Honda FourTrax Foreman Rubicon TRX520FM6 2020 Owner'S Manual Download Page 1 | Manualshive

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2020

2020

2020

2020

OWNER’S MANUAL

OWNER’S MANUAL

TRX520FM6 4x4 with Power Steering

TRX520FM6 4x4 with Power Steering
FOURTRAX FOREMAN RUBICON

FOURTRAX FOREMAN RUBICON

Read this manual carefully,
it contains important safety information.

Minimum recommended operator age: 16

Models sold in and used in California:
The removal or modification of evaporative
emission-related parts on this OHRV is illegal. Violators
may be subject to civil and/or criminal penalties as
provided under California and federal law.

Part Number

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Summary of Contents for FourTrax Foreman Rubicon TRX520FM6 2020

Page 1: ...N RUBICON Read this manual carefully it contains important safety information Minimum recommended operator age 16 Models sold in and used in California The removal or modification of evaporative emiss...

Page 2: ...formation available before 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...

Page 3: ...US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways is illegal The vehicle is equipped with a USDA qualified spark arrester Obey local laws and regulation...

Page 4: ...ed 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 contains a d...

Page 5: ...ur ATV best and is dedicated to your complete satisfaction Please report any change of address or ownership to your dealer so we will be able to contact you concerning important product information Yo...

Page 6: ...n labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with opera...

Page 7: ...ty Instructions how to use this ATV correctly and safely This entire manual is filled with important safety information please read it carefully 3DANGER You WILL be KILLED or SERIOUSLY HURT if you don...

Page 8: ...on your ATV Instruments Controls 9 The location and function of indicators and controls on your ATV and operating instructions for various controls and features Before Riding 57 The importance of wear...

Page 9: ...ur ATV and how to be an environmentally responsible rider Taking Care of the Unexpected 205 What to do if you have a flat tire your engine won t start etc Technical Information 227 ID numbers technica...

Page 10: ...20 TRX520FM6 31HR56500 book 9...

Page 11: ...tant 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 on your A...

Page 12: ...16 Children under age 16 should never operate this vehicle Refer to the age warnings provided in this manual and on the ATV Always Wear a Helmet It s a proven fact helmets significantly reduce the num...

Page 13: ...a safe area until you build your skills and get accustomed to the ATV s size and weight Because many crashes involve inexperienced or untrained riders we urge all riders to take a ATV operator course...

Page 14: ...ing 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 don t drink and ride and don t let your friends...

Page 15: ...mportant safety information Anyone who rides the vehicle should read and understand this information before riding The labels should be considered permanent parts of the vehicle If a label comes off o...

Page 16: ...balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriou...

Page 17: ...ressure Maximum weight capacity 573lbs 260kg Front 4 4psi 30kPa Rear 4 4psi 30kPa Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead t...

Page 18: ...ith a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid...

Page 19: ...Instructions for other components are presented in other sections of this manual where they will be most useful Operation Component Locations 11 Indicators Displays 14 Multi function Display 20 Speed...

Page 20: ...Stop Switch 40 Headlight Switch 41 Headlight Dimmer Switch 41 Recoil Starter Canada only 42 Throttle Lever 43 Front Brake Lever 44 Rear Brake Lever Parking Brake Lever 44 Rear Brake Pedal 44 Parking...

Page 21: ...ions headlight dimmer switch P R lever rear brake lever parking brake lever engine stop switch start override button ignition switch differential lock switch throttle lever front brake lever headlight...

Page 22: ...Instruments Controls 12 Operation Component Locations rear cargo rack front cargo rack rear brake pedal recoil starter Canada only front utility box 20 TRX520FM6 31HR56500 book 12...

Page 23: ...Instruments Controls 13 Operation Component Locations trailer hitch shift lever storage compartment accessory socket side utility box utility pocket flag pole bracket 20 TRX520FM6 31HR56500 book 13...

Page 24: ...d more enjoyable Refer to the indicators frequently Their functions are described on the following pages 3 4 5 6 7 2 1 3 differential lock indicator 4 PGM FI indicator 2 reverse indicator 1 neutral in...

Page 25: ...for a few seconds and then go off after initial lamp check These indicators are identified in the table on page 17 with the words Lamp Check When applicable the reverse or neutral indicators comes bac...

Page 26: ...re identified in the table on page 18 with the words Display Check If any part of these displays does not come on when it should have your dealer check for problems Meter Input Signal Failure If the n...

Page 27: ...re is any abnormality in the differential system See page 38 Lamp Check 4 PGM FI indicator Lights when there is any abnormality in the PGM FI Programmed Fuel Injection system Should also light for a f...

Page 28: ...position page 23 Maintenance minder indicator Shows when specified maintenance interval is reached page 32 Speedometer Shows riding speed Fuel gauge Shows approximate fuel supply available page 24 Di...

Page 29: ...the lower parts of multi function display Adjusts the digital clock page 26 Changes the speed and mileage units page 22 Resets the tripmeter to zero 0 page 27 This button also used to reset the maint...

Page 30: ...art of the multi function display push the mode select button 7 Multi function Display 4WD indicator Odometer Gear position indicator Tripmeter Speedometer Coolant temperature gauge Maintenance minder...

Page 31: ...e fuel gauge If there is a coolant temperature warning with your ATV the display will automatically change to the coolant temperature gauge If you try to change the display back to ordinary display it...

Page 32: ...H and KM To change the speed and mileage units press and hold the mode select button 1 for more than 5 seconds in the odometer mode page 21 with the ATV stopped The 4WD indicator 1 shows when the 4WD...

Page 33: ...ear position is properly displayed on the gear position indicator If the gear position indicator shows or blinks turn the ignition switch to the OFF w position and then turn it back to the ON q positi...

Page 34: ...dless of what mode the display is in when the fuel level reaches 1st segment 3 the display will automatically switch to the fuel gauge display You should refuel as soon as possible The amount of fuel...

