INSTALLATION INSTRUCTIONS Accessory Application Publications No. RECOIL STARTER KIT P/N 08U78-HP7-100 TRX420FA/FE/FM/TE/TM TRX420FPA/FPE/FPM Honda Dealer: Please give a copy of these instructions to your customer. Mll 12542 Issue Date November 2008 PARTS LIST TOOLS AND SUPPLIES REQUIRED (6) (7) (3) (8) (5) (4) (1) Socket (10, 12, and 17 mm) Ratchet Recoil pulley holder (T/N: 07SMB-HM70100) Seal driver attachment (T/N: 07947-SD90101) Engine oil Shop towel Torque wrench TORQUE CHART (9) Tighten all screws, bolts and nuts to their specified torque values. Refer to the Service Manual for the tightening torques of removed parts. Item N m kgf m Ibf ft (2) 6 mm flange bolt 12 1.2 9 8 mm flange bolt 30 3.0 22 12 mm flange bolt 108 11 80 (10) (11) No. Description Qty (1) Recoil starter 1 (2) 6 mm flange bolt 4 (3) Recoil pulley comp. 1 (4) 12 mm flange bolt 1 (5) O-Ring 1 (6) Oil seal 1 (7) Relay 1 (8) Condenser unit 1 (9) Rectifier 1 (10) Sub harness 1 (11) 8 mm flange bolt 2 2008 American Honda Motor Co., Inc All Rights Reserved. 08U78-HP7-1000-91 1 of 8
INSTALLATION NOTE: Disconnect the negative cable from the battery before installing this accessory. 2. Remove the following parts. Refer to the Service Manual for specific instructions. AIR CLEANER CASE LID 1. Refer to the Service Manual for the ATV, then remove the parts. LEFT TANK SIDE COVER TRX420FA/FPA only. REAR COVER AIR CLEANER ELEMENT SEAT CLIP AIR CLEANER CASE RIGHT CENTER MUDGUARD Remove. RIGHT TANK SIDE COVER 2 of 8 08U78-HP7-1000-91 2008 American Honda Motor Co., Inc All Rights Reserved.
3. Remove the brake arm joint and brake rod adjusting nut as shown. 5. Remove the bolts as shown. BRAKE ROD ADJUSTING NUT BRAKE ARM JOINT 4. Remove the brake cable as shown. 8 mm FLANGE BOLT (Discard) 6. Remove the caliper as shown. SHOP TOWEL CALIPER BRAKE CABLE 2008 American Honda Motor Co., Inc All Rights Reserved. 08U78-HP7-1000-91 3 of 8
7. Remove the following parts. Refer to the Service Manual for specific instructions. 9. Install the recoil pulley as shown. Use the special tool to hold the recoil pulley while torquing the flange bolt. 12 mm FLANGE BOLT CLAMP FE, TE type only. 6 mm FLANGE BOLT RECOIL PULLEY COMP. O-RING WASHER (Discard) O-RING ENGINE OIL 12 mm FLANGE BOLT 12 mm FLANGE BOLT (Discard) O-RING (Discard) REAR COVER CAP (Discard) Wipe off oil, dust, etc. BOLT (Save) 10. Install the recoil starter as shown. 8. Install the oil seal as shown. Use the special tool to install the oil seal. 6 mm FLANGE BOLT OIL SEAL RECOIL STARTER CLAMP (Reuse) FA, FPA, FE, TE type only. 6 mm FLANGE BOLT (Reuse) 4 of 8 08U78-HP7-1000-91 2008 American Honda Motor Co., Inc All Rights Reserved.
