Honda 2011 FOURTRAX FOREMAN 4x4 ES Owner'S Manual Download Page 260 | Manualshive

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How To Avoid Costly Repairs

Quick Reference

Quick Reference

The following is a brief, but important collection of information you
need to know about your Honda. You’ll also find space to record
important notes.

The engine of your Honda can be the most expensive component to
repair. Proper maintenance, especially the use of the recommended
fluids and filters, prevents premature wear and damage.

Frequent causes of costly repairs are:

Engine oil –– insufficient quantity, improper oil.

Record important information on the following page:

Air cleaner –– dirty, leaking because of improper installation
(poor seal).

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Summary of Contents for 2011 FOURTRAX FOREMAN 4x4 ES

Page 1: ...to US EPA Noise Emission regulations but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways...

Page 2: ...hecks detailed in this manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual...

Page 3: ...ive harm If you have any questions or if you ever need special service or repairs remember that your Honda dealer knows your ATV best and is dedicated to your complete satisfaction You may also want t...

Page 4: ...important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potent...

Page 5: ...u don t follow instructions A Few Words About Safety A Few Words About Safety Safety Headings Safety Section Instructions These signal words mean This entire manual is filled with important safety inf...

Page 6: ...safety information you should know plus a look at the safety related labels on your ATV The location and function of indicators and controls on your ATV and operating instructions for various control...

Page 7: ...da an owner maintenance schedule and instructions for specific maintenance and adjustment items How to store and transport your ATV and how to be an environmentally responsible rider What to do if you...

Page 8: ......

Page 9: ...ost important information and recommendations to help you ride your ATV safely Please take a few moments to read these pages This section also includes information about the location of safety labels...

Page 10: ...important The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle Refer to the age warnings provided in this manual and on the ATV Your ATV is desi...

Page 11: ...oad Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards Even if you have ridden other A...

Page 12: ...ke good judgments and ride safely Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So...

Page 13: ...the vehicle If a label comes off or becomes hard to read contact your Honda dealer for replacements Your ATV comes with a hang tag and several labels containing important safety information Anyone wh...

Page 14: ...6 Safety Labels ATV Safety...

Page 15: ...7 Safety Labels ATV Safety TRX500FE TRX500FPE...

Page 16: ...For Canada 8 Safety Labels ATV Safety...

Page 17: ...s listed on this page are described in this section Instructions for other components are presented in other sections of this manual where they will be most useful cont d Operation Component Locations...

Page 18: ...eadlight Dimmer Switch Recoil Starter Throttle Lever Front Brake Lever Rear Brake Lever Rear Brake Pedal Parking Brake Flag Pole Bracket Accessory Socket Starting Primer Knob Gearshift Switch Reverse...

Page 19: ...brake lever choke knob rear brake lever parking brake lever headlight dimmer switch start button headlight switch reverse selector knob parking brake lock lever gearshift switches 2WD 4WD select switc...

Page 20: ...rear cargo rack front cargo rack recoil starter rear brake pedal seat lock lever starting primer knob 12 Instruments Controls Operation Component Locations...

Page 21: ...trailer hitch accessory socket utility box fuel valve storage compartment flag pole bracket 13 Instruments Controls Operation Component Locations...

Page 22: ...ect button 3 4WD indicator 4 high oil temperature indicator 5 neutral indicator 6 reverse indicator 14 Indicators Displays Instruments Controls The indicators and displays on your ATV keep you informe...

Page 23: ...d in the table on page with the words If any part of these displays does not come on when it should have your Honda dealer check for problems When the ignition switch is turned ON the multi function d...

Page 24: ...ive mode is in the 4WD mode The 4WD indicator blinks if there is a possible problem with the 2WD 4WD select system See your Honda dealer as soon as possible High oil temperature indicator Lights when...

Page 25: ...Odometer Tripmeter Shows mileage per trip page Hourmeter Shows hours and tenths of hours of engine operation page Digital clock Shows the time hours and minutes page Hour select button Advances the ho...

Page 26: ...0FPE 18 Multi function Display Indicators Displays Instruments Controls The multi function display includes the following functions The digital clock will reset if the battery is disconnected The digi...

Page 27: ...nsmission is not shifted into gear properly Before riding check that the gear position is properly displayed on the gear position indicator The gear position indicator shows the gear position when the...

Page 28: ...the oil change interval specified on the maintenance schedule If the oil is changed before the oil change indicator appears be sure to reset the oil change indicator after changing the oil The indicat...

Page 29: ...has two functions odometer and tripmeter The tripmeter has two sub modes tripmeter A and tripmeter B The odometer registers total distance traveled in miles while the ignition switch is ON The tripme...

Page 30: ...5 RESET button 22 Indicators Displays Instruments Controls To reset the tripmeter to zero press and hold the RESET button for more than 2 seconds with the display in the tripmeter A or tripmeter B mod...

Page 31: ...RX500FPE 1 23 Hourmeter Indicators Displays Instruments Controls The hourmeter shows accumulated hours while the ignition is ON The hourmeter provides accurate service period information for initial a...

Page 32: ...in advancing Release the button when the display reaches the desired hour To advance the minute display one unit at a time press and release the minute select button To advance the minute display auto...