Page 35: ...times alternately and fuel mark blinks you should refuel as soon as possible The amount of fuel reserve is approximately 1 29 US gal 4 9 Fuel gauge failure If the fuel gauge E F 6 is blinking the fuel...

Page 36: ...e mode select button the display will begin advancing fast Press and hold the button for 0 5 5 5 seconds advance one minute at a time 5 5 10 5 seconds advance five minutes at a time 10 5 seconds or mo...

Page 37: ...meter 1 shows mileage per trip since you last reset the tripmeter while the ignition switch is ON q with the TRIP mark 2 The tripmeter returns to 0 0 when the readout exceeds 999 9 To reset the tripme...

Page 38: ...switch is ON q The normal operating temperature range is within the section between the 1st segment 3 and 4th segment 4 When coolant temperature is low the coolant temperature gauge will display Lo 5...

Page 39: ...s stop the engine and check the reserve tank coolant level Read pages 215 216 and do not ride the ATV until the problem has been corrected NOTICE Continuing to ride with an overheated engine can cause...

Page 40: ...e ignition switch is ON q with the hour meter mark 2 The hour meter provides accurate service period information for initial and regular maintenance The hour meter locks at 99 999 9 when the readout e...

Page 41: ...ch is ON q with the maintenance minder indicator The maintenance tripmeter decreases from 600 miles 1 000 km after reset The maintenance hour meter decreases from 100 hour after reset Initial setting...

Page 42: ...e display Initial Maintenance Appears at 100 miles 150 km or 20 operating hours whichever comes first Regular Maintenance Interval 1 Appears 600 miles 1 000 km or 100 operating hours after the Initial...

Page 43: ...er indicator will appear then it will blinks twice and the multi function display will temporarily show all the modes and digital segments The indicator message will disappear Reset operation will be...

Page 44: ...turn it to the right for the ON q position The ignition switch is also used to reset the maintenance tripmeter maintenance hour meter page 33 Ignition Switch Key Position Function ON q Electrical cir...

Page 45: ...ent drive mode look at the 4WD indicator 2 2WD mode the 4WD indicator disappears when the 2WD mode engages 4WD mode the 4WD indicator appears when the 4WD mode engages If the 4WD indicator does not ap...

Page 46: ...e same speed Because locking all four wheels together changes the way the vehicle handles and increases the amount of room necessary to turn a speed limiter restricts the speed to 20 mph 32 km h Pushi...

Page 47: ...ll be interrupted and the differential lock indicator will slowly flash If the differential lock indicator does not stay on when the front differential lock mode is selected steer the handlebar either...

Page 48: ...s any abnormality in the differential system If this occurs the differential actuator will stop moving and the differential system will be fixed in the current position either 2WD mode 4WD mode or fro...

Page 49: ...button is pushed the starter motor will crank the engine The starter motor will not operate if the engine stop switch is in the OFF r position when the start override button is pushed To activate the...

Page 50: ...e position to start the engine and it should normally remain in the RUN e position even when the engine is OFF If your ATV is stopped with the ignition switch ON q and the engine stop switch OFF r the...

Page 51: ...adlight dimmer switch 2 is used to change between the high and low beams of the headlights and to activate the assist headlight To operate turn the switch to HI u for high beam of the headlights and a...

Page 52: ...ntrols Features The recoil starter 1 is used to start the engine when the battery is low See Using the Recoil Starter Canada only page 86 Recoil Starter Canada only RIGHT SIDE 1 recoil starter 1 20 TR...

Page 53: ...ss the throttle lever 1 with your thumb To reduce engine rpm release pressure on the throttle lever The throttle will automatically return to the closed position engine idle when you remove your thumb...

Page 54: ...ar brake lever parking brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see page 91 The rear brake pedal is used to slow or stop your ATV To...

Page 55: ...1 on the rear brake lever parking brake lever 2 is used to apply the parking brake or to shift the transmission into reverse Parking Brake Reverse Lever P R Lever LEFT HANDLEBAR 1 P R lever 1 2 2 rear...

Page 56: ...formation on Parking see page 106 To release the parking brake Squeeze the rear brake lever parking brake lever until the P R lever is released from the slot on the rear brake lever parking brake leve...

Page 57: ...ilable from your dealer To mount a pole in the bracket 1 follow the instructions that come with the flag pole kit Flag poles are required in some riding areas Check local regulations before riding Fla...

Page 58: ...ch you ll need a proper size ball 2 as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the trailer manufacturer s instructions For load limits and operat...

Page 59: ...ll phone etc NOTICE Do not plug in any heat generating accessory such as an automobile cigarette lighter because it can damage the socket To use the accessory socket turn the ignition switch to ON q s...

Page 60: ...may drain the battery The accessory socket s rated capacity is DC 12 V 120 Watts 10 A or less If you exceed this limit you may blow a fuse See If a Fuse Blows page 217 When you are done using an acce...

Page 61: ...close Push down the front of the utility box cover until it locks in place Make sure that the stud 3 is locked securely in position by pulling up lightly on the front of the utility box cover Do not s...

Page 62: ...sh down the front of the utility box cover until it locks in place Make sure that the studs 3 are locked securely in position by pulling up lightly on the front of the utility box cover Do not store v...

Page 63: ...s The utility pocket 1 is located on the left side cover You may store small lightweight items in the pocket Do not store valuable items in the utility pocket Utility Pocket LEFT SIDE COVER 1 1 utilit...

Page 64: ...1 is located below the rear cargo rack 2 To open the compartment unhook the rubber strap 3 Be careful not to flood this area when washing your ATV Storage Compartment REAR 1 storage compartment 2 3 2...

Page 65: ...cle and allow the EPS system to cool down until the PS indicator goes off After cooling down steering will return to normal EPS operation The PS indicator should light when the ignition switch is turn...

Page 66: ...Instruments Controls 56 20 TRX520FM6 31HR56500 book 56...

Page 67: ...tments to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride 58 Protective Apparel 58 Rider Training 60 Age Recommendation...

