Honda HP400BA Owner's Manual
Thank you for purchasing a Honda power carrier. We want to help you get the best
results from your new power carrier and to operate it safely. This manual contains the
information on how to do that; please read it carefully.
This owners manual describes the operation and maintenance of the HP400 power
carrier. All information in this publication is based on the latest product information
available at the time of printing.
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.
This manual should be considered a permanent part of the power carrier and should
remain with it if it is resold.
Safety Messages
Your safety and the safety of others is very important. We have provided important
safety messages in this manual and on the power carrier. Please read these
messages carefully.
A safety message alerts you to potential hazards that could hurt you or others. Each
safety message is preceded by a safety alert symbol a and one of three words:
DANGER, WARNING, or CAUTION.
These mean
. D’
m You WlLL be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
I l
.
m You CAN be KlLLED or SERIOUSLY HURT if you don’t follow
instructions.
You CAN be HURT if you don’t follow instructions.
Each message tells you what the hazard is, what can happen, and what you can do
to avoid or reduce injury.
Damage Prevention Messages
You will also see other important messages that are preceded by the word NOTICE.
This word means:
pmicq y
our power carrier or other property could be damaged if you
don’t follow instructions.
The purpose of these messages is to help prevent damage to your power carrier other
property, or the environment.
It is illegal in some areas to operate an engine without a U.S.D.A. qualified spark
arrester: Check local laws and regulations. An optional spark arrester for this power
carrier is available from your authorized Honda power carrier dealer.
1
CONTENTS
1. SAFETY .............................................................................................................................................
Safety label locations.. ............................................................................................................
Safety Information ..................................................................................................................
2. COMPONENT IDENTIFICATION
3. CONTROLS .......................................................................................................................................
Fuel valve ................................................................................................................................
Engine switch ..........................................................................................................................
Throttle lever.. ..........................................................................................................................
Starter grip.. .............................................................................................................................
Gear shift lever
Drive clutch levers
Steering clutch levers
Carrier bed release
4. PRE-OPERATION CHECKS ...........................................................................................................
Fuel recommendation ............................................................................................................
Engine oil ...............................................................................................................................
Air cleaner .............................................................................................................................
5. STARTING THE ENGINE
6. OPERATION ....................................................................................................................................
High altitude operation..
7. STOPPING THE ENGINE
8. CARRYING LOADS.. ......................................................................................................................
Load carrying safety ..............................................................................................................
Tie-down hooks ....................................................................................................................
Side rails and side plates.. ....................................................................................................
Using the front stopper plate ................................................................................................
Dumping loads..
Load carrying capacity.. ........................................................................................................
9. MAINTENANCE ...............................................................................................................................
Maintenance schedule.. ........................................................................................................
Tool kit ...................................................................................................................................
Engine oil change .................................................................................................................
Spark plug service ................................................................................................................
Servicing the air cleaner .......................................................................................................
Adjusting the track tautness
Track adjustment
Adjusting the drive clutch cable
Adjusting the brake cable .....................................................................................................
Checking brake wear
Adjusting the steering clutch cable
Adjusting the dumping lock cable
Checking the transmission oil
Checking the clutch oil ..........................................................................................................
Spark arrester maintenance (Optional
Lubrication
Temporary installation of a disengaged
10. TRANSPORTING/STORAGE..
11. TROUBLESHOOTING..
12. SPECIFICATIONS .................................................
13. CUSTOMER SERVICE INFORMATION
14. INDEX .............................................................................................................................................. 50
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............................................................................................................................. 42
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lever
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............................................................................................ .35
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....................................................................................... .38
......................................................................................... .39
................................................................................................ 40
part) ......................................................................... .41
track ....................................................................... .43
. ................. . ...................................................... .48
........................................................................................ .49
.20
.23
.24
.24
.25
.26
.27
.29
.31
.32
.33
.34
.34
.36
.37
.40
.45
.47
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.3
.4
.5
6
6
6
7
7
.8
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.9
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10
10
12
13
14
17
19
23
28
30
2
1. SAFETY
SAFETY LABEL LOCATIONS
The labels shown here contain important safety information. Please read them
carefully. These labels are considered permanent parts of your power carrier,
so if a label comes off or becomes hard to read, contact your authorized Honda
power carrier dealer for a replacement.
SAFETY INFORMATION
Honda power carriers are designed to give safe and dependable service if
operated according to instructions. Read and understand the Owner’s
Manual before operating the power carrier. Failure to do so could result in
personal injury or equipment damage.
Keep children and pets away from the area of operation to avoid possible
injury from contact with the power carrier.
To avoid accidents or loss of control, do no ride on the power carrier; walk
behind, and hold both handlebars firmly. Do not allow others to ride on the
power carrier as passengers.
Watch for obstacles while operating the power carrier. Do not use the power
carrier when visibility is poor. Under conditions of poor visibility, there is a
greater risk of striking an obstacle.
To avoid accidents or overturning, observe the load limits described on
page 27. Be sure the load is secure and does not protrude from the power
carrier or block visibility.