Page 33: ...TRX500FE TRX500FPE 1 adjust button 2 hour select button 3 minute select button 2 2 1 1 3 3 25 Indicators Displays Instruments Controls...

Page 34: ...ate fuel supply available The fuel tank capacity is When segment E and low fuel indicator flash you should refill the tank as soon as possible The amount of fuel remaining when the flashing starts is...

Page 35: ...age Remember to check that the fuel valve is in the ON position each time you refuel If the fuel valve is left in the RES position you may run out of fuel with no reserve Reserve Fuel RES for extra fu...

Page 36: ...1 B B A fully ON B fully OFF CENTER OF HANDLEBAR 1 choke knob A A 28 Choke Knob Controls Features Instruments Controls The choke knob may be used when starting the engine See page 1 69...

Page 37: ...TER OF HANDLEBAR 1 ignition switch 1 ON OFF ON OFF Function Key Position 29 Ignition Switch Controls Features Instruments Controls The ignition switch is used for starting and stopping the engine page...

Page 38: ...D 4WD select switch is located above the throttle lever To select the drive mode slide the 2WD 4WD select switch to the desired position To check your present drive mode look at the 4WD indicator 2WD...

Page 39: ...starter motor will not operate if the engine stop switch is in the OFF position when the start button is pushed The engine stop switch is used to stop the engine in an emergency To operate slide the s...

Page 40: ...ls The headlight dimmer switch is used to change between the high and low beams of the headlight To operate turn the switch to HI for high beam LO for low beam The headlight switch is used to turn the...

Page 41: ...atures Instruments Controls Starting Procedure Using the Recoil Starter The starting primer knob is located on the carburetor float bowl The knob may be used when starting the engine in extremely cold...

Page 42: ...ures Instruments Controls The throttle controls engine rpm speed To increase engine rpm press the throttle lever with your thumb To reduce engine rpm release pressure on the throttle lever The throttl...

Page 43: ...ntrols Features Instruments Controls Shifting Gears These switches are used to select the next higher or lower gear in the transmission To operate press the upshift switch to engage the next higher ge...

Page 44: ...rols Riding in Reverse The reverse selector knob located on the rear brake lever parking brake lever is used to shift into reverse To operate with your ATV stopped and the transmission in neutral make...

Page 45: ...ATV To operate pull the lever For information on braking techniques see page The rear brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see...

Page 46: ...ying the parking brake When using the parking brake be sure to turn the ignition switch OFF to avoid discharging the battery The lock lever on the rear brake lever parking brake lever allows it to be...

Page 47: ...tures Instruments Controls Flag poles are optional equipment available from your Honda dealer To mount a pole in the bracket follow the instructions that come with the flag pole kit Flag poles are req...

Page 48: ...railer hitch is located on the rear axle housing To use the hitch you ll need a proper size ball as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the t...

Page 49: ...automobile cigarette lighter because it can damage the socket The accessory socket is attached to the left side under the assist headlight You can use the accessory socket to power a trouble light sp...

Page 50: ...e accessory socket otherwise you may drain the battery The accessory socket s rated capacity is DC 12V 120 Watts 10A or less If you exceed this limit you may blow a fuse See page When you are done usi...

Page 51: ...o open To close The utility box is located on the left side of the front fender You may store small lightweight items in the box Lift the D ring on the quick release fastener Turn it counterclockwise...

Page 52: ...3 rubber strap 1 44 Storage Compartment Controls Features Instruments Controls To open the compartment unhook the rubber strap Be careful not to flood this area when washing your ATV The storage compa...

Page 53: ...sist The steering will perform as a normal non PS system during this brief period After cooling down it will then return to normal PS operation The PS indicator should light when the ignition switch i...

Page 54: ...46 Instruments Controls...

Page 55: ...nd adjustments to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride Protective Apparel Rider Training Age Recommendation...

Page 56: ...that you always wear an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved shirt or jacket whenever you ride Although complete protection is not possible wearing pro...

Page 57: ...ng An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker on any helmet you buy USA only Always wear...

Page 58: ...or the ATV Rider Developing your riding skills is an on going process Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice riding the ATV in a s...

Page 59: ...cause a crash and you or your passenger could be injured or killed Never carry a passenger on this ATV 51 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended a...

Page 60: ...ume alcohol or drugs before or while operating this ATV 52 No Alcohol or Drugs Are You Ready to Ride Before Riding Alcohol drugs and ATVs don t mix Even a small amount of alcohol can impair your abili...

Page 61: ...em you find is corrected A pre ride inspection is a must not only for safety but because having a breakdown or even a flat tire can be a major inconvenience If your ATV has overturned or been involved...

Page 62: ...e wheels to see that the axle nuts are tightened Use a wrench to make sure all accessible nuts bolts and fasteners are tight Check for and remove any dirt vegetation or other debris that could be a fi...

Page 63: ...e the front and rear brake levers and step on the rear brake pedal to check that the controls operate normally Check for proper freeplay pages Make sure there is no brake fluid leakage Check for prope...

Page 64: ...erfere with your balance and control of the ATV In addition exceeding the weight limits or carrying an unbalanced load can seriously affect your ATV s handling braking and stability Adding accessories...