Page 68: ...ng You don t have any alcohol or drugs in your system For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved...

Page 69: ...ycle boots to help protect your feet ankles and lower legs Off road motorcycle gloves to help protect your hands Riding pants with knee and hip pads a riding jersey with padded elbows and a chest shou...

Page 70: ...te ASI For information about the ASI training course nearest you call the national toll free number 800 887 2887 USA only Other riding tips can be found in the Tips Practice Guide for the ATV Rider bo...

Page 71: ...n the front or rear cargo racks Age Recommendation WARNING 3WARNING A child using an ATV that is not recommended for their age could lose vehicle control while riding resulting in severe injury or dea...

Page 72: ...erating an ATV Consult your doctor to be sure it is safe to operate a vehicle after taking medication No Alcohol or Drugs WARNING 3WARNING Operating this ATV after consuming alcohol or drugs can serio...

Page 73: ...nspected by your dealer There may be damage or other problems you cannot see Check the following items before you get on the ATV WARNING 3WARNING Improperly maintaining this ATV or failing to correct...

Page 74: ...lts Check the wheels to see that the axle nuts are tightened Use a wrench to make sure all accessible nuts bolts and fasteners are tight Underbody Exhaust System Check for and remove any dirt vegetati...

Page 75: ...e Check the freeplay and adjust if needed Press the throttle to make sure it moves smoothly without sticking and snaps shut automatically when it is released in all steering positions page 156 Brakes...

Page 76: ...t before you ride Headlight and Headlight Dimmer Switch Check for proper function page 41 Engine Stop Switch Check for proper function page 40 Steering Check that the wheels turn properly as you steer...

Page 77: ...modifications that change this ATV s design and performance can also make it unsafe Also the weight of any accessories will reduce the maximum load the ATV can carry More specific information on load...

Page 78: ...gue using either a tongue jack or other support to keep the trailer level The weight of added accessories will reduce the maximum cargo weight you can carry Load Limits maximum weight capacity 573 lb...

Page 79: ...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 handlebar movement Do not allow cargo...

Page 80: ...and always follow these guidelines Make sure the accessory does not obscure any lights reduce ground clearance limit suspension travel or steering travel or interfere with operating any controls Make...

Page 81: ...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 or emission control system co...

Page 82: ...Before Riding 72 20 TRX520FM6 31HR56500 book 72...

Page 83: ...ormance and service life refer to Break in Guidelines page 235 Safe Riding Precautions 75 Off road Use Only 75 Keep Hands and Feet on Controls 76 Control Speed 77 Use Care on Unfamiliar or Rough Terra...

Page 84: ...Braking 91 Riding Your ATV 93 Making Turns 93 Skidding or Sliding 95 Riding Up Hills 96 Riding Down Hills 100 Crossing or Turning on Hills or Slopes 101 Riding Over Obstacles 103 Riding Through Water...

Page 85: ...ed and manufactured for off road use only not for pavement Riding on pavement can affect handling and control You should not ride your ATV on pavement When riding off road also remember to always obey...

Page 86: ...rom the handlebars or one foot from the footpegs can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV WARNING 3WARNING Operating this ATV on public s...

Page 87: ...errain visibility and other operating conditions plus your own skills and experience Control Speed WARNING 3WARNING Operating this ATV at excessive speeds increases your chances of losing control of t...

Page 88: ...tructions like hidden rocks bumps or holes in time to react Use Care on Unfamiliar or Rough Terrain WARNING 3WARNING Failure to use extra care when operating this ATV on unfamiliar terrain could resul...

Page 89: ...n operating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control which could result in a crash including an overturn Do not operate on excessively rough slipp...

Page 90: ...onoxide gas which can collect rapidly in an enclosed area and cause illness or death WARNING 3WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause...

Page 91: ...parking brake page 45 2 Turn the ignition switch 1 to ON q Confirm the following The transmission is in neutral the neutral indicator 2 is ON and the gear position indicator shows N The engine stop sw...

Page 92: ...rature Press the start override button with the throttle completely closed The engine will not start if the throttle is fully open because the electronic control module cuts off the fuel supply Snappi...

Page 93: ...cedure 5 If the engine starts then open the throttle slightly if idling is unstable If the engine does not start wait 10 seconds then follow steps 1 4 again If the engine still won t start refer to If...

Page 94: ...pressing the start override button Do not press the throttle lever while starting in gear The engine will not start if the throttle is fully open because the electronic control module cuts off the fu...

Page 95: ...ch to OFF w The engine stop switch should normally remain in the RUN e position even when the engine is OFF If your ATV is stopped with the engine stop switch OFF r and the ignition switch ON q the ba...

Page 96: ...then pull it out slowly approximately 4 in 100 mm 4 Pull the grip up briskly and fully 5 After the engine starts allow the starter grip to return slowly Pull the recoil starter grip straight out so t...

Page 97: ...osition when released To upshift to a higher gear put the toe of your boot under the shift lever and raise it one full stroke To downshift step on the shift lever and depress it one full stroke To sel...

Page 98: ...ving in a straight line Close the throttle release completely before shifting Improper shifting may damage the engine transmission and drivetrain Upshift to a higher gear or reduce throttle before eng...

Page 99: ...uing to hold the P R lever squeeze the rear brake lever parking brake lever 3 then depress the shift lever once to shift into R reverse gear 5 Make sure that the reverse indicator comes on and the gea...

Page 100: ...ottle and gradually apply both the front and rear brakes Do not abruptly apply the rear brake by alone 9 To shift out of reverse and into neutral raise the shift lever one stroke to shift into N neutr...

Page 101: ...heels As a general rule the front braking system provides about 70 percent of total stopping power For full braking effectiveness use both the pedal and lever simultaneously Using both braking systems...

Page 102: ...cy situation are important riding skills When descending a long steep grade use engine compression braking by downshifting with intermittent use of both brakes Continuous brake application can overhea...

