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Honda FourTrax Foreman TRX500FE2 2019, Owner'S Manual

The Honda FourTrax Foreman TRX500FE2 2019 Owner's Manual is a comprehensive guide packed with essential information about this powerful ATV. With easy-to-understand instructions, maintenance tips, and safety guidelines, this manual is a must-have for every Honda FourTrax Foreman TRX500FE2 2019 owner. Download your free copy today from manualshive.com.

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Index

262

Index

display check  .............................................................................. 16
display, multi-function  ................................................................ 20
drivetrain boots  ........................................................................191

E

electric power steering (EPS)  .......................................................55
emission control systems  ..........................................................246
engine,

flooded ................................................................................... 83
guards ................................................................................... 189
number ................................................................................. 238
oil .......................................................................................... 131
pinging ..................................................................................128
starting ....................................................................................80
stop switch .............................................................................. 40
stopping .................................................................................. 85
won’t start  ............................................................................ 216

environment .............................................................................212
exhaust system,

cleaning .................................................................................. 64
purging ................................................................................. 167

F

final gear oil,

front ......................................................................................143
rear ....................................................................................... 140

flag pole bracket  ........................................................................48
flat tire  ..................................................................................... 222
flooded engine  ........................................................................... 83
front boot guards  ..................................................................... 190
front differential lock  .................................................................. 36
front driveshaft boots  ...............................................................192
front driveshaft guards  ............................................................. 190

19 TRX500FE2_31HR4850.book  Page 262  Wednesday, April 4, 2018  11:48 AM

Summary of Contents for FourTrax Foreman TRX500FE2 2019

Page 1: ... 2019 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 ...

Page 2: ...le 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 without written permission This vehicle pictured in this owner s manual may not match your actual vehicle Honda Motor Co Ltd 2018 19 TRX500FE2_31HR4850 book Page 1 Wednesday April 4 2018 10 38 AM ...

Page 3: ...ghway 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 regulations It conforms to US EPA and Environment Climate Change Canada emission regulations for ATVs 2019 Honda TRX500FE2 4 4 ES with Power Steering FOURTRAX FOREMAN OWNER S MANUAL 19 TRX500FE2_31HR4850 book Page 2 Wednesd...

Page 4: ... 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 detailed list of topics at the beginning of each section and an index at the back of the book As you read this manual you will find information that is preceded by a symbol This information is intended to help you avoi...

Page 5: ...s 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 You may also want to visit our website at USA www powersports honda com Canada www honda ca Happy riding 19 TRX500FE2_31HR4850 book Page 4 Wednesday April 4 2018 11 48 AM ...

Page 6: ...his 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 operating or maintaining an ATV You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels on the ATV Safety Messages preceded by a safety alert symbol 2 an...

Page 7: ...ow 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 t follow instructions 3WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions 3CAUTION You CAN be HURT if you don t follow instructions 19 TRX500FE2_31HR4850 book Page 6 Wednesday April 4 2018 1...

Page 8: ...uments 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 wearing a helmet and other protective gear how to make sure you and your ATV are ready to ride and important information about loading Basic Operation Riding 73 How to start and stop the engine shift gears and brake Also ...

Page 9: ... be an environmentally responsible rider Taking Care of the Unexpected 213 What to do if you have a flat tire your engine won t start etc Technical Information 237 ID numbers technical specifications and other technical facts Consumer Information 253 Information on warranties emission controls how to get Honda service manuals Index 260 Quick Reference Handy facts about fuel engine oil tire sizes a...

Page 10: ...19 TRX500FE2_31HR4850 book Page 9 Wednesday April 4 2018 11 48 AM ...

Page 11: ...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 ATV Important Safety Information 2 Safety Labels 5 19 TRX500FE2_31HR4850 book Page 1 Wednesday April 4 2018 11 48 AM ...

Page 12: ... 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 number and severity of head injuries So always wear an approved motorcycle helmet We also recommend that you wear eye protection sturdy boots gloves and other protective gear page 58 Never Carry a Passenger Your ATV is d...

Page 13: ... 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 approved by the ATV Safety Institute ASI See page 60 Contact an authorized ATV dealer or call 1 800 887 2887 USA only to find out about the training courses nearest you Be Alert for Off road Hazards The terrain can pr...