Page 65: ...g load limits apply to standard equipment only Modifying your ATV using non standard equipment or riding on terrain that is not flat and smooth could further reduce these limits includes the weight of...

Page 66: ...tow another vehicle or trailer Do not tow by tying a rope or cable to the rear rack Load cargo on the rear rack as far forward as possible Make sure cargo on the front rack does not interfere with ha...

Page 67: ...designed and tested for your ATV Because Honda cannot test all other accessories you must be personally responsible for proper selection installation and use of non Honda accessories Check with your...

Page 68: ...seriously impair your ATV s handling stability and braking making it unsafe to ride We also advise you not to make any modifications or remove any equipment such as the USDA qualified spark arrester...

Page 69: ...ce life refer to Break in Guidelines page For information about carburetor adjustment for riding at high altitude see page cont d Safe Riding Precautions Off road Use Only Keep Hands and Feet on Contr...

Page 70: ...c Operation Riding Braking Riding Your ATV Making Turns Skidding or Sliding Riding Up Hills Riding Down Hills Crossing or Turning on Hills or Slopes Riding Over Obstacles Riding Through Water Parking...

Page 71: ...e 1 and the section beginning on page Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice in a safe area until you build your skills and get ac...

Page 72: ...Feet on Controls Safe Riding Precautions Basic Operation Riding You should never ride your ATV on public streets roads or highways even if they are not paved Drivers of street vehicles may have diffi...

Page 73: ...e terrain visibility and other operating conditions and your experience 1 footpeg 1 65 Control Speed Basic Operation Riding Safe Riding Precautions Riding at excessive speed increases the chance of an...

Page 74: ...errain Always be alert to changing terrain conditions when operating the ATV 66 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Page 75: ...on these kinds of terrain Attempting wheelies jumps and other stunts increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off 67 D...

Page 76: ...operating the engine in an enclosed area such as a garage Your ATV s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Before star...

Page 77: ...s to the throttle with the choke knob in the fully OFF position Immediately after the engine starts operate the choke knob to keep fast idle With the throttle closed press the start button If the engi...

Page 78: ...life of the engine High Air Temperature 35 C 95 F or above Do not use the choke Low Air Temperature 10 C 50 F or below Follow the procedure for With the throttle closed press the start button When air...

Page 79: ...o RUN If the engine does not start wait 10 seconds then follow the procedure page You can restart the engine while the vehicle is stopped by squeezing the front brake lever and pressing the start butt...

Page 80: ...dicator light is on then turn the ignition switch OFF To stop the engine in an emergency use the engine stop switch To operate slide the switch to the OFF position Emergency Engine Stop If your ATV is...

Page 81: ...o operate the recoil starter After the engine starts allow the starter grip to return slowly Grasp the starter grip firmly then pull it out slowly approximately 4 in 100 mm Pull the grip up briskly an...

Page 82: ...t and downshift To upshift the transmission press the upshift switch once To downshift the transmission press the downshift switch once With the throttle closed press the upshift switch once to shift...

Page 83: ...c shift system malfunctions the transmission cannot be shifted by pressing the gearshift switches See your Honda dealer In an emergency a gear may be selected manually so you may move the vehicle See...

Page 84: ...high Downshifting when engine speed is near its allowable maximum may over rev the engine and possibly cause damage To prevent transmission damage do not coast or tow the ATV for long distances with t...

Page 85: ...r knob 2 rear brake lever parking brake lever 1 77 Riding in Reverse Basic Operation Riding If you need to ride in reverse make sure the area behind you is clear and only operate the ATV at low speed...

Page 86: ...afe speed while riding in reverse gear The transmission cannot be shifted from neutral back into reverse when the engine speed is above 3 000 rpm or speed of your ATV is above 2 mph 3 km h To shift ou...

Page 87: ...ow or stop apply the brake lever and brake pedal smoothly while downshifting to match your speed For full braking effectiveness use both the pedal and lever simultaneously Using both braking systems w...

Page 88: ...engine compression braking by downshifting with intermittent use of both brakes Continuous brake application can overheat the brakes and reduce their effectiveness Riding with your foot resting on th...

Page 89: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 81 Making Turns Riding Your ATV Basic Operation Riding Learn how to tur...

Page 90: ...rating from a full stop To make a sharp turn at low speed It helps to shift your body slightly forward on the seat and lean inside as you steer the handlebar Shifting weight forward allows the rear wh...

Page 91: ...Basic Operation Riding The terrain surface can be a major factor affecting turns Skidding during a turn is more likely to occur on slippery surfaces such as snow ice mud and loose gravel If you skid...

Page 92: ...ing The ATV s ability to safely climb hills largely depends on the rider s skill and judgment Begin by practicing on smooth gentle slopes As you gain experience you ll learn the hazards and your own l...

Page 93: ...start up any hill To climb a hill take a running start in an appropriate gear and speed for the conditions Maintain a steady speed as you ascend the hill Never open the throttle suddenly or make sudd...

Page 94: ...ft into neutral set the parking brake and turn the engine off Then assess the situation If the ATV starts rolling backwards before you begin braking Keep your weight uphill Carefully apply the front b...