Page 103: ...ebar in the front differential lock mode will cause steering to be heavy and increase turning radius Making Turns WARNING 3WARNING Turning improperly can make the ATV go out of control causing a colli...

Page 104: ...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 wheels to turn easier and it also improves front wheel stee...

Page 105: ...ays during a turn steer in the direction of the skid Avoid hard braking or accelerating until you have regained directional control Remember that steering the handlebar in the front differential lock...

Page 106: ...ght toward the front wheels to help keep them on the ground To do this shift your body slightly forward on the seat and lean forward For greater weight shift move your body farther forward and lean fo...

Page 107: ...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 sudden gear changes The ATV could flip over backward Never g...

Page 108: ...rking brake and turn the engine off 4 Then assess the situation If the ATV starts rolling backwards before you begin braking 1 Keep your weight uphill 2 Carefully apply the front brakes first then car...

Page 109: ...to walk the ATV back down the hill Make sure your intended path is clear in case you lose control of the ATV 1 Stand with your body facing downhill beside the vehicle so you can reach the rear brake l...

Page 110: ...ch a downhill stop and survey the terrain below Never ride past the limit of your visibility Never go down a hill at high speed Riding Down Hills WARNING 3WARNING Going down a hill improperly could ca...

Page 111: ...d on any hill with a loose surface Riding on hills or slopes is different from riding on level terrain Be careful when riding on any hill Make sure that you practice on gentle smooth slopes before att...

Page 112: ...or loose surface you may also need to steer slightly uphill to maintain a straight course across the slope Avoid crossing hills that are excessively steep slippery or rough Making Turns on Slopes Comp...

Page 113: ...acle reduce your speed and be prepared to stop Never try to ride over large obstacles such as large rocks or fallen logs Riding Over Obstacles WARNING 3WARNING Improperly operating over obstacles coul...

Page 114: ...lt in emissions control system malfunction Have your ATV dealer inspect the oxygen sensor immediately after water enters the muffler Riding Through Water WARNING 3WARNING The ATV tires have some abili...

Page 115: ...slippery rocks 4 Avoid getting the spark plug or air cleaner wet as this would cause the engine to stop 5 After leaving the water always test both the front and rear brakes Riding through water can m...

Page 116: ...by applying the parking brake When using the parking brake be sure to turn the ignition switch to OFF w to avoid discharging the battery Parking on a Steep Incline or a Loose or Slippery Surface If y...

Page 117: ...ection Agency EPA the California Air Resources Board CARB and Environment Climate Change Canada ECCC see page 236 USA only Maintenance replacement or repair of the emission control devices and systems...

Page 118: ...r Oil 138 Front Final Gear Oil 140 Coolant 142 Air Cleaner 150 Engine Throttle 156 Clutch System 158 Reverse Inhibitor System 159 Spark Plug 160 Valves 163 Spark Arrester 164 Chassis Suspension 165 Br...

Page 119: ...enance Schedule The service intervals in this schedule are based on average riding conditions Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine r...

Page 120: ...led only by a Honda technician or other qualified mechanic Instructions are included in this manual only to assist in emergency service Some of the most important safety precautions follow However we...

Page 121: ...ake 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 flammable solvent not gasoline to clean parts Keep...

Page 122: ...ormed 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 tools and equipm...

Page 123: ...y of Maintenance Schedule Notes Procedures NOTES 1 Service more frequently when riding in dusty areas sand or snow 2 Service more frequently after riding in very wet or muddy conditions 3 Replace ever...

Page 124: ...age MAINT MAINT INTERVAL mi 100 600 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 FUEL LINE I THROTTLE OPERATION I 156 AIR CLEANER NOTE 1 C C 150 AIR CLEANER HOUSING DRAIN TUBE NOTE 2...

Page 125: ...MAINT MAINT INTERVAL mi 100 600 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 DRIVETRAIN BOOTS I I 184 FRONT REAR FINAL GEAR OIL R EVERY 2 YEARS I 138 140 BRAKE FLUID NOTE 3 I I 168 B...

Page 126: ...ce including the 100 mile 150 km or 1 month or 20 hours initial maintenance is considered a normal owner operating cost and will be charged for by your dealer Use the space under Notes to record anyth...

Page 127: ...a 117 Service Preparations Maintenance Component Locations front brake lever P R lever rear brake lever parking brake lever throttle lever front brake fluid reservoir reverse assist lever 20 TRX520FM6...

Page 128: ...box main fuse 1 main fuse 2 EPS fuse rear brake pedal rear brake light switch front final gear oil fill cap front final gear oil drain bolt fuel fill cap engine oil filter rear final gear oil fill cap...

Page 129: ...gauge 40 A spare fuse fuse puller tool kit spark arrester rear suspension spring pre load adjusters spark plug engine oil fill cap dipstick engine oil drain bolt clutch adjuster coolant reserve tank a...

Page 130: ...torage compartment page 54 After using the tools be sure to use the rubber band 2 to fasten the tool kit securely An optional larger tool kit may be available Check with your dealer s parts department...

Page 131: ...s manual air pressure gauge 4 40 A spare fuse 5 and fuse puller 6 should be stored in the plastic document bag and fastened with the rubber band 7 To remove the rear fender cover see page 123 Be caref...

Page 132: ...er s manual air pressure gauge 40 A spare fuse and fuse puller Removal 1 Pull the seat latch 1 at the rear of the seat 2 Slide the seat 2 back and lift it Installation 1 Insert the front prongs 3 into...

Page 133: ...e 40 A spare fuse and fuse puller Removal 1 Remove the seat page 122 2 Unhook the rubber strap 1 3 Firmly pull the studs 2 from the grommets 3 4 Slide the rear fender cover 4 forward to disengage the...

Page 134: ...intenance Removal 1 Remove the seat page 122 2 Carefully remove the right studs 1 and left studs from the grommets 3 Remove the tank cover assembly 2 by releasing the right tabs 3 and left tabs from t...