11. Install the condenser unit and the rectifier as shown. Right rear wheel inside CONDENSER UNIT 13. Connect the condenser unit harness and the rectifier harness to the ATV s harness as shown. Connect the connectors by the color of their plugs. CONDENSER UNIT HARNESS RECTIFIER 6 mm FLANGE BOLT Use the bolt that originally secured the rear cover cap. 12. Route the condenser unit harness and the rectifier harness as shown. RECTIFIER HARNESS 2-PIN WATERPROOF CONNECTOR (White) DUMMY CONNECTOR (Discard) CONDENSER UNIT HARNESS 2-PIN WATERPROOF CONNECTOR (Black) 14. Remove the ATV s harness as shown. BAND RECTIFIER HARNESS ATV S HARNESS (Save) 2008 American Honda Motor Co., Inc All Rights Reserved. 08U78-HP7-1000-91 5 of 8
15. Remove the relay and clips from the ATV s harness. RELAY 17. Install the sub harness in the reverse order of removing the ATV s harness and, secure the 2-pin and 8-pin connectors as shown. ATV S HARNESS 2-PIN WATERPROOF CONNECTOR Secure the clip to the cowl. 8-PIN WATERPROOF CONNECTOR Secure the clip to the cowl. CLIP CLIP ATV S HARNESS 16. Install the relays and clips onto the sub harness. RELAY (Reuse) SUB HARNESS 18. Connect the negative cable to the battery. Steps 19 through 23 are for testing the function after installation. CLIP (Reuse) 19. Disconnect the 2-pin connector (black) under the right side cover. SUB HARNESS 2-PIN CONNECTOR (Black) RELAY CLIP (Reuse) SUB HARNESS RECTIFIER HARNESS 6 of 8 08U78-HP7-1000-91 2008 American Honda Motor Co., Inc All Rights Reserved.
20. Check that the transmission is in neutral. 21. Fully and briskly pull the grip up. 22. Check that the engine starts and then turn the ignition switch OFF to stop the engine. Connect the 2-pin connector (black). If the engine does not start, check that the condenser connector is securely connected. 24. Install the caliper in the reverse order of removal. 23. Measure battery voltage and charging voltage. Battery voltage Inspect the charging condition by measuring the voltage across the battery terminals. NOTE: Use a digital circuit tester to inspect the MF battery. Voltage across terminals: Fully charged: 13.0-13.2 V Below charged: 12.3 V or lower Charging voltage After warming up the engine, hook up a voltmeter across the battery terminals. NOTE: Be careful not to allow a short circuit during the measurement. If the battery terminal is disconnected and reconnected when current is flowing, the circuit tester or other electrical parts may be damaged. Always turn the ignition switch OFF before performing the job. Use a fully charged battery for the charging voltage measurement. With the headlight turned on, start the engine with the electric starter, gradually increase the engine speed to 5,000 rpm, and measure the voltage (charging voltage) across the battery terminals. STANDARD: Measured BV < Measured CV < 15.5 V@5,000 rpm BV = Battery voltage CV = Charging voltage The charging system is normal if the measured voltage falls between the above-described limits. 25. Install the ATV s parts in the reverse order of removal. 26. Give these installation instructions to the customer for their reference. Using the Recoil Starter The recoil starter is used to start the engine when the battery is low. To operate the recoil starter: 1. Check that the transmission is in neutral. 2. Grasp the starter grip firmly, then pull it out slowly approximately 100 mm (4 in). 3. Pull the grip up briskly and fully. Right side 8 mm FLANGE BOLT CALIPER If the engine cannot be started with the electric starter, check that the rectifier connector is securely connected. When the measured voltage is outside of the above-described limits, check that the relay connector is securely connected, and measure the battery voltage again. STARTER GRIP 2008 American Honda Motor Co., Inc All Rights Reserved. 08U78-HP7-1000-91 7 of 8
2007 TRX420FM/TM: Recoil Starter Information When the engine is difficult to start due to a completely dead battery, use the following procedures. 1. Remove the reverse indicator lens. 2. Push out the rubber socket from behind. 3. Remove the bulb from the rubber socket. REVERSE INDICATOR LENS BULB RUBBER SOCKET HANDLEBAR COVER The illustration is of the FM type. 4. Start the engine with the recoil starter. Reinstall the bulb while the engine is running. BULB RUBBER SOCKET 5. Reassemble in the reverse order. The illustration is of the FM type. 8 of 8 08U78-HP7-1000-91 2008 American Honda Motor Co., Inc All Rights Reserved.