Page 95: ...ot too steep and you have good footing you may be able to walk the ATV back down the hill Make sure your intended path is clear in case you lose control of the ATV Stand with your body facing downhill...

Page 96: ...scribed in this owner s manual 88 Riding Down Hills Riding Your ATV Basic Operation Riding It s usually advisable to descend hills with the ATV pointed straight downhill Avoid angles that would cause...

Page 97: ...ms extended and braced against the handlebar then go down slowly with the throttle closed Use mainly the rear brake to control speed Avoid using either the front brake or rear brake hard or abruptly w...

Page 98: ...f the seat and lean toward the uphill side On a slippery or loose surface you may also need to steer slightly uphill to maintain a straight course across the slope Avoid crossing hills that are excess...

Page 99: ...as described in this owner s manual 91 Riding Over Obstacles Riding Your ATV Basic Operation Riding Before operating in a new area check for obstacles Watch out for bumps rain ruts potholes and other...

Page 100: ...y the brakes repeatedly until they dry out and operate normally Riding through water can make the brakes less effective than normal and may reduce stopping ability After leaving the water always test...

Page 101: ...le back and forth to allow shifting the transmission into neutral If rocks or other objects are available you can block the wheels as shown for additional security If the ATV begins to move either whi...

Page 102: ...94 Basic Operation Riding...

Page 103: ...specific maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking good For information about the exhaust emission and noise...

Page 104: ...e Oil Filter Gear Case Oil Differential Oil Air Cleaner Throttle Clutch System Engine Idle Speed Spark Plug Valves Spark Arrester Brakes Tires Battery Appearance Care Carburetor Choke Cable Knob Rever...

Page 105: ...educe air pollution Careful pre ride inspections and good maintenance are especially important because your ATV is designed to be ridden over rough off road terrain To help you properly care for your...

Page 106: ...rform many of these tasks with the tools provided with your ATV Other tasks that are more difficult and require special tools are best performed by professionals Removing the wheels should normally be...

Page 107: ...Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around gasoline Use only non flamm...

Page 108: ...dule can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual Other items involve more extensive procedures and may require special training...

Page 109: ...e more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the o...

Page 110: ...QUENCY WHICHEVER COMES FIRST INITIAL INITIAL 150 km 100 mi 20 operating hours or 1 month R REGULAR Every 1 000 km 600 mi 100 operating hours or 12 months R MONTH HOURS MAINT INTERVAL MAINT 102 Mainten...

Page 111: ...600 6 100 I I I I I I I I C I I 2000 1200 12 200 I I I I I I I I I I I C I I I I I Refer to page 165 123 125 145 154 148 155 145 137 164 136 143 157 FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITI...

Page 112: ...rd will help ensure that your ATV is properly maintained Retain detailed receipts to verify the maintenance was performed If the ATV is sold these receipts should be transferred with the ATV to the ne...

Page 113: ...front brake fluid reservoir choke knob fuel fill cap front brake lever throttle lever parking brake lever rear brake lever 105 Servicing Your Honda Maintenance Component Locations...

Page 114: ...ight switch front brake caliper engine oil filter air cleaner owner s manual differential oil drain bolt throttle stop screw engine idle speed rear brake pedal differential oil fill cap 106 Servicing...

Page 115: ...engine oil drain bolt gear case oil drain bolt air pressure gauge battery tool kit main fuse fuse box PS fuse TRX500FPE only gear case oil fill cap engine oil fill cap dipstick 107 Servicing Your Hond...

Page 116: ...kit and the gear change tool are stored under the seat page After using the tools be sure to use the rubber band to fasten the tool kit securely An optional larger tool kit may be available Check wit...

Page 117: ...nda Be careful not to flood this area when washing your ATV The owner s manual should be stored in the plastic bag and fastened with the rubber band Your ATV provides storage for the owner s manual so...

Page 118: ...ntil locks Installation Removal Pull the seat lock lever at the right side of the seat Slide the seat back and lift it Insert the front prongs into the hooks on the frame and press the studs into the...

Page 119: ...pumps at service stations normally display the pump octane number For information on the use of oxygenated fuels see page Use of lower octane gasoline can cause persistent pinging or spark knock a lou...

Page 120: ...fueling Procedure Fuel Servicing Your Honda Safety Precautions Fuel tank capacity including reserve Reserve capacity Refer to on page The tank should be refilled as soon as possible after switching to...

Page 121: ...bottom of the filler neck Avoid over filling the tank There should be no fuel in the filler neck If the fuel valve was set to RES turn the fuel valve ON If you replace the fuel fill cap use only a Hon...

Page 122: ...ife Even the best oil wears out Changing oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil...

Page 123: ...lter Servicing Your Honda Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label Your ATV does not need oil additives Use the re...

Page 124: ...chart may be used when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines...

Page 125: ...TV check the engine oil level cont d Refer to on page Check the engine oil level each day before operating your ATV and add if needed Unsnap and remove the left engine sub cover Start the engine in a...

Page 126: ...en remove the oil fill cap dipstick and check the oil level The oil level should be between the upper level mark and the lower level mark on the oil fill cap dipstick Install the left engine sub cover...

Page 127: ...il filter specified for your model or a filter of equal quality This procedure requires mechanical skill and professional tools such as a torque wrench and oil filter wrench as well as a means for dis...