Page 14: ...n 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 drink and ride either Keep Your Honda in Safe Condition It s important to keep your ATV properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far ...

Page 15: ...nformation 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 or becomes hard to read contact your dealer for replacements 19 TRX500FE2_31HR4850 book Page 5 Wednesday April 4 2018 11 48 AM ...

Page 16: ...ing 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 seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS NEVER operate ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE NEVER USE ON PUBLIC ROADS NEVER CARRY PASSE...

Page 17: ...the maximum front cargo limit of 88 lbs 40 kg Refer to instructions in the Owner s Manual WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Maximum weight capacity 551lbs 250kg Front 4 4psi 30kPa Rear 4 4psi 30kPa 19 TRX500FE2_31HR4850 book Page 7 Wednesday April 4 2018 11 48 AM ...

Page 18: ...OLLOW ALL INSTRUCTIONS AND WARNINGS NEVER operate ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS WITH DRUGS OR ALCOHOL Towing an improperly loaded trailer can cause loss of control Read towing instructions in owner s manual Tow weight limit 850lbs 385kg 30lbs 14kg Tongue weight Overloading this ATV or carrying cargo improperly can chang...

Page 19: ...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 and Mileage Unit Changing 22 4WD Indicator 22 Gear Position Indicator 23 Fuel Gauge 24 Digital Clock 26 Odometer 27 Tripmeter 27 Coolant Temperature Gauge 28 Hour meter 30 Maintenance Tripmeter Maintenance Hour meter ...

Page 20: ...0 Headlight Switch 41 Headlight Dimmer Switch 41 Recoil Starter Canada only 42 Throttle Lever 43 Gearshift Switch 44 Front Brake Lever 45 Rear Brake Lever Parking Brake Lever 45 Rear Brake Pedal 45 Parking Brake Reverse Lever P R Lever 46 Flag Pole Bracket 48 Trailer Hitch 49 Accessory Socket 50 Utility Box 52 Utility Pocket 53 Storage Compartment 54 EPS Electric Power Steering 55 19 TRX500FE2_31H...

Page 21: ...h 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 switch gearshift switches 4WD switch 19 TRX500FE2_31HR4850 book Page 11 Wednesday April 4 2018 11 48 AM ...

Page 22: ...ents Controls 12 Operation Component Locations rear cargo rack front cargo rack flag pole bracket rear brake pedal recoil starter Canada only 19 TRX500FE2_31HR4850 book Page 12 Wednesday April 4 2018 11 48 AM ...

Page 23: ...Instruments Controls 13 Operation Component Locations utility box trailer hitch accessory socket storage compartment utility pocket 19 TRX500FE2_31HR4850 book Page 13 Wednesday April 4 2018 11 48 AM ...

Page 24: ...Refer to the indicators frequently Their functions are described on the following pages 3 4 5 6 2 1 7 multi function display 4 PGM FI indicator 2 reverse indicator 1 neutral indicator 3 differential lock indicator 6 PS Electric Power Steering indicator 5 high coolant temperature indicator 8 mode select button 7 8 19 TRX500FE2_31HR4850 book Page 14 Wednesday April 4 2018 11 48 AM ...

Page 25: ...s 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 back on and remain on until you shift out of reverse or neutral after initial lamp check When applicable the differential lock indicator comes back on and remains on until you shift out of the front differential lock mo...

Page 26: ...he 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 neutral indicator reverse indicator differential lock indicator PGM FI indicator high coolant temperature indicator stay on and the gear position indicator and coolant temperature gauge C H blinks have your dealer check...

Page 27: ...or Lights when there is any abnormality in the PGM FI Programmed Fuel Injection system Should also light for a few seconds and then go off when the ignition switch is turned on If the indicator comes on at any other time reduce speed and take your vehicle to your dealer as soon as possible Lamp Check 5 High coolant temperature indicator Lights when coolant temperature is high enough to adversely a...