Page 135: ...emoval Removal 1 Pull up the center pin to release the lock 2 Pull out the clip of the hole Installation 1 Insert the clip into the hole 2 Press down the center pin securely to lock the clip 1 2 1 2 2...

Page 136: ...use of oxygenated fuels see page 240 Use of lower octane gasoline can cause persistent pinging or spark knock a loud rapping noise which if severe can lead to engine damage Light pinging experienced w...

Page 137: ...capacity 1 29 US gal 4 9 When there is only one segment left in the fuel gauge page 24 fuel will be low and you should refuel as soon as possible Refer to Safety Precautions on page 111 Fuel Capacity...

Page 138: ...ap clockwise until it clicks If you replace the fuel fill cap use a Honda Genuine replacement part or equivalent NOTICE Gasoline can damage the camouflage coating Do not allow spilled gasoline to pool...

Page 139: ...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 can cause s...

Page 140: ...ls displaying a circular API energy conserving or resource conserving service label on the container They may affect lubrication and clutch performance Do not use non detergent vegetable or castor bas...

Page 141: ...within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is lab...

Page 142: ...your ATV on a firm level surface 2 Start the engine in a well ventilated area and let it idle for 3 5 minutes If the air temperature is below 10 C 50 F let the engine idle for an additional 5 minutes...

Page 143: ...d the lower level mark 6 on the oil fill cap dipstick 7 If the oil level is near or below the lower level mark then add the specified oil into the fill cap hole up to the upper level mark on the oil f...

Page 144: ...e damage This procedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid page 204 If you do not have the skills or the too...

Page 145: ...35 Engine Oil Filter cont d 2 Place an oil drain pan under the crankcase and remove the engine oil drain bolt 1 and sealing washer 2 UNDER ENGINE 2 1 engine oil drain bolt 1 2 sealing washer 20 TRX520...

Page 146: ...ver 4 Reposition the spring 7 to the crankcase cover and install a new oil filter with the rubber seal 8 facing out away from the engine You will see the OUT SIDE TOWARDS FILTER COVER mark 9 on the fi...

Page 147: ...her and tighten it to the specified torque 18 lbf ft 25 N m 2 5 kgf m 2 Fill the crankcase with the recommended grade oil approximately 3 2 US qt 3 0 3 Reinstall the oil fill cap dipstick 4 Start the...

Page 148: ...e 111 Change the oil with the rear final gear at normal operating temperature to assure complete and rapid draining Oil Recommendation type hypoid gear oil viscosity weight SAE 80W 90 suggested oil Ho...

Page 149: ...ed oil into a suitable container and dispose of it in an approved manner page 204 NOTICE Improper disposal of drained fluids is harmful to the environment 6 Fill the rear final gear case with the reco...

Page 150: ...e 111 Change the oil with the front final gear at normal operating temperature to assure complete and rapid draining Oil Recommendation type hypoid gear oil viscosity weight SAE 80W 90 suggested oil H...

Page 151: ...d oil into a suitable container and dispose of it in an approved manner page 204 NOTICE Improper disposal of drained fluids is harmful to the environment 6 Fill the front final gear case with the reco...

Page 152: ...ifreeze container label Use only distilled water as a part of the coolant solution Water that is high in mineral content or salt may be harmful to the aluminum engine NOTICE Using coolant with silicat...

Page 153: ...y Precautions on page 111 Check the engine coolant level each day before operating your ATV and add if needed 1 Make sure the vehicle is on level ground 2 With the engine at normal operating temperatu...

Page 154: ...to the reserve tank Do not attempt to add coolant by removing the radiator cap 5 Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark 6 After adding coolant r...

Page 155: ...rvice Manual page 244 To properly dispose of drained coolant refer to You the Environment page 204 NOTICE Improper disposal of drained fluids is harmful to the environment Coolant Replacement WARNING...

Page 156: ...or any obstruction with low water pressure Have the radiator checked by your dealer if the air flow is restricted over more than 20 of the radiator surface Clean the radiator core after riding the ATV...

Page 157: ...ove the radiator cap lid page 144 2 Remove the reserve tank 1 by removing the bolt 2 and clips 3 page 125 3 Release the hoses 4 from the guides 4 Hold the reserve tank being careful not to spill the c...

Page 158: ...lips 6 Remove the left radiator grill cover 5 by releasing the tab A 6 tab B 7 tab C 8 hook A 9 and hook B 10 9 3 clips 8 tab C 5 left radiator grill cover 6 tab A 7 tab B 9 hook A 10 hook B LEFT FRON...

Page 159: ...core 12 and radiator grill covers NOTICE Do not apply pressured water directly to the radiator core The pressured water can damage the radiator core 9 Install the removed parts in reverse order of rem...

Page 160: ...mine the correct service interval for your riding conditions Your ATV s air cleaner has very specific performance requirements Use a new Honda Genuine air cleaner specified for your model or an air cl...

Page 161: ...d 1 Remove the seat page 122 2 Unlatch the spring hooks 1 and retainer clips 2 3 Remove the air cleaner housing cover 3 Cleaning UNDER SEAT 1 2 1 spring hooks 3 air cleaner housing cover 3 2 2 retain...

Page 162: ...e foam or seams of the air cleaner Replace the air cleaner if it is damaged 9 Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not fully absorb the oil 10 Pour clean...

Page 163: ...cleaner assembly into the air cleaner housing 14 Fasten the screw 15 Reassemble by reversing the disassembly sequence Install the air cleaner housing cover with the FRONT mark 9 facing forward and fit...

Page 164: ...ur Honda 154 Air Cleaner Do not push the dust cover 1 too far into the breather joint 2 If the dust cover is dirty clean it Dust Cover UNDER SEAT 1 2 1 dust cover 2 breather joint 20 TRX520FM6 31HR565...

Page 165: ...nt inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle 1 Remove the drain tube 1 by removing the clip 2 under the air cleaner housing 3 2 Drain th...

Page 166: ...en the lock nut 4 3 Turn the adjuster to obtain the correct freeplay 4 Tighten the lock nut and reinstall the sleeve 5 After adjustment check for smooth operation of the throttle lever from fully clos...