Page 128: ...1 RIGHT SIDE 2 1 right engine sub cover 2 screw 120 Engine Oil Filter Servicing Your Honda Install a New Engine Oil Filter Remove the right engine sub cover by removing the screw 2 1 1...

Page 129: ...ved manner page Check that the oil filter cover O rings are in good condition and then install a new oil filter Use only the Honda Genuine oil filter or a filter of equivalent quality specified for yo...

Page 130: ...drain plug with a new sealing washer and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Stop the engine wait 2 3 minutes and check the oil level Ma...

Page 131: ...oil Honda shaft drive oil or equivalent 123 Changing Oil Oil Recommendation Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the gear case at normal operatin...

Page 132: ...all the drain plug and tighten it to the specified torque Pour the drained oil into a suitable container and dispose of it in an approved manner page Install the oil fill cap and oil level check bolt...

Page 133: ...l Honda shaft drive oil or equivalent 125 Oil Recommendation Changing Oil Differential Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the differential at normal opera...

Page 134: ...ined reinstall the drain plug and tighten it to the specified torque Pour the drained oil into a suitable container and dispose of it in an approved manner page Make sure the oil level is at the lower...

Page 135: ...will allow dirt dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer can help you determine the...

Page 136: ...DER SEAT 2 1 1 retainer clips 2 air cleaner housing cover 128 Cleaning Air Cleaner Servicing Your Honda Unlatch the retainer clips Remove the air cleaner housing cover Remove the seat page 1 2 3 1 2 1...

Page 137: ...cleaner if it is damaged Gently wash the air cleaner and sub air cleaner in clean non flammable high flash point solvent such as kerosene not gasoline After cleaning gently squeeze out the remaining s...

Page 138: ...venly spread the oil into the air cleaner Gently squeeze out any excess oil To keep your hands dry place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner Install th...

Page 139: ...1 dust cover 2 breather joint UNDER SEAT 1 2 131 Dust Cover Air Cleaner Servicing Your Honda Do not push the dust cover too far into the breather joint If the dust cover is dirty clean it 1 2...

Page 140: ...be serviced in accordance with the Maintenance Schedule Riding through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the...

Page 141: ...Safety Precautions Refer to on page Check freeplay at the throttle lever Freeplay Inspection After adjustment check for smooth operation of the throttle lever from fully closed to fully open in all st...

Page 142: ...from fully open to fully closed in all steering positions If there is a problem see your Honda dealer Inspect the condition of the throttle cables from the throttle lever down to the carburetor If the...

Page 143: ...b 135 Carburetor Choke Cable Knob Servicing Your Honda Safety Precautions Refer to on page Check the condition of the choke cable Check the operation of the choke knob If the cable is damaged or kinke...

Page 144: ...s may be worn See your Honda dealer or refer to official Honda Service Manual page Turn the clutch adjuster counterclockwise until you feel slight resistance Turn the adjuster 1 4 turn clockwise then...

Page 145: ...Other Checks Check the reverse assist lever and cable for loose connections or other damage If the cable is worn or kinked have it replaced by your Honda dealer Refer to on page Check the reverse ass...

Page 146: ...problems in your engine s fuel delivery system Adjusting the idle will not compensate for a fault elsewhere Adjust idle speed by turning the throttle stop screw Idle speed in neutral Park your ATV on...

Page 147: ...ne damage Safety Precautions Use only the recommended type of spark plug in the recommended heat range Refer to on page cont d Loosen the screw and remove the clip Remove the seat page Disconnect the...

Page 148: ...cleaner if available or a wire brush Inspect the spark plug electrodes for wear The center electrode should have a flat tip and sharp edges and the side electrode should not be eroded If the electrode...

Page 149: ...nt cross threading Tighten the spark plug If the old plug is good 1 8 turn after it seats If installing a new plug tighten it twice to prevent loosening First tighten the plug NGK turn after it seats...

Page 150: ...ent and have the proper tools instructions on adjusting valve clearances are given in the official Honda Service Manual Otherwise the valves should be adjusted by your Honda dealer Excessive clearance...

Page 151: ...and muffler to cool Regular servicing prevents carbon build up which can diminish engine performance and also complies with USDA regulations for regular maintenance to assure proper function The spar...

Page 152: ...s from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary Check the gasket Replace if necessary I...

Page 153: ...ght brake lever freeplay does not feel within the normal range while riding check the brake pads for wear page Worn pads should be replaced If the pads are not worn beyond the recommended limit there...

Page 154: ...uld be above the LOWER level mark If the level is at or below the LOWER level mark check the brake pads for wear page Worn brake pads should be replaced If the pads are not worn have your brake system...

Page 155: ...tact with your eyes wash them out with clean water and immediately call a doctor If it comes in contact with your skin wash with clean water and if necessary call a doctor Check for deterioration or c...

Page 156: ...g conditions The pads will wear faster in wet or muddy conditions Inspect the pads visually during all regular service intervals to determine the pad wear Always inspect both pads in both the right an...

Page 157: ...SIDE 1 149 Rear Brake Pedal Freeplay Brakes Servicing Your Honda Measure the distance the rear brake pedal moves before the brake starts to take hold Freeplay measurement at the tip of the end of the...

