DIY Network

4-Wheel ATV: Introduction and Routine Maintenance From "Weekend Mechanic" episode WKM-313

	Bruce Bonebrake does some routine maintenance on this 4-wheeler, then adds a winch for added insurance against getting stuck in the outback.
	Figure A

In this episode, Weekend Mechanic host Bruce Bonebrake does some routine maintenance on a Honda 4-wheel all-terrain vehicle -- including tune-up, sparkplug change, oil and oil-filter change, front- and rear-brakes service. He also replaces a broken mud-guard, upgrades the wheels and tires, and performs an accessory upgrade by adding an electric winch to the front of the 4-wheeler. In this first segment, he demonstrates some basic maintenance with a sparkplug and oil-change.

Materials:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, etc.), some of the specialty tools (figure A) that will be needed for these projects include hydraulic bleed pump, high-speed drill, hole saw, torque wrench and an air-compressor and set of pneumatic tools.

DIY Difficulty Rating for the Project: This routine maintenance shown in this episode should be no problem for the experienced weekend mechanic. The brake work, wiring and winch addition are a little more challenging. Some experience with motorcycle maintenance and repair would be a plus. Overall, we gave these projects a difficulty rating of 2 on a 5-point intermediate-level scale. It took us about 8 hours to finish this job. Allow yourself a full weekend to complete this project properly.

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Tune-Up and Oil Change

• To access the engine parts for the routine maintenance and tune-up, we removed the seat and side-panel. While working in this area, our first task was to replace the ripped mudguard on the left side of the ATV (figure B).

• We removed the fasteners that secure the mudguard to the body fenders (figure C) and left foot-peg. Once the mud-guard was removed, we left it off to make access to the engine parts simpler. The replacement mudguard gets added later.

  Figure B

  Figure C

  
  
• With the side-pane removed, the sparkplug is exposed and can be disconnected from the sparkplug wire (figure D).

• Remove the sparkplug from the engine using a standard sparkplug socket (figure E).

  Figure D

  Figure E

  
  
• Once the sparkplug is removed, inspect the tip for wear or scoring (figure F).

• Important: Use caution to avoid any dirt or debris falling into the engine while the sparkplug is out.

• In this tight location, it's easiest to install the sparkplug by hand then tighten it down with a sparkplug socket (figure G). Use caution to avoid over-tightening the plug and cracking it.

  Figure F

  Figure G

  
  
• To change the oil, remove the drain-plug underneath the 4-wheeler, and catch the oil in a catch basin (figure H). Our oil was dirty, and clearly needed changing.

• While the oil drain-plug is removed, it's a good idea to replace the sealing ring around the base of the plug with a new one (figure I). With the seal replaced, reinstall the drain-plug by screwing it back into the bottom of the engine.

  Figure H

  Figure I

  
  
• To replace the oil filter, remove the three bolts that hold the filter cover secure on the side of the engine, then remove the cover and filter slowly and carefully (figure J). As you remove it, check the filter for excess sediment or embedded metal shavings.

• Use a shop rag to clean the inside of the filter housing and cover.

• Remove and replace the old O-rings on the filter housing (figure K). It's a good idea to always replace the O-rings any time that you change the oil filter. Lubricate the new O-rings with motor oil to achieve a good seal when the cover is replaced.

  Figure J

  Figure K

  
  
• Center and place the new filter in the housing cover (figure L) to make it easier to install.

• Slide the new filter inside the housing, seat the cover and secure it with the three bolts (figure M).

  Figure L

  Figure M

  
  
• Fill the engine with new oil (figure N) and replace the filler cap. Our 4-wheeler holds about 3 quarts of 10W-40 engine oil.

• Finally, with the sparkplug change and oil-change complete, we install the new mudguard to replace the old torn one (figure O). Reattach the body side-panel and seat that were removed earlier.

  Figure N

  Figure O

  
  

Important: Included in this segment are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools. Also wear eye protection any time that you are working beneath a vehicle.

Safety Alert: Always dispose of automotive fluids (antifreeze, motor oil, transmission fluid, etc.) and other toxic substances responsibly. Most auto center offer recycling of automotive fluids.

Safety Alert: Always wear a helmet and drive safely when riding a 4-wheeler.

RESOURCES :

Warn Industries Inc.
Provided the winch installed on the ATV in WKM, episode 313.
Website: www.warn.com

The Complete Idiot's Guide to Motorcycles
ISBN: 0028624165
Author: editors of Motorcyclist magazine