Page 167: ...all steering positions If there is a problem see your dealer 3 Inspect the condition of the throttle cable from the throttle lever down to the throttle body If the cable is kinked or chafed have it re...

Page 168: ...lutch adjuster 2 counterclockwise until you feel slight resistance 5 Turn the adjuster 1 4 turn clockwise then tighten the lock nut to hold the adjuster in this position 6 After adjustment start the e...

Page 169: ...4 and turn the adjusting nut 5 to obtain the correct freeplay After adjustment tighten the lock nut securely 4 Return the dust cover and rubber sleeve Other Checks Check the reverse assist lever and c...

Page 170: ...age 122 and tank cover assembly page 124 2 Clean any dirt from around the spark plug base 3 Disconnect the spark plug cap 1 Take care to avoid damaging the spark plug wire when disconnecting the cap 4...

Page 171: ...tip and sharp edges and the side electrode 3 should not be eroded If the electrodes and insulator tip appear unusually fouled or burned we suggest that you contact your dealer 6 Discard the spark plug...

Page 172: ...the plug b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose the piston may be damaged I...

Page 173: ...of power and possibly damage the valves For those who are mechanically proficient and have the proper tools instructions on adjusting valve clearances are given in the official Honda Service Manual O...

Page 174: ...eaching the environment The use of safety glasses is recommended for this procedure Because of the possible fire hazard check that there are no combustible materials in the area before purging the spa...

Page 175: ...oad by adding or subtracting cargo accessories or when riding conditions change The way you ride your ATV and the type of ride you want to experience can also influence your suspension needs Lower spr...

Page 176: ...spring pre load adjuster 1 has 5 positions for different load or riding conditions Use the pin spanner 2 to adjust the shock spring pre load Suspension Spring Pre Load 1 FRONT REAR 1 2 5 4 3 2 1 1 spr...

Page 177: ...ATV is more heavily loaded Also increase spring pre load for stiffer suspension Make sure that both shock absorbers are adjusted to the same position Always adjust the shock absorber position in sequ...

Page 178: ...s If the brake lever or brake pedal freeplay does not feel within the normal range while riding check the brake pads for wear page 171 Worn pads should be replaced If the pads are not worn beyond the...

Page 179: ...tem as soon as possible NOTICE Brake fluid can damage plastic and painted surfaces Handle with care Wipe up spills immediately Avoid brake fluid contact with skin or eyes If it comes in contact with y...

Page 180: ...on a level surface check the fluid level It should be between the UPPER 2 and LOWER 3 level mark If the level is at or below the LOWER level mark check the brake pads for wear page 171 Worn brake pad...

Page 181: ...sually during all regular service intervals to determine the pad wear Check the wear indicator 1 If the wear indicator aligns with the edge of the reference mark 2 both pads must be replaced see your...

Page 182: ...akes Check the wear indicator If the wear indicator 3 aligns with the reference mark 4 replace both pads as a set see your dealer for this service 3 RIGHT REAR 3 wear indicator 4 reference mark 4 20 T...

Page 183: ...ver parking brake lever 1 moves before the brake starts to take hold Freeplay measurement at the tip of the end of the brake lever should be 1 1 3 16 in 25 30 mm 3 If necessary adjust to the specified...

Page 184: ...r Make sure the cutout on the adjusting nut is properly seated on the brake arm pin 3 Check that the brake lever and brake pedal assemblies are positioned properly and the securing bolts are tight Mak...

Page 185: ...behind the engine from time to time Adjustment is done by turning the adjusting nut 2 Hold the rear brake light switch and turn the nut in direction A if the switch operates too late and in direction...

Page 186: ...punctures Always select your riding area with care The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recomm...

Page 187: ...iding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tires make your ATV ride harshly are more prone to da...

Page 188: ...w miles the readings will be higher If you let air out of warm tires to match the recommended cold tire pressures the tires will be underinflated Be sure to check tire pressure at the riding site sinc...

Page 189: ...essures you should also look for Bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Cuts slits or cracks in the tires Replace the tire if you can see fabric...

Page 190: ...e condition of a tire tread measure the groove depth 1 in the center of the tire or check the wear indicator 2 For best performance you should replace a tire before the tread depth at the center reach...

Page 191: ...the tire replaced or permanently repaired as soon as possible For more information on temporary repairs see If You Have a Flat Tire page 211 A permanent repair such as an internal plug patch can be m...

Page 192: ...replace just one tire The recommended tires for your ATV are When you replace a tire remember Have the tire replaced by your dealer if possible If you have a tire professionally replaced at a non Hond...

Page 193: ...shafts The rear driveshaft guards 5 protect the rubber driveshaft boots and the rear driveshafts Check the guards and plate for cracks damage or looseness at intervals shown in the Maintenance Schedul...

Page 194: ...ber driveshaft boots 1 rubber propeller shaft boots 2 and rubber yoke joint boot 3 for cuts damage or leaking grease If necessary have your dealer replace them 1 rubber driveshaft boots 1 FRONT REAR 1...

Page 195: ...arge If you have electrical accessories on your ATV or do not ride frequently we recommend that you charge the battery frequently see Battery Charging page 189 If you do not expect to ride your ATV fo...

Page 196: ...e results from removing the battery and slow charging it every 30 days see Battery Charging page 189 Before you remove the battery be sure to read all the information that follows as well as the infor...

Page 197: ...nder cover page 123 4 Release the rings and remove the rubber band 1 5 Disconnect the negative terminal lead 2 from the battery 3 first then disconnect the positive terminal lead 4 6 Remove the batter...

Page 198: ...every 30 days Installation 1 Check that the battery rubber 6 for damage If necessary replace the battery rubber 2 Make sure the battery rubber is properly installed 3 Reinstall the battery in the reve...

Page 199: ...ecifically for your Honda which can be purchased from your dealer These units can be left connected for long periods without risking damage to the battery However do not intentionally leave the charge...