Page 28: ...val is reached page 32 Speedometer Shows riding speed Fuel gauge Shows approximate fuel supply available page 24 Digital clock Shows the time hours and minutes page 26 Odometer Shows accumulated mileage page 27 Tripmeter Shows mileage per trip page 27 Coolant temperature gauge Shows approximate coolant temperature page 28 Hour meter Shows hours and tenths of hours of engine operation page 30 Maint...

Page 29: ...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 maintenance tripmeter and maintenance hour meter page 33 19 TRX500FE2_31HR4850 book Page 19 Wednesday April 4 2018 11 48 AM ...

Page 30: ...function display push the mode select button 7 Multi function Display 4WD indicator Odometer Gear position indicator Tripmeter Speedometer Coolant temperature gauge Maintenance minder indicator Hour meter Fuel gauge Maintenance tripmeter Digital clock Maintenance hour meter 3 1 multi function display 2 1 4 2 gear position indicator 5 lower part of the multi function display 3 speedometer 6 4WD ind...

Page 31: ...here 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 will automatically return to the coolant temperature gauge Fuel gauge page 24 Digital clock page 26 Odometer page 27 Tripmeter page 27 Coolant temperature gauge page 28 When ATV is moving When ATV is not moving Hour ...

Page 32: ...e 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 mode engages page 35 Speed and Mileage Unit Changing 4WD Indicator 1 1 mode select button 1 1 4WD indicator 19 TRX500FE2_31HR4850 book Page 22 Wednesday April 4 2018 11 48 AM ...

Page 33: ...roperly 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 position again If the gear position indicator shows rock the vehicle back and forth and make sure the gear position indicator is displayed properly and then if the gear position indicator still shows or blinks see your deal...

Page 34: ...e 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 remaining when the fuel gauge reaches the 1st segment is approximately 1 82 US gal 6 9 ℓ Fuel Gauge 1 1 fuel gauge 2 2 fuel mark 3 1st segment 3 19 TRX500FE2_31HR4850 book Page 24 Wednesday April 4 2018 11 48 AM ...

Page 35: ...d fuel mark blinks you should refuel as soon as possible The amount of fuel reserve is approximately 1 29 US gal 4 9 ℓ Fuel gauge failure If the fuel gauge E F 6 is blinking the fuel gauge function has failed See your dealer 4 E _ _ _ _ _ F 4 5 5 LO FUEL 6 6 E F 19 TRX500FE2_31HR4850 book Page 25 Wednesday April 4 2018 11 48 AM ...

Page 36: ...ton 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 more advance ten minutes at a time 4 Release the mode select button when the display reaches the desired time 5 To end the adjustment press and release the mode select button for less than 0 5 seconds or turn the igniti...

Page 37: ...age 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 tripmeter to zero press the mode select button 3 and hold it in for at least 2 seconds in the tripmeter mode Odometer Tripmeter 1 2 1 odometer 2 ODO mark 1 3 1 tripmeter 3 mode select button 2 2 TRIP mark 19 TRX500FE2_31HR48...

Page 38: ...he 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 Coolant Temperature Gauge 2 1 coolant temperature gauge 4 4th segment 4 1 3 2 coolant temperature mark 3 1st segment 5 Lo 5 19 TRX500FE2_31HR4850 book Page 28 Wednesday April 4 2018 11 48 AM ...

Page 39: ... and check the reserve tank coolant level Read pages 226 227 and do not ride the ATV until the problem has been corrected NOTICE Continuing to ride with an overheated engine can cause serious engine damage If the C H 8 blinks the meter input signal fails See your dealer 7 6 6 5th segment 7 high coolant temperature indicator 8 8 C H 19 TRX500FE2_31HR4850 book Page 29 Wednesday April 4 2018 11 48 AM...

Page 40: ...h 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 99999 9 when the readout exceeds 99999 9 Hour meter 1 2 1 hour meter 2 hour meter mark 19 TRX500FE2_31HR4850 book Page 30 Wednesday April 4 2018 11 48 AM ...

Page 41: ...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 of the maintenance tripmeter is 100 miles 150 km Initial setting of the maintenance hour meter is 20 hour Maintenance Tripmeter Maintenance Hour meter 1 maintenance tripmeter 1 2 3 2 3 maintenance hour meter 2 maintenanc...