Page 158: ...urn the brake pedal adjusting nut located on the brake operating rod at the rear of the frame Make sure the cutout on the adjusting nut is properly seated on the brake arm pin Adjust the freeplay of t...

Page 159: ...lever 151 Rear Brake Lever Freeplay Brakes Servicing Your Honda If necessary adjust to the specified range Inspection Measure the distance the rear brake lever parking brake lever moves before the bra...

Page 160: ...rod at the rear of the frame Make sure the cutout on the adjusting nut is properly seated on the brake arm pin Adjust the freeplay of the rear brake lever parking brake lever with the front wheels po...

Page 161: ...Servicing Your Honda Check that the rear brake lever and brake pedal assemblies are positioned properly and the securing bolts are tight Make sure that the brake cables brake arm spring parking and fa...

Page 162: ...check brake wear without disassembly Application of the brake control causes the arrow on the brake arm to move toward a reference mark on the brake panel Apply the brake control and check the moveme...

Page 163: ...er to on page Rear Brake Only Check the operation of the rear brakelight switch at the right side behind the engine from time to time The brakelight should turn on at 0 6 in 15 mm of pedal stroke See...

Page 164: ...ur Honda Safety Precautions Refer to on page Make sure the engine is OFF and the parking brake is set Remove the rear brake drain bolt from the bottom of the rear brake panel If any water drains the b...

Page 165: ...es must be the proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tires Although the tires are designed specifically for...

Page 166: ...dling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tires make your ATV ride harshl...

Page 167: ...159 Tires Servicing Your Honda Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your ATV has only been ridden for a few miles the readings...

Page 168: ...e system found in service stations This will minimize the possibility of tire damage from overinflation If you use a high pressure system at a service station add air in small amounts and check the pr...

Page 169: ...so if you hit a pothole or other hard object while riding stop as soon as you safely can and carefully inspect the tires for damage Tread Wear For best performance you should replace a tire before the...

Page 170: ...temporary repairs see page A tire that is repaired either temporarily or permanently will have lower speed and performance limits than a new or undamaged tire If you have a tire professionally repaire...

Page 171: ...e designed to match the performance capabilities of your ATV and provide the best combination of handling braking and comfort It is best to replace all four tires however if that is not possible you m...

Page 172: ...engine guard protects the engine crankcase and the skid plates protect the frame and rear final gear case The front boot guards protect the rubber driveshaft boots and the front driveshaft guards pro...

Page 173: ...joint boot 165 Servicing Your Honda Drivetrain Boots Safety Precautions Refer to on page Check the rubber driveshaft boots rubber propeller shaft boots and rubber yoke joint boot for cuts damage or le...

Page 174: ...when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your ATV or do not ride frequently we recommend that you charge the battery freque...

Page 175: ...Battery Charging Refer to on page If you plan to store your ATV we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life If you do...

Page 176: ...r Honda The battery is located in a compartment under the seat Remove the battery Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Release the ri...

Page 177: ...emperature and direct sunlight Clean the battery box after removing the battery for storage Dry the battery box and if paint is missing re paint the area Slow charge the battery see following section...

Page 178: ...recommend using a charger designed specifically for your Honda which can be purchased from your Honda dealer These units can be left connected for long periods without risking damage to the battery Ho...

Page 179: ...cts that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your ATV If your ATV is still warm from recent operation give the engine and exhaust system time...

Page 180: ...fter washing rinse your ATV thoroughly with plenty of clean water to remove any residue Detergent residue can corrode alloy parts Dry your ATV with a chamois or a soft towel Leaving water on the surfa...

Page 181: ...ply a spray cleaner polish and wipe with a non abrasive cloth Apply a high quality chrome aluminum polish and wipe with a non abrasive cloth Dull corroded chrome or aluminum Heavy grime Oil leaks Brak...

Page 182: ...y for motorcycles or automobiles Apply the polish or wax according to the instructions on the container If a surface on your ATV is chipped or scratched your Honda dealer has touch up paint to match y...

Page 183: ...and store your Honda and how to be an environmentally responsible ATV owner Preparing for a Ride What to Take to the Riding Area What to Take on the Trail Transporting Your Honda Storing Your Honda Y...

Page 184: ...USA only the Ministry of Natural Resources Canada only riding clubs and off road magazines are good sources of information Along with your ATV and riding gear you should take along some tools and supp...

Page 185: ...expect to ride how far you might go from your base camp or help and how experienced you or your companions are in making repairs If you decide to take some tools spare parts or other supplies on the...

Page 186: ...port your ATV we recommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking gas...

Page 187: ...wn straps in the areas shown Suitable tie down straps are available from your Honda dealer Ordinary rope is not recommended because it can stretch under load Using tie down straps in any other areas c...

Page 188: ...blem before storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again For more information about storage refer to the available from your Honda dealer U...

Page 189: ...to on page This procedure requires a means for draining and disposing of drained fuel page Change the engine oil and filter page Fill the fuel tank Make sure the fuel fill cap is properly installed c...

Page 190: ...ry and charge it fully Store it in an area protected from freezing temperatures and direct sunlight Slow charge the battery page once a month Cover your ATV with a porous material Avoid using plastic...

