🏷️ Basic Information Identification Make: Honda Model: FL400R Common Name: Pilot Vehicle Type: All-Terrain Vehicle (ATV) Codes Chassis Code: FL400R Engine Code: Not explicitly provided, but typically the XR500R engine was adapted. Generation Generation Identifier: First Generation 👋 Introduction Market Position Vehicle Segment: Sport/Recreational ATV Target Audience: Enthusiasts, off-road riders, utility users Competitive Analysis Competitors Era: Yamaha Warrior, Suzuki QuadSport, Kawasaki Mojave Key Features Performance Focus: Emphasis on sport riding capabilities and robust construction Manual Value Proposition Completeness: Highly detailed, covering all aspects from basic maintenance to complex rebuilds Visuals: Includes helpful pictures and part diagrams to aid understanding 📋 Manual Details Coverage Areas Applicable Years: 1989, 1990 Page Count Total Pages: 262 Manual Type Type: Service and Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, drivetrain Chassis: Suspension (front and rear), steering, brakes Electrical: Ignition system, lighting, battery, starter, charging system, wiring diagrams Bodywork: Frame, body panels, seats, controls Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication Diagnostics: Troubleshooting common issues, diagnostic procedures for engine and electrical systems Repair: Complete tear down and rebuild procedures for all major components Technical Data: Torque specifications, clearances, adjustments Special Tools: Identification and usage of specialized tools required for repairs Engine Rebuild: Detailed steps for piston, cylinder, crankshaft, and valve train disassembly and reassembly. Carburetor Overhaul: Instructions for disassembling, cleaning, and reassembling the carburetor, including jetting information. Suspension Adjustment: Guidance on adjusting preload and damping for front and rear suspension. Electrical Troubleshooting: Includes wiring diagrams and step-by-step diagnostic procedures for electrical faults. Technical Depth Depth: Comprehensive, suitable for both novice DIY mechanics and experienced technicians Special Procedures: Covers specific procedures like timing chain adjustment, valve clearance checks and adjustments. 📊 Manual Specifications File Format PDF Features: Searchable text, clickable chapters for easy navigation Print Quality Print Restriction: No restrictions on printing Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Paper: N/A (Digital PDF) File Management Saving Options: No restrictions on saving or burning to disc ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, single-cylinder Displacement: 478cc (29.2 cu. in.) Bore X Stroke: 92.0 mm x 90.0 mm (3.62 in. x 3.54 in.) Compression Ratio: 8.5:1 Cooling System: Liquid-cooled Fuel System: Carbureted (likely a Keihin carburetor, specific model typically detailed in manual) Ignition System: CDI (Capacitor Discharge Ignition) Performance Horsepower Estimate: Estimated 30-35 HP (specific figures often not published for ATVs of this era, but based on similar engines) Torque Estimate: Estimated 25-30 lb-ft (specific figures often not published) 🔧 Transmission Standard Transmission Type: 5-speed manual with reverse Clutch Type: Wet multi-plate Final Drive: Shaft drive Features Gear Ratios: Detailed in the manual Transmission Fluid Type: Honda ATV oil or equivalent (specific grade in manual) 📐 Dimensions Exterior Length: Approx. 74.6 in. (1895 mm) Width: Approx. 43.9 in. (1115 mm) Height: Approx. 43.7 in. (1110 mm) Wheelbase: Approx. 49.2 in. (1250 mm) Weights Dry Weight: Approx. 370 lbs (168 kg) Fuel Capacity: Approx. 3.3 US gal. (12.5 L), including 0.7 US gal. (2.6 L) reserve 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet industry safety standards for ATVs of its time. Active Features Braking System: Front: Dual hydraulic disc; Rear: Single hydraulic disc Suspension: Front: Independent double-wishbone with adjustable shocks; Rear: Swingarm with adjustable shock Passive Features Roll Over Protection: N/A (Standard ATV design, operator responsibility for safe operation) Operator Training: Manual likely includes advisories on safe operation and rider training. 💡 Technology Features Infotainment Infotainment System: N/A (Basic recreational vehicle, no integrated infotainment systems). Driver Assistance Driver Aid Features: N/A (No electronic driver assistance features). Connectivity Connectivity Features: N/A (No connectivity features). 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/hour intervals (typically every 1,000-2,000 miles or annual service). Air Filter Cleaning: Regular inspection and cleaning, frequency depends on operating conditions (detailed in manual). Spark Plug Replacement: Refer to manual for recommended interval (e.g., 4,000-6,000 miles). Fluid Specifications Engine Oil Type: SAE 10W-30 API SE or SF (Specifics detailed in manual). Engine Oil Capacity: Refer to manual for exact capacity (approx. 2.0-2.5 liters). Coolant Type: Ethylene glycol-based antifreeze/coolant (specific mixture ratio in manual). Brake Fluid Type: DOT 3 or DOT 4 (Specifics detailed in manual). Known Issues Carburetor Tuning: Carburetors can require periodic cleaning and adjustment due to fuel deposits or wear. Electrical Connections: Corrosion or loose connections in the electrical system can lead to intermittent issues. Suspension Wear: Like any off-road vehicle, suspension components (bushings, ball joints, shocks) can wear over time. Torque Specs Engine Mounting: Specific torque values for critical fasteners are included. Wheel Nuts: Torque specifications for wheel lug nuts/bolts are provided. 📚 Vehicle History Brand Heritage Honda Atv Legacy: Honda has a long history of innovation in ATVs, starting with the ATC series, transitioning to the ATV (4-wheel) platform....