Page 42: ... 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 Maintenance or Regular Maintenance Interval 2 is performed and maintenance minder is reset whichever comes first in the maintenance schedule Regular Maintenance Interval 2 Appears 600 miles 1 000 km or 100 operating ...

Page 43: ... 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 cancelled if the mode select button is released before the indicator blinks twice If the maintenance is done before the setting interval be sure to reset the meters after the maintenance 5 6 2 2 maintenance minder ind...

Page 44: ...ight 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 circuits on OFF w No electrical circuits function CENTER OF HANDLEBAR OFF ON 1 q ON w OFF 1 ignition switch 19 TRX500FE2_31HR4850 book Page 34 Wednesday April 4 2018 11 48 AM ...

Page 45: ... 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 appear when selecting the 4WD mode accelerate your ATV slowly until the 4WD indicator appears The 4WD indicator and differential lock indicator both flash together when there is any abnormality in the front final gear sys...

Page 46: ...ng 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 Pushing and holding the start override button in this mode allows you to momentarily override the 20 mph 32 km h speed limiter up to 40 mph 64 km h to help you free the vehicle in more severe conditions You should only use this fea...

Page 47: ... 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 to the left or right all the way while your ATV is stopped If the differential lock indicator is still flashing move your ATV slowly while steering the handlebar all the way to right or left 2 4WD mode in the locking...

Page 48: ...the front final gear system If this occurs the front final gear actuator will stop moving and the front final gear system will be fixed in the current position either 2WD mode 4WD mode or front differential lock mode If both the differential lock indicator and 4WD indicator flash reduce speed and take your ATV to your dealer as soon as possible LEFT HANDLEBAR 3 start override button 3 2 differenti...

Page 49: ...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 speed limiter override mode see Front Differential Lock and Speed Limiter Override Differential Lock Switch and Start Override Button page 36 Start Override Button 1 1 start override button START or SPEED LIMITER OVER...

Page 50: ...rt 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 battery will discharge Turn the ignition switch to OFF w to prevent battery discharge Engine Stop Switch e r LEFT HANDLEBAR 1 1 engine stop switch r OFF e RUN 19 TRX500FE2_31HR4850 book Page 40 Wednesday April 4 2018...

Page 51: ... and low beams of the headlight and to activate the assist headlight To operate turn the switch to HI u for high beam of the headlight and activate the assist headlight LO i for low beam of the headlight and deactivate the assist headlight Headlight Switch y t Headlight Dimmer Switch u i LEFT HANDLEBAR 1 2 1 headlight switch y ON t OFF u HI i LO 2 headlight dimmer switch 19 TRX500FE2_31HR4850 book...

Page 52: ...he 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 19 TRX500FE2_31HR4850 book Page 42 Wednesday April 4 2018 11 48 AM ...

Page 53: ...ever 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 Throttle Lever RIGHT HANDLEBAR A 1 throttle lever 1 A to open the throttle 19 TRX500FE2_31HR4850 book Page 43 Wednesday April 4 2018 11 48 AM ...

Page 54: ...he transmission To operate press the upshift switch 1 to engage the next higher gear or press the downshift switch 2 to engage the next lower gear See Shifting Gears page 87 Gearshift Switch LEFT HANDLEBAR 1 upshift switch 1 2 2 downshift switch 19 TRX500FE2_31HR4850 book Page 44 Wednesday April 4 2018 11 48 AM ...

Page 55: ...rking brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see page 92 The rear brake pedal is used to slow or stop your ATV To operate depress the pedal For information on braking techniques see page 92 Front Brake Lever Rear Brake Lever Parking Brake Lever Rear Brake Pedal 19 TRX500FE2_31HR4850 book Page 45 Wednesday April 4 2018 11 48 AM ...

Page 56: ...ever 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 brake lever parking brake lever 19 TRX500FE2_31HR4850 book Page 46 Wednesday April 4 2018 11 48 AM ...

Page 57: ...e 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 lever bracket The brake lights are activated 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 To shift the transmission into reverse See Ri...

Page 58: ...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 Flag Pole Bracket RIGHT REAR 1 flag pole bracket 1 19 TRX500FE2_31HR4850 book Page 48 Wednesday April 4 2018 11 48 AM ...