Page 191: ...as been stored for more than two months ask your Honda dealer to drain and replace the fuel Perform a pre ride inspection page then test ride your ATV at low speeds Charge the battery page as required...

Page 192: ...y increase noise they also reduce engine performance and may be illegal Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which da...

Page 193: ...a wide range of problems Take time to read this section before you ride Also review the tips in page General Guidelines If Your Engine Quits or Won t Start If You Have a Flat Tire If a Fuse Blows If...

Page 194: ...doesn t feel right If you continue riding you could cause more damage and endanger your own safety After stopping take time to assess the situation Carefully inspect your ATV to identify the problem...

Page 195: ...time to assess the situation and your options before deciding what to do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have perma...

Page 196: ...cases the cause of the problem may be a simple operational oversight If you have a problem starting the engine or experience poor engine performance the following information may help you If you can...

Page 197: ...ealer SYMPTOM POSSIBLE CAUSE out of fuel flooded engine loose or unconnected spark plug cap loose battery cables weak battery WHAT TO DO Fill the fuel tank See page Install the spark plug cap securely...

Page 198: ...high oil temperature indicator Refer to page If applicable switch to the recommended octane gasoline page or change your brand of gasoline If the problem persists see your Honda dealer poor engine per...

Page 199: ...ition switch to the ON position Press both shift switches and check that they are functioning If both switches are functioning shift into neutral and restart the engine If one or both switches are not...

Page 200: ...he transmission is in neutral go to step 4 If the transmission is not in neutral remove the left engine sub cover page use the gear change tool to shift to neutral so you will be able to start the eng...

Page 201: ...ft switches will not operate To reactivate the system turn the ignition switch to the OFF position then turn it back to the ON position With the ATV unoccupied align the hexagonal hole of the gear cha...

Page 202: ...a temporary repair As soon as possible have the tire permanently repaired by your Honda dealer Any tire that cannot be repaired should be replaced Whenever the ATV is to be operated far from service...

Page 203: ...f the temporary repair fails you can crash and be seriously injured or killed If you must ride with a temporary tire repair ride slowly and carefully until the tire is permanently repaired or replaced...

Page 204: ...firm level surface Avoid getting grease oil or dirt on the disc or pad surfaces when removing and installing each wheel Any contamination can cause poor brake performance or rapid pad wear after reass...

Page 205: ...ce the wheel rim Hand tighten the wheel nuts on the wheel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque If a torque w...

Page 206: ...l or extended operation under adverse conditions If the indicator comes on while you re riding don t ignore it Pull safely to a stop Stop the engine as soon as it s safe to do so and let it cool If th...

Page 207: ...d by excess current flow short circuit or overload If something electrical on your ATV stops working the first thing you should check for is a blown fuse Check all the fuses before looking elsewhere f...

Page 208: ...f the Unexpected Main Fuse Access Remove the seat page To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuses To access the main fuse and shift moto...

Page 209: ...f damage to the electrical system Circuit Fuse Access To check or replace a circuit fuse pull the old fuse out of its retaining clips If the fuse is blown replace it with a spare fuse of the same rati...

Page 210: ...ou replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses that were installed If you do not...

Page 211: ...carefully inspect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there...

Page 212: ...e If you lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer where you purchased your Honda ATV They may have it list...

Page 213: ...If the transmission is not in neutral the vehicle will not move Remove the left engine sub cover page use the gear change tool to shift to neutral so you will be able to start the engine Refer to pag...

Page 214: ...he damage is and what tools and supplies you have with you If any component of the brake system is damaged you may be able to ride carefully back to your base using the other brake components for slow...

Page 215: ...ties and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification Specifications Break in Guidelines High Altitude Carburetor Adjustment Emi...

Page 216: ...ation The VIN engine serial number and key number may be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN is stam...

Page 217: ...icle Identification Technical Information The color code is helpful when ordering replacement parts You may record the color and code in the Quick Reference section at the rear of this manual The colo...

Page 218: ...ice label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 stroke oil USA Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil 2 6 US qt 2 5 2 5 US qt 2 4 including reserve after...

Page 219: ...SO 0 006 in 0 15 mm 0 006 in 0 15 mm 485 lb 220 kg or passenger capacity bore stroke maximum weight capacity displacement spark plug standard compression ratio spark plug gap valve clearance cold idle...

Page 220: ...Pa caster trail tire size front tire size rear tire pressure front rear cold tire pressure front rear cold battery generator headlight assist headlight brake tail light neutral indicator reverse indic...

Page 221: ...lbf ft 64 N m 6 5 kgf m 9 lbf ft 12 N m 1 2 kgf m main shift motor other PS Electric Power Steering engine oil drain bolt rear final gear case oil drain bolt engine oil filter cover bolts differentia...

Page 222: ...on Help assure your ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts ra...

Page 223: ...epower will be greater than this if no carburetor modification is made High altitude performance can be improved by specific modifications to the carburetor If you always operate your engine at altitu...

Page 224: ...Information The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Environment Canada EC require that your ATV comply with applicable exhaust emissions standards duri...

Page 225: ...hen subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons The e...

