, or other flammables.
A defective catalytic converter contributes to air pollution, and can
impair your engine’s performance. Follow these guidelines to protect
your ATV’s catalytic converter.
• Always use unleaded fuel. Even a small amount of leaded fuel
can contaminate the catalyst metals, making the catalytic
converter ineffective.
• Keep the engine in good running condition.
A poorly running engine can cause the catalytic converter to
overheat causing damage to the converter or the ATV.
• If your engine is misfiring, backfiring, stalling, or otherwise not
running properly, stop riding and turn off the engine. Have your
ATV serviced as soon as possible.
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Technical Information
217
19 TRX680FA (U)-32HN8A400.book Page 217 Thursday, June 14, 2018 1:25 PM
Index
Index
218
Index
A
accessories .................................................................................56
accessory socket .........................................................................40
age recommendation .................................................................47
air cleaner,
filter ......................................................................................131
housing drain tube ................................................................135
air pressure,
gauge ....................................................................................109
tyre .......................................................................................154
apparel, protective ......................................................................44
appearance care .......................................................................170
B
bank angle sensor ......................................................................68
battery .....................................................................................165
Brakes,
cables ....................................................................................151
brakes,
cables ....................................................................................151
fluid ......................................................................................145
front brake lever ......................................................................36
pad wear ...............................................................................148
parking ....................................................................................37
rear brake lever .......................................................................36
rear brake lever freeplay ........................................................150
rear brake pedal ......................................................................36
braking .......................................................................................79
break-in guidelines ...................................................................214
button,
hour select ..............................................................................25
minute select ...........................................................................25
odometer/tripmeter select .......................................................22
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Index
219
Index
C
capacity, fuel ............................................................................112
care, appearance ......................................................................170
cargo,
loading and operational guidelines ..........................................55
weight limit .............................................................................54
catalytic converter ....................................................................216
climbing hills ..............................................................................54
colour label ..............................................................................209
compartment,
owner’s manual .....................................................................109
tool kit ..................................................................................108
component fails ........................................................................206
controls & features .....................................................................27
crash, if you ..............................................................................203
crossing or turning on hills or slopes ...........................................89
D
digital clock ................................................................................25
dimmer switch, headlight ...........................................................32
dipstick .....................................................................................117
display, multi-function ................................................................17
drive mode indicator ...................................................................19
drive mode select switch .............................................................29
drivetrain boots ........................................................................163
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Index
220
Index
E
engine,
flooded ...................................................................................68
guard ....................................................................................160
number .................................................................................208
oil ..........................................................................................114
pinging ..................................................................................111
starting ....................................................................................66
stop switch ..............................................................................31
stopping ..................................................................................69
won’t start ............................................................................189
environment .............................................................................184
F
flag pole bracket ........................................................................38
flat tyre ....................................................................................193
flooded engine ...........................................................................68
front boot guards .....................................................................161
front driveshaft guards .............................................................161
front final gear oil .....................................................................124
fuel,
fill cap ...................................................................................112
gauge ......................................................................................26
recommendation ...................................................................111
tank capacity .........................................................................112
fuses ........................................................................................199
19 TRX680FA (U)-32HN8A400.book Page 220 Thursday, June 14, 2018 1:25 PM
Index
221
Index
G
gap, spark plug ........................................................................211
gear oil,
front final ..............................................................................124
rear final ................................................................................122
gear shifting ...............................................................................71
guards ......................................................................................160
H
headlight dimmer switch ............................................................32
headlight switch .........................................................................32
hills,
crossing or turning on slopes ...................................................89
riding down hills ...................................................................... 88
riding up hills ...........................................................................84
stopping on hills ......................................................................86
hour select button ......................................................................25
hour meter .................................................................................24
I
identification, vehicle ................................................................208
ignition cut-off system, bank angle .............................................68
ignition switch ............................................................................27
indicators,
4WD indicator ...................................................................16, 30
drive mode indicator ................................................................19
gear position indicator .............................................................20
high oil/coolant temperature indicator .....................................16
neutral indicator ......................................................................16
oil change indicator .................................................................21
PGM-FI indicator ......................................................................17
reverse indicator ......................................................................16
inspection, pre-ride .....................................................................49
19 TRX680FA (U)-32HN8A400.book Page 221 Thursday, June 14, 2018 1:25 PM
Index
222
Index
K
key, lost ....................................................................................204
kit, tool ....................................................................................108
L
lamp check .................................................................................14
limit, weight ...............................................................................54
loading guidelines ......................................................................55
lubrication,