Page 59: ... 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 operational guidelines see page 67 Trailer Hitch REAR 1 trailer hitch 1 2 ball 2 19 TRX500FE2_31HR4850 book Page 49 Wednesday April 4 2018 11 48 AM ...

Page 60: ... 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 start the engine Then turn the headlights OFF t and open the accessory socket cap 3 Accessory Socket LEFT FRONT 1 accessory socket 1 3 accessory socket cap 2 2 assist headlight 3 19 TRX500FE2_31HR4850 book Page 50 Wednes...

Page 61: ...ttery 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 228 When you are done using an accessory unplug it and cover the socket with the cap Be careful not to flood this accessory socket when washing your ATV 19 TRX500FE2_31HR4850 book Page 51 Wednesday April 4 2018 11 48 AM ...

Page 62: ...the front of the utility box cover 2 To 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 Utility Box LEFT FRONT FENDER 1 utility box 3 3 stud 1 2 utility box cover 2 19 TRX500FE2_31HR4850 book Page 52 Wednesday April 4 2018 11 48 AM ...

Page 63: ... 1 is located on the left side cover You may store small lightweight items in the pocket NOTICE Do not store valuable items in the utility pocket Utility Pocket 1 utility pocket 1 LEFT SIDE COVER 19 TRX500FE2_31HR4850 book Page 53 Wednesday April 4 2018 11 48 AM ...

Page 64: ...ow 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 1 3 rubber strap 2 2 rear cargo rack 3 19 TRX500FE2_31HR4850 book Page 54 Wednesday April 4 2018 11 48 AM ...

Page 65: ...his brief period After cooling down it will then return to normal EPS operation The PS indicator should light when the ignition switch is turned on and remain on until the engine is started The PS indicator also lights when there is any abnormality in the EPS system If this occurs the electric power assist for turning will not be available but the manual steering system will perform as usual If th...

Page 66: ...Instruments Controls 56 19 TRX500FE2_31HR4850 book Page 56 Wednesday April 4 2018 11 48 AM ...

Page 67: ...r 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 61 No Passengers 61 No Alcohol or Drugs 62 Is Your ATV Ready to Ride 63 Pre ride Inspection 63 Load Limits Guidelines 67 Loading 67 Load Limits 68 Loading Guidelines 69 Accessories Modifications 70 Accessories 70 Mod...

Page 68: ... 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 shirt or jacket whenever you ride Although complete protection is not possible wearing proper gear can reduce the chance of injury when you ride Following are suggestions to help you choose the proper gear Helmet and...

Page 69: ...p 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 shoulder protector WARNING 3WARNING Operating this ATV without wearing an approved motorcycle helmet eye protection and protective clothing could increase your chances of severe injury or death in the event of a crash Alw...

Page 70: ...tion 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 booklet that came with your ATV USA only Rider Training WARNING 3WARNING Operating this ATV without proper instruction could increase your risk of a crash which could lead to serious injury or death Beginning and inexper...

Page 71: ...ar 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 death A child under 16 should never operate an ATV with engine size greater than 90cc No Passengers WARNING 3WARNING Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV and could...

Page 72: ...nsult 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 seriously affect your judgment cause you to react more slowly affect your balance and perception and result in serious injury or death Never consume alcohol or drugs before or while operating this ATV 19 TRX500FE2_31HR4850...

Page 73: ...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 a problem before riding can cause a crash in which you can be seriously hurt or killed Always perform a pre ride inspection before every ride and correct any problems Pre ride Inspection Engine Oil Check the level and...

Page 74: ... 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 vegetation or other debris that could be a fire hazard or interfere with the proper operation of the vehicle Air Cleaner Housing Drain Tube Check for deposits in the drain tube If necessary clean the tube page 158 and che...

Page 75: ... cargo is secure Throttle 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 159 Brakes Squeeze 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 175 177 Make sure there is ...

Page 76: ... 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 the handlebar Move the handlebar right and left and check that there is no excessive backlash 19 TRX500FE2_31HR4850 book Page 66 Wednesday April 4 2018 11 48 AM ...

