Target Audience:
Do-it-yourself enthusiasts and experienced mechanics seeking detailed repair information.
Value Proposition:
Inexpensive way to maintain and repair the Honda FL400R Pilot, saving on labor costs and dealer service.
Ease Of Use:
Easy-to-read text sections with clear, step-by-step instructions and detailed visuals.
Completeness:
Covers every single detail on the machine, based on complete disassembly.
Efficiency:
Aids in completing required jobs correctly and efficiently.
Primary Coverage:
1989 Honda FL400R Pilot ATV
Secondary Coverage:
General maintenance, repair, and troubleshooting for the specified model year.
Estimated Page Count:
Unknown (factory manuals typically range from 300-600 pages for comprehensive coverage)
Manual Classification:
Factory Service Repair Workshop Manual
File Compatibility:
Windows and Mac OS
Distribution Method:
Instant Download
Engine Mechanical:
Engine removal/installation, cylinder head/valve, crankshaft/piston/cylinder, crankcase/transmission, clutch, cooling system, lubrication system.
Fuel System:
Fuel system components, carburetor adjustments, fuel tank, lines.
Electrical System:
Battery/charging system, alternator, starter clutch, electric starter, ignition system, lights, meters, switches, wiring diagram.
Drivetrain Suspension:
Front wheel/suspension/steering, rear wheel/suspension, transmission.
Braking System:
Hydraulic brake system, component inspection and service.
Chassis Bodywork:
Frame, body panels, exhaust system.
Maintenance:
Scheduled maintenance, lubrication, fluid changes, inspections.
Repair Overhaul:
Complete disassembly and reassembly of major components, detailed repair instructions.
Diagnostics Troubleshooting:
Systematic troubleshooting guides, diagnostic procedures, common issue resolutions.
Depth Level:
Comprehensive (from basic maintenance to complete engine and chassis overhaul).
Diagrams Illustrations:
High-quality diagrams, exploded views, and detailed illustrations for clarity.
Print Quality:
Printable (designed for home or shop printing).
Searchability:
Likely searchable text within the PDF for quick information retrieval.
Binding Type:
Digital (PDF) - N/A for physical binding, but printable for binding.
Paper Type:
Digital (PDF) - N/A for physical paper type, but printable on various paper weights.
Engine Type:
Single-cylinder, four-stroke
Engine Displacement:
397 cc
Bore X Stroke:
85.0 mm x 70.0 mm
Horsepower:
Approx. 28 hp @ 6000 rpm (speculative, typical for this engine size in its era)
Torque:
Approx. 25 lb-ft @ 4500 rpm (speculative)
Fuel Delivery:
Carburetor (likely a single Keihin carburetor)
Cooling Method:
Liquid-cooled
Oil Capacity:
Refer to manual for specific capacity; typically around 1.5-2.0 liters.
Oil Change Interval:
Refer to manual; typically every 100 hours or annually.
Air Filter Maintenance:
Regular inspection and cleaning/replacement based on operating conditions.
Engine Oil Type:
Honda GN4 10W-40 or equivalent API SG/SH rated oil.
Coolant Type:
Mixture of permanent antifreeze and distilled water (50/50 ratio), or specific Honda coolant.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Oil Type:
Refer to manual for specific transmission oil; often shared with engine oil or a specific gear oil.
Common Wear Items:
Brake pads, clutch plates, suspension bushings, wheel bearings, and carburetor tuning are common maintenance items.
Electrical System Reliability:
Older wiring harnesses can degrade; manual will assist in diagnosing and repairing electrical faults.
Honda Atv Legacy:
Honda is a pioneer in the ATV market, known for reliable and innovative designs. The Pilot was a unique sport/utility offering.
Fl400R Development:
The FL400R Pilot was introduced to cater to the growing sport ATV market, featuring a liquid-cooled engine and a more robust chassis than many earlier models.
Production Period:
Mid-to-late 1980s (FL400R production typically spanned from 1985-1990, with the 1989 model being a key representative).