Page 200: ...V is still warm from recent operation give the engine and exhaust system time to cool off Park in a shady area Washing your ATV in bright sunlight may cause the finish to fade because water droplets i...

Page 201: ...ith plenty of clean water to remove any residue Detergent residue can corrode alloy parts 6 Dry your ATV with a chamois or a soft towel Leaving water on the surface to air dry can cause dulling and wa...

Page 202: ...int chrome glass and clear plastic Light road grimes Spray any difficult to reach or very dirty areas with a spray cleaner degreaser Rinse and dry Apply a spray cleaner polish and wipe with a non abra...

Page 203: ...ud or dust To remove mud or dust use a wet sponge and a liquid kitchen abrasive then rinse well with clean water Dry with chamois or a soft towel If necessary remove heat stains by using a commerciall...

Page 204: ...iles Apply the polish or wax according to the instructions on the container If a surface on your ATV is chipped or scratched your dealer has touch up paint to match your ATV s color Be sure to use you...

Page 205: ...ur Honda and how to be an environmentally responsible ATV owner Preparing for a Ride 196 What to Take to the Riding Area 196 What to Take on the Trail 197 Transporting Your Honda 198 Storing Your Hond...

Page 206: ...ad magazines are good sources of information Along with your ATV and riding gear you should take along some tools and supplies in case you have a problem For some of the difficulties you might encount...

Page 207: ...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 trail be sure you can carry them safely an...

Page 208: ...mmend 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 gasoline could be a haza...

Page 209: ...ler Ordinary rope is not recommended because it can stretch under load Using tie down straps in any other areas can damage your ATV 3 Rock the vehicle back and forth to make sure the tie down straps a...

Page 210: ...epairs won t be forgotten and it will be easier to get your ATV running again For more information about storage refer to the Honda Winter Storage Guide available from your dealer USA only We suggest...

Page 211: ...r perform the following Remove the spark plug cap from the spark plug page 160 Remove the spark plug Do not connect the spark plug to the spark plug cap Pour a tablespoon 15 20 cc of clean engine oil...

Page 212: ...over your ATV with a porous material Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate NOTICE Do not store your ATV in an u...

Page 213: ...n four months change the engine oil page 134 3 If your ATV has been stored for more than two months ask your dealer to drain and replace the fuel 4 Charge the battery page 189 as required Install the...

Page 214: ...may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s protectiv...

Page 215: ...lp you deal with a wide range of problems Take time to read this section before you ride Also review the tips in Preparing for a Ride page 196 General Guidelines 206 If Your Engine Quits or Won t Star...

Page 216: ...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 then consider your options before y...

Page 217: ...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 permanent repairs mad...

Page 218: ...rting the engine or experience poor engine performance the following information may help you If you can t correct the problem see your dealer If your ATV won t start listen as you press the start ove...

Page 219: ...r dead battery Charge the battery page 189 If charging doesn t help see your dealer faulty starter motor If all possible causes are negative the starter motor may be faulty See your dealer SYMPTOM Sta...

Page 220: ...fuel mixture See your dealer sooty exhaust rich fuel mixture See your dealer detonates or pings under load If applicable switch to the recommended octane gasoline page 126 or change your brand of gaso...

Page 221: ...lug an installation tool tire cement and an instruction sheet Follow the instructions provided with the repair kit to make a temporary repair As soon as possible have the tire permanently repaired by...

Page 222: ...V will be hard to handle and if the tire comes off the rim it may lock up the wheel and cause you to crash WARNING 3WARNING Riding your ATV with a temporary tire repair can be risky If the temporary r...

Page 223: ...or rear wheels off the ground and place a support block under the vehicle 4 Remove the wheel nuts 5 Remove the wheel Avoid getting grease oil or dirt on the front brake disc or pad surfaces when remov...

Page 224: ...e 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 wrench was not used for installat...

Page 225: ...ant leak Shut the engine off and wait until the steaming stops Look for a leak but don t touch the engine or radiator system Let everything cool off first Check for any restriction of air flow to the...

Page 226: ...necessary add the recommended oil page 132 to the upper level mark If you must leave your ATV to get oil secure it as much as possible Start the engine and check that the coolant temperature gauge and...

Page 227: ...for is a blown fuse 1 Check all the fuses before looking elsewhere for another possible cause of the problem Replace any blown fuses and check component operation The main fuse and the circuit fuses a...

Page 228: ...ove the rear fender cover page 123 4 To access the main fuse 1 2 remove the fuse cover 3 5 To access the main fuse 2 4 remove the fuse box cover 5 6 Pull the main fuse 1 2 out If the main fuse 1 is bl...

Page 229: ...ng clips with the fuse puller on the underside of the rear fender cover page 121 If the fuse is blown replace it with a spare fuse 8 of the same rating If you do not have a replacement fuse with the p...

Page 230: ...he fuse 2 Remove the seat page 122 3 Remove the rear fender cover page 123 4 To access the EPS fuse 1 remove the fuse cover 2 If the EPS fuse is blown install the spare fuse page 121 5 Install the fus...

Page 231: ...temporarily If you 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 install...

Page 232: ...spect 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 is minor dam...

Page 233: ...nd 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 listed in their records If t...

Page 234: ...ot recommended If you can t charge the battery or it appears unable to hold a charge contact your dealer Canada only Your ATV will operate even if the battery is low or dead as long as the engine is r...

Page 235: ...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 slowing or stopping...

Page 236: ...Taking Care of the Unexpected 226 20 TRX520FM6 31HR56500 book 226...

Page 237: ...contains dimensions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 228 Specifications 230 Break in Guidelines 235...

Page 238: ...s You may record these numbers in the Quick Reference section at the rear of this manual The VIN 1 is stamped on the front of the frame Remove the radiator cap lid page 144 The engine number 2 is stam...

Page 239: ...is attached on the left side of the frame 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 Color La...