Page 77: ...at 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 limits accessories and modifications follows How much weight you put on your ATV and how you load it are important to your safety If you decide to carry cargo you should be aware of the following information Loading ...

Page 78: ...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 551 lb 250 kg includes the weight of the rider all cargo and accessories front cargo rack weight limit rear cargo rack weight limit tow weight limit 88 lb 40 kg 176 lb 80 kg 850 lb 385 kg Combined weight of the trailer and a...

Page 79: ...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 to extend beyond the edges of either the front or rear racks Make sure all cargo is secured before riding Balance cargo weight evenly on both sides Never exceed the maximum weight limit When towing a trailer take car...

Page 80: ...w 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 sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls Do not add any electrical equipment that will exceed the vehicle s electrical system capaci...

Page 81: ...y 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 components that would make your ATV illegal in your area Removing or modifying your lights exhaust system emission control system or other equipment can also make your ATV illegal Modifications 19 TRX500FE2_31HR4850 boo...

Page 82: ...Before Riding 72 19 TRX500FE2_31HR4850 book Page 72 Wednesday April 4 2018 11 48 AM ...

Page 83: ...ce life refer to Break in Guidelines page 245 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 Terrain 78 Do Not Perform Stunts 79 Starting Stopping the Engine 80 Preparation 81 Starting Procedure 82 Flooded Engine 83 Bank Angle Sensor Ignition Cut off System 83 Stalled Engine 84 How to Stop the Engine 85 Using the ...

Page 84: ...g Your ATV 94 Making Turns 94 Skidding or Sliding 96 Riding Up Hills 97 Riding Down Hills 101 Crossing or Turning on Hills or Slopes 102 Riding Over Obstacles 104 Riding Through Water 105 Parking 107 19 TRX500FE2_31HR4850 book Page 74 Wednesday April 4 2018 11 48 AM ...

Page 85: ...or 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 local off road riding laws and regulations Obtain permission to ride on private property Avoid posted areas and obey no trespassing signs Off road Use Only WARNING 3WARNING Operating this ATV on paved surfaces may seriou...

Page 86: ...s 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 streets roads or highways could cause you to collide with another vehicle Never operate this ATV on any public street road or highway even a dirt or gravel one Keep Hands and Feet on Controls WARNING 3WARNING Removing ...

Page 87: ...ther 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 the ATV which can result in a crash Always go at a speed that is proper for your vehicle the terrain visibility and other operating conditions and your experience 1 1 footpeg 19 TRX500FE2_31HR4850 book Page 77 Wednesday Apri...

Page 88: ...dden 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 result in the ATV overturning or going out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 19 TRX500FE2_31HR4850 book Pag...

Page 89: ...cessively 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 slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Do Not Perform Stunts WARNING 3WARNING Attempti...

Page 90: ...h 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 a rapid build up of toxic carbon monoxide gas Breathing this colorless odorless gas can quickly cause unconsciousness and lead to death Only run your vehicle s engine when it is located in a well ventilated area outd...

Page 91: ... 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 switch 3 is set to RUN e Preparation 1 1 ignition switch 3 2 2 neutral indicator 3 engine stop switch 19 TRX500FE2_31HR4850 book Page 81 Wednesday April 4 2018 11 48 AM ...

Page 92: ...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 Snapping the throttle or fast idling for more than 5 minutes may cause exhaust pipe and muffler discolorations Starting Procedure 19 TRX500FE2_31HR4850 book Page 82 Wednesday April 4 2018 11 48 AM ...

Page 93: ...ngine 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 Your Engine Quits or Won t Start page 216 Your vehicle s banking lean angle sensor system is designed to automatically stop the engine if the vehicle is overturned Before restarting the engine you must turn the ignit...

Page 94: ...rt 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 fuel supply Once you have started the engine release the front brake lever then apply throttle gradually Stalled Engine 19 TRX500FE2_31HR4850 book Page 84 Wednesday April 4 2018 11 48 AM ...

Page 95: ...ngine 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 battery will discharge Emergency Engine Stop To stop the engine in an emergency use the engine stop switch To operate slide the switch to either OFF r position How to Stop the Engine 19 TRX500FE2_31HR4850 book Page 85 W...