Page 226: ...mptoms have the vehicle inspected and repaired by your Honda ATV dealer Symptoms Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burning backfirin...

Page 227: ...E ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of...

Page 228: ...ls that come near it Park your ATV away from high grasses dry leaves or other flammables A defective catalytic converter contributes to air pollution and can impair your engine s performance Follow th...

Page 229: ...ed on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing e...

Page 230: ...toms 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...

Page 231: ...This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals Warranty Coverage Warranty Service Contacting Honda Your Honda Dealer The Honda R...

Page 232: ...lable from Helm Inc USA only Canada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of...

Page 233: ...h add 6 Calif add 8 25 Qty Price Each 225 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00...

Page 234: ...e Telephone Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Check here if your billing address is different from the shipping address shown above VISA Discover...

Page 235: ...wner s card with your Warranties Booklet USA only Your warranty coverage will not be voided if you choose to perform your own maintenance However you should have the proper tools and service informati...

Page 236: ...you the results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the rep...

Page 237: ...o work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Mot...

Page 238: ...roducts Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the pa...

Page 239: ...Club USA only Consumer Information www hrca honda com You may be eligible for a Honda Rider s Club of America HRCA membership with the purchase of your new Honda You can log on to the HRCA Clubhouse w...

Page 240: ...31 filter 127 housing drain tube 132 air pressure gauge 108 tire 158 altitude high 215 American Honda contacting 229 apparel protective 48 appearance care 171 authorized manuals 224 battery 166 brakel...

Page 241: ...just 14 17 24 hour select 14 17 24 minute select 14 17 24 odometer tripmeter select 14 16 20 21 RESET 14 16 20 22 capacity fuel 112 carburetor altitude adjustment 215 care appearance 171 cargo loading...

Page 242: ...32 dipstick 118 display check 15 display multi function 18 driveshaft boots 165 compartment owner s manual 109 storage 44 tool kit 108 component fails 206 consumer information 223 controls features 27...

Page 243: ...ed 71 guard 164 idle speed 138 number 208 oil 114 pinging 111 starting 68 stop switch 31 stopping 72 won t start 188 environment 184 exhaust system cleaning 54 purging 143 final gear case oil 123 flag...

Page 244: ...21 recommendation 111 refueling 112 reserve fuel supply 112 tank capacity 112 valve 27 fuses 199 headlight dimmer switch 32 headlight switch 32 high altitude carburetor adjustment 215 gap spark plug 1...

Page 245: ...Club 231 service manual 224 hourmeter 23 hour select button 14 17 24 identification vehicle 208 idle speed engine 138 ignition switch 29 indicators gear position indicator 19 high oil temperature ind...

Page 246: ...imit weight 57 load limits 57 loading guidelines 58 lubrication differential oil 125 engine oil 114 gear case oil 123 maintenance component locations 105 importance 97 precautions 99 record 104 safety...

Page 247: ...8 neutral indicator 14 16 noise emission control system 219 numbers serial 208 obstacles riding over 91 odometer tripmeter 21 odometer tripmeter select button 14 16 20 21 oil differential 125 engine 1...

Page 248: ...37 gear shifting into 77 indicator 14 16 riding in 77 selector knob 36 rider training 50 Rider s Club Honda 231 parking 93 passengers no carrying 51 pavement no riding on 63 pinging engine 111 plug sp...

Page 249: ...riding precautions 63 schedule maintenance 100 seat removal 110 serial numbers 208 service customer 229 manuals 224 warranty 228 riding basic operations 61 clothing 48 over obstacles 91 precautions 63...

Page 250: ...cations 210 speedometer 17 18 stalled engine 71 stalling on a hill 86 start button 31 starting engine 68 troubleshooting 188 stop switch engine 31 stopping engine 72 storage ATV 180 compartment 44 own...

Page 251: ...8 flat 194 replacing 163 repairing 162 tread conditions 160 161 tool kit 108 trailer hitch 40 trailer towing operational guidelines 58 weight limits 57 training rider 50 transporting your ATV 178 trou...

Page 252: ...el 27 valve clearance 142 vehicle identification no VIN 208 warning labels 5 warranty coverage 227 extended 227 service 228 washing your ATV 172 water draining from brakes 156 riding through 92 weight...

Page 253: ...245 Memo...

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Page 257: ...249 Memo...

Page 258: ...250 Memo...

Page 259: ...251 Memo...

Page 260: ...tant notes The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequen...

Page 261: ...Quick Reference Quick Reference Engine No VIN Ignition Key No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr...

Page 262: ...bolts underbody exhaust system air cleaner housing drain tube leaks loose parts cables lights throttle brakes reverse assist lever switches steering unleaded gasoline pump octane number 86 or higher E...

Page 263: ...A 2 10 A 2 40 A 3 6 psi 25 0 kPa 3 6 psi 25 0 kPa 4 4 psi 30 0 kPa 3 6 psi 25 0 kPa Front Rear Front Rear or main shift motor other standard Front Rear PS Electric Power Steering TRX500FPE only TRX50...

Page 264: ...adlight dimmer switch HI headlight dimmer switch OFF headlight switch ON headlight switch OFF engine stop switch RUN engine stop switch START button SEE PAGE upshift switch gearshift switch downshift...

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