To avoid overturning, be careful when changing the direction of the power
carrier while operating it on slopes, and do not operate the power carrier on
upward slopes greater than 25” or downward slopes greater than 15”.
When operating the power carrier in reverse gear and walking backward,
there is greater risk of slipping or tripping. Be especially careful when
backing up.
Know how to stop the power carrier quickly, and understand the operation
of all controls. Never permit anyone to operate the power carrier without
proper instruction.
Gasoline is extremely flammable and is explosive under certain conditions.
Allow the engine to cool before refueling. Refuel inawellventilatedarea
with the engine stopped. Do not smoke or allow flames or sparks in the
refueling area or where gasoline is stored.
Do not overfill the fuel tank. After refueling, make sure the fuel tank cap is
closed properly and securely.
Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel may
ignite. lf any fuel is spilled, make sure the area is dry before starting the
engine.
Never run the engine in an enclosed or confined area. Exhaust contains
poisonous carbon monoxide gas; exposure may cause loss of conscious-
ness and may lead to death.
The muffler becomes very hot during operation and remains hot for a while
after stopping the engine. Be careful not to touch the muffter while it is hot.
To avoid severe bums or tire hazards, let theenginecool before transporting
the power carrier or starting it indoors.
*FRAME SERIAL
CARRIER
2. COMPONENT IDENTIFICATION
THROTTLE LEVER
CAP
TRAkK
STEERING CLUTCH
GEAR SHIFT LEVE
FdL
VALVE
*ENGINE SERIAL NUMBER
DRIVE CLUTCH LEVERS
STARTER GRIP
AIR CLEANER
\
CARRIER BED RELEASE LEVER
*Record the frame and engine serial numbers for your reference. Refer to the
serial numbers when ordering parts, and when making technical or warranty
inquiries (see page 49).
Frame serial number:
Engine serial number:
5
3. CONTROLS
Fuel valve
The fuel valve opens and closes the fuel passage to the carburetor. Turn the
fuel valve to the ON position before starting the engine and to the OFF position
when the engine is stopped.
A l
.
m When the power carrier is not in use, always leave the fuel
valve in the OFF position to reduce the possibility of fuel leakage.
Gasoline is extremely flammable and is explosive under certain conditions. Fuel vapor or spilled fuel may ignite.
FUEL VALVE
Engine switch
The engine switch controls the electrical circuit for the spark plug ignition
system and must be turned to the ON position to enable the engine to start and
run. The engine will stop when the engine switch is turned to the OFF position.
. l
.
m When the power carrier is not in use always leave the
engine switch in the OFF position to prevent accidental starting.
ENGINE SWITCH
6
Throttle lever
The throttle lever controls engine speed. When the throttle lever is moved to
the START (CHOKE) position, it also closes the choke for cold starting. The
choke is open when the throttle lever is in the HI, NORMAL, or LO position.
THROlTLE LEVER
Starter grip
Pull the starter grip to operate the recoil starter.
r-Nmiq
damage.
Return the starter grip slowly back to the engine to prevent
STARTER GRIP
7
Gear shift lever
Use the gear shift lever to select drive speed or to back up. Shift gears with the
engine running and the drive clutch levers released.
I
N
z 1
m
Drive clutch levers
Use the drive clutch levers to propel or stop the power carrier. The two levers
are connected and move simultaneously. When the levers are held down
against. the handlebars, this releases the brake and engages the drive: the
power carrier will move if the transmission is in gear. When the levers are
released, this disengages the drive and applies the brake: the power carrier
will stop.
DRIVE CLUTCH LEVERS
R
N: NEUTRAL
1: LOW SPEED
2: HIGH SPEED
R: REVERSE
RUN
8
Steering clutch levers
Use the steering clutch levers to steer the power carrier. Pull up the right lever
to steer right. Pull up the left lever to steer left.
STEERIN CLUTCH
LEVERS
Carrier bed release lever
Pull the release lever to unlock the carrier bed when you wish to tilt the bed for
dumping a load. With the carrier bed unlocked, tilt it by lifting the handlebar.
To lock the carrier bed again, push down firmly on the handlebar.
A -
.
m Before operating the power carrier check that the carrier
bed is locked. If the carrier bed is not locked, it may tilt while going
downhill and accidentally dump the load, which may cause personal
injury and property or equipment damage.
LIFT
CARRIER BED
RELEASE LEVER
UNLOCK
HANDLEBAR
LOCK
DOWN
9
4. PRE-OPERAYION CHECKS
____
-------
-------
-----
Fuel Recommendation
Check the power carrier on level ground with the engine stopped.
Unscrew the fuel tank cap, and check the fuel level. Refill the tank if the fuel
level is low. Do not fill above the UPPER LEVEL.
Gasoline is extremely flammable and is explosive under certain
conditions.
Refuel in a well-ventilated area with the engine stopped. Do not
smoke or allow flames or sparks in the area where the engine is
refueled or where gasoline is stored.
Do not overfill the fuel tank (there should be no fuel in the filler neck).
After refueling, make sure the tank cap is closed properly and
securely.
Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor
may ignite. If any fuel is spilled, make sure the area is dry before
starting the engine.