Page 96: ... 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 that the cord does not touch the side cover Repeated contact with the side cover can damage the starter cord If the starter grip does not return smoothly because of dirt in the assembly see your dealer Using the Recoil...

Page 97: ...2 once To select reverse see Riding in Reverse page 90 After starting the engine and letting it warm up follow these procedures 1 With the transmission in neutral release the parking brake but continue squeezing the rear brake lever parking brake lever 2 With the throttle closed press the upshift switch once to shift into 1st first gear UPSHIFTING SEQUENCE DOWNSHIFTING SEQUENCE 1 upshift switch 2 ...

Page 98: ...1st gear to neutral when the engine speed is above 3 000 rpm or the ground speed is above 2 mph 3 km h If the electric shift system malfunctions the transmission cannot be shifted by pressing the gearshift switches See your dealer In an emergency a gear may be selected manually so you may move the vehicle See Emergency Gear Selection Operation page 220 procedures Learning when to shift gears comes...

Page 99: ...eed 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 the engine off Recommended Shift Points Ride in the highest gear that lets the engine run and accelerate smoothly This will give you good fuel economy and effective emissions control 19 TRX500FE2_31HR4850 book Page 89 Wednesday April...

Page 100: ...ontinuing to hold the P R lever squeeze the rear brake lever parking brake lever 3 then press the downshift 4 switch once to shift into R reverse gear WARNING 3WARNING Improperly operating in reverse could cause you to hit an obstacle or person behind you resulting in serious injury Make sure there are no obstacles or people behind you before selecting reverse gear When it is safe to proceed go sl...

Page 101: ...Do not abruptly apply the rear brake by itself 9 To shift out of reverse and into neutral press the upshift switch 5 once to shift into N neutral gear Make sure that the reverse indicator goes off and the gear position indicator shows N 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 WARNING 3WARN...

Page 102: ...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 will stop your ATV faster with greater stability To slow or stop apply the brake lever and brake pedal smoothly while downshifting to match your speed Gradually increase braking as you feel the brakes slowing your speed The increase ...

Page 103: ...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 overheat the brakes and reduce their effectiveness Riding with your foot resting on the brake pedal or your hands on the brake levers may overheat the brakes reducing effectiveness For information on how to apply the brakes ...

Page 104: ... 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 collision or overturn Always follow proper procedures for turning as described in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 19 TRX500FE2_3...

Page 105: ...t 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 steering To make a turn from a full stop Apply the throttle gradually when you turn and start at the same time Remember to shift your body forward to make sharp low speed turns and whenever you turn while accelerating fro...

Page 106: ...er 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 mode will cause steering to be heavy and increase turning radius Skidding or Sliding WARNING 3WARNING Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly whic...

Page 107: ...ont 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 forward Riding Up Hills WARNING 3WARNING Operating on excessively steep hills can cause the vehicle to overturn more easily than operating on level surfaces or small hills Never operate the ATV on hills too steep for th...

Page 108: ... 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 go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Shift weight forward when climbing hills 19 TRX500FE2_31HR4850 book Page 98 Wednesd...

Page 109: ...urn 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 carefully apply the rear brake Do not apply either brake abruptly if you are rolling backwards or the vehicle may overturn If the ATV continues sliding backwards After you ve applied the brakes get off and away from the ...

Page 110: ...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 lever parking brake lever with your right hand 2 Be sure your legs are clear of the wheels Check your footing 3 Slowly and carefully back the ATV down the hill using the rear brake lever parking brake lever to control spee...

Page 111: ...p 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 cause loss of control or cause the ATV to overturn Always follow proper procedures for going down hills as described in this owner s manual On downhills shift your weight back 19 TRX500FE2_31HR4850 book Page 101 Wednesd...

Page 112: ...h 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 attempting to ride on steeper or more difficult terrain Remember that steering the handlebar in the front differential lock mode will cause steering to be heavy and increase turning radius Crossing or Turning on Hills or...

Page 113: ...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 Compared to riding on level ground you may need to shift more weight and lean more when making turns on slopes Do not make turns on any slopes until you have first mastered the techniques for making turns on level terrain...

Page 114: ...d