engine oil ..............................................................................114
front final gear oil ..................................................................124
rear final gear oil ...................................................................122
M
maintenance,
component locations .............................................................105
importance ..............................................................................97
precautions .............................................................................99
record ...................................................................................104
safety ......................................................................................98
schedule ................................................................................100
maximum weight limit ................................................................54
minute select button ..................................................................25
modifications ..............................................................................57
multi-function display .................................................................17
N
neutral indicator .........................................................................16
numbers, serial .........................................................................208
19 TRX680FA (U)-32HN8A400.book Page 222 Thursday, June 14, 2018 1:25 PM
Index
223
Index
O
obstacles, riding over ..................................................................91
odometer ...................................................................................22
oil,
engine ...................................................................................114
front final gear ......................................................................124
high oil/coolant temperature indicator .............................14, 197
rear final gear ........................................................................122
operation component locations ..................................................11
owner’s manual storage ...........................................................109
oxygen sensor ..........................................................................170
P
parking .......................................................................................93
passenger, no carrying ................................................................47
pavement, no riding on ..............................................................61
petrol .......................................................................................111
petrol containing alcohol ..........................................................215
pinging, engine ........................................................................111
plugs, spark ..............................................................................138
pre-ride inspection ......................................................................49
problems, unexpected ..............................................................185
propeller shaft boots & yoke joint boot .....................................164
protective apparel .......................................................................44
19 TRX680FA (U)-32HN8A400.book Page 223 Thursday, June 14, 2018 1:25 PM
Index
224
Index
R
rear boot guards .......................................................................162
rear driveshaft boots .................................................................163
rear final gear oil ......................................................................122
recoil starter ...............................................................................33
removal, seat ............................................................................110
reverse,
gear, shifting into ....................................................................77
indicator ..................................................................................16
riding in ...................................................................................77
rider training ..............................................................................46
riding,
basic operations ......................................................................59
clothing ...................................................................................44
over obstacles ..........................................................................91
precautions .............................................................................61
preparing for .........................................................................176
safety ........................................................................................2
safety precautions ...................................................................61
through water .........................................................................92
19 TRX680FA (U)-32HN8A400.book Page 224 Thursday, June 14, 2018 1:25 PM
Index
225
Index
S
safety,
important precautions .............................................................99
riding precautions ....................................................................61
schedule, maintenance .............................................................100
seat removal .............................................................................110
serial numbers ..........................................................................208
shift lever ...................................................................................28
shifting gears ..............................................................................71
skid plate ..................................................................................160
skidding or sliding ......................................................................83
spark arrester ...........................................................................143
spark knock ..............................................................................111
spark plugs ...............................................................................138
specifications ............................................................................210
speedometer ..............................................................................17
stalling on a hill ..........................................................................86
start button ................................................................................31
starting,
engine .....................................................................................66
troubleshooting .....................................................................189
stop switch, engine ....................................................................31
stopping engine .........................................................................69
storage,
ATV .......................................................................................180
owner’s manual .....................................................................109
switch,
2WD/4WD select .....................................................................30
headlight .................................................................................32
headlight dimmer ....................................................................32
ignition ....................................................................................27
19 TRX680FA (U)-32HN8A400.book Page 225 Thursday, June 14, 2018 1:25 PM
Index
226
Index
T
throttle,
cable .....................................................................................136
lever ................................................................................34, 136
tool kit .....................................................................................108
trailer hitch .................................................................................39
trailer towing,
operational guidelines .............................................................55
weight limits ............................................................................54
training, rider .............................................................................46
transporting your ATV ..............................................................178
tripmeter ....................................................................................22
trouble, unexpected .................................................................185
troubleshooting, starting ..........................................................189
turning,
on hills or slopes ......................................................................89
on level ground .......................................................................82
tyres,
air pressure ............................................................................154
flat ........................................................................................193
repairing ................................................................................158
replacing ...............................................................................159
thread conditions ..................................................................156
V
valve clearance .........................................................................142
valve, fuel ...................................................................................27
vehicle identification no. (VIN) ..................................................208
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Index
227
Index
W
washing your ATV ....................................................................171
water,
riding through .........................................................................92
weight limit ................................................................................54
wheel removal ..........................................................................195
19 TRX680FA (U)-32HN8A400.book Page 227 Thursday, June 14, 2018 1:25 PM
00X32-HN8-A400
32HN8A40 WPCXXXX.2018.XX.19
PRINTED IN USA
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