Avoid repeated or prolonged contact with skin or breathing of vapor.
KEEP OUT OF REACH OF CHILDREN.
Fuel tank capacity: 1.6 e (1.68 US gal, 1.41 Imp gal)
UPPER LEVEL
--
--
ff3
LOW LEVEL
--
-
-
q
Use gasoline with a pump octane rating of 86 or higher
We recommend unleaded gasoline because it produces fewer engine and
spark plug deposits and extends exhaust system life.
Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid
getting dirt or water in the fuel tank.
10
_.
Occasionally you may hear light “spark knock” or “pinging” (metallic rapping
noise) while operating under heavy loads, This is no cause for concern.
If spark knock or pinging occurs at a steady engine speed, under normal load,
change brands of gasoline. If spark knock or pinging persists, see an
authorized Honda power carrier dealer.
m Running the engine with persistent spark knock or pinging can cause engine damage.
Running the engine with persistent spark knock or pinging is misuse, and the
Distributor’s Limited Warranty does not cover parts damaged by misuse.
Oxygenated Fuels
Some conventional gasolines are being blended with alcohol or an ether
compound. These gasolines are collectively referred to as oxygenated fuels.
To meet clean air standards, some areas of the United States and Canada use
oxygenated fuels to help reduce emissions.
If you use an oxygenated fuel, be sure it is unleaded and meets the minimum
octane rating requirement.
Before using an oxygenated fuel, try to confirm the fuel’s contents. Some
states/provinces require this information to be posted on the pump.
The following are the EPA-approved percentages of oxygenates:
Ethanol (ethyl or grain alcohol)
You may use gasoline containing up to 10% ethanol by volume. Gasoline
containing ethanol may be marketed under the name “Gasohol”.
MTBE (methyl tertiary butyl ether)
You may use gasoline containing up to 15% MTBE by volume.
METHANOL (methyl or wood alcohol)
You may use gasoline containing up to 5% methanol by volume as long as it
also contains cosolvents and corrosion inhibitors to protect the fuel system.
Gasoline containing more than 5% methanol by volume may cause starting
and/or performance problems. It may also damage metal, rubber, and plastic
parts of your fuel system.
If you notice any undesirable operating symptoms, try another service station
or switch to another brand of gasoline.
Fuel system damage or performance problems resulting from the use of an
oxygenated fuel containing more than the percentages of oxygenates given
above are not covered under warranty.
11
ENGINE OIL
l Engine oil is a major factor affecting engine performance and service
life. Nondetergent oils and 2-stroke oils are not recommended because they have inadequate lubricating characteristics.
l Check the oil level with the power carrier on a level surface and the
engine stopped.
Use Honda 4-stroke oil, or an equivalent
high detergent, premium quality motor oil
certified to meet or exceed U.S. automobile
manufacturer’s requirements for Service
Classification SG, SF/CC, CD.
Motor oils classified SG, SF/CC, CD will
show this designation on the container.
SAE 1 OW/30 is recommended for general,
all-temperature use.
Other viscosities shown in the chart may be
used when the average temperature in your
area is within the indicated range.
1.
Remove the oil filler cap, and wipefhe dipstick clean.
2.
Insert the dipstick into the filler neck, but do not screw it in.
3.
Remove the dipstick and check the oil level. If the oil level is near or below
the end of the dipstick, fill to the upper level mark with the recommended
oil.
TEMP ; , , , , , , ,
-30 -20
-10 0 30 20 30 40%
AMBIENT TEMPERATURE
12
AIR CLEANER
1. Remove the two wing bolts to remove the air cleaner cover.
2. Remove and inspect the air cleaner elements. If the elements are dirty,
follow the cleaning procedure described on page 33.
3. Reinstall the air cleaner elements, cover and wing bolts. Securely tighten
the wing bolts.
piiBEFjNOTICE/N
run engine without the air cleaner. Rapid engine
ever
wear will result from contaminants, such as dust and dirt, being drawn
through the carburetor, into the engine.
WING BOLTS
AIR CLEANER COVER
APER ELEMENT
RM ELEMENT
13
5. STARTING THE ENGINE
Starting the engine
1. Check that the gear shift lever is in the NEUTRAL position. Allow the drive
clutch levers to remain in the STOP position.
STOP
2. Turn the fuel valve to the ON position.
Check for tighteness of drain knob.
GEAR SHIFT LEVER
NEUTRAL
14
DRAIN KNOB
3. Move the throttle lever to the START (CHOKE) position.
START
(CHOKE)
THROTTLE L
NOTE: If restarting a warm engine, the choke will not be needed. Restart a
warm engine with the throttle lever in the LO position.
4. Turn the engine switch to the ON position.
15
5. Pull the starter grip lightly until you feel resistance, then pull briskly.
R GRIP
pimicq
l Do not allow the starter grip to snap back against the engine.
Return it gently to prevent damage to the starter.
l Do not pull the starter grip while the engine is running, as that may
damage the starter.
6. Allow the engine to warm up for 2 or 3 minutes. Move the throttle lever to
the LO position when the engine is warm enough to idle smoothly.
16
THROTTLE LEVER
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