Page 240: ...8 US gal 14 7 including reserve fuel tank reserve 1 29 US gal 4 9 engine oil capacity after disassembly 3 5 US qt 3 3 after draining 3 1 US qt 2 9 after draining oil filter change 3 2 US qt 3 0 engine...

Page 241: ...S qt 1 6 Capacities passenger capacity operator only maximum weight capacity 573 lb 260 kg rider all cargo and accessories Engine Specifications displacement 31 6 cu in 518 cm3 bore stroke 3 78 2 81 i...

Page 242: ...ar 3 153 transmission ratio 1st 4 230 2nd 2 388 3rd 1 608 4th 1 178 5th 0 848 reverse 5 743 final drive shaft Chassis Suspension caster 1 trail 0 04 in 1 mm tire size front AT25 8 1211 MAXXIS MU25 tir...

Page 243: ...2 assist headlight 12 V 50 W brake tail light LED neutral indicator LED reverse indicator LED high coolant temperature indicator LED PGM FI indicator LED differential lock indicator LED PS Electric P...

Page 244: ...ver bolts 7 lbf ft 10 N m 1 0 kgf m rear final gear oil drain bolt 9 lbf ft 12 N m 1 2 kgf m rear final gear oil fill cap 9 lbf ft 12 N m 1 2 kgf m front final gear oil drain bolt 9 lbf ft 12 N m 1 2...

Page 245: ...our 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 rapid acceleration...

Page 246: ...issions standards during its useful life when operated and maintained according to the instructions provided The Vehicle Emission Control Information Label 1 is attached on the left front of the frame...

Page 247: ...components is recommended The exhaust emission control system is separate from the crankcase emission control system Evaporative Emission Control System USA 50 States meets California An evaporative e...

Page 248: ...and poor fuel economy Federal regulations prohibit removing or disabling a device or element of design that may affect your engine s emission performance unless your ATV will be used exclusively in c...

Page 249: ...OLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part of the intake system Lack of proper mai...

Page 250: ...this information to be posted on the pump The following are the EPA approved percentages of oxygenates for non road vehicles ETHANOL ethyl or grain alcohol up to 10 by volume You may use gasoline con...

Page 251: ...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 o...

Page 252: ...Technical Information 242 20 TRX520FM6 31HR56500 book 242...

Page 253: ...r Information This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 244 Warranty Coverage 245 Warranty Service 246 Contacting Honda 247...

Page 254: ...can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician but most mechanically capable owners should find them...

Page 255: ...website at www honda ca It is important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage does not apply to normal wear or deterioration...

Page 256: ...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 repair it is best t...

Page 257: ...If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance...

Page 258: ...es and products 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 fro...

Page 259: ...Consumer Information 249 20 TRX520FM6 31HR56500 book 249...

Page 260: ...ting 247 apparel protective 58 appearance care 190 authorized manuals 244 B bank angle sensor ignition cut off system 83 battery 185 brake light switch adjustment 175 brakes cable 174 fluid 168 front...

Page 261: ...limit 68 cleaning appearance care 190 climbing hills 96 clip 125 clutch system 158 color label 229 compartment owner s manual 121 tool kit 120 component fails 225 consumer information 243 controls fe...

Page 262: ...electric power steering EPS 55 emission control systems 236 engine flooded 83 guard 183 number 228 oil 129 pinging 126 starting 80 stop switch 40 stopping 85 won t start 208 environment 204 EPS Electr...

Page 263: ...ing 127 reserve fuel supply 127 tank capacity 127 fuses 217 G gap spark plug 160 231 gasohol 240 gasoline 126 gear shifting 87 guards 183 H headlight dimmer switch 41 headlight switch 41 high coolant...

Page 264: ...on indicator 18 23 high coolant temperature indicator 14 17 215 maintenance minder indicator 20 31 neutral indicator 14 17 PGM FI indicator 14 17 PS Electric Power Steering indicator 14 18 reverse ind...

Page 265: ...icator 20 31 precautions 111 record 116 safety 110 schedule 112 tripmeter 31 manual service 244 maximum weight limit 68 modifications 71 multi function display 20 N neutral indicator 14 17 noise emiss...

Page 266: ...spection 63 problems unexpected 206 propeller shaft boots yoke joint boot 184 protective apparel 58 R rear driveshaft boots 184 rear driveshaft guards 183 rear fender cover removal 123 rear final gear...

Page 267: ...labels 5 riding precautions 75 schedule maintenance 112 seat removal 122 serial numbers 228 service customer 247 manuals 244 warranty 246 shifting gears 87 skidding or sliding 95 spark arrester 164 s...

Page 268: ...tment 165 spring pre load 166 switch 4WD 35 differential lock 36 engine stop 40 headlight 41 headlight dimmer 41 ignition 34 T tank cover assembly removal 124 throttle cable 156 157 lever 43 156 157 t...

Page 269: ...starting 208 turning on hills or slopes 101 on level ground 93 U utility box front utility box 52 side utility box 51 utility pocket 53 V valve clearance 163 vehicle identification no VIN 228 W warnin...

Page 270: ...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 Engin...

Page 271: ...Quick Reference Quick Reference Engine No VIN Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 20 TRX520FM6 31HR56500 book 261...

Page 272: ...brakes reverse assist lever switches steering Fuel Capacity unleaded gasoline pump octane number 86 or higher 3 88 US gal 14 7 reserve 1 29 US gal 4 9 Engine Oil Capacity API Service Classification S...

Page 273: ...Pa Rear 4 4 psi 30 kPa Spark Plugs standard BKR5E 11 NGK or K16PR U11 DENSO Coolant ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Honda HP Coolant or an equi...

Page 274: ...ch 36 differential lock indicator lights when the front differential lock mode engages 36 start override button 39 e RUN engine stop switch 40 r OFF engine stop switch 40 y ON headlight switch 41 t OF...

Page 275: ...d which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary servic...

Page 276: ...PRINTED IN USA WPCXXXX 2019 XX L 00X31 HR5 6500 31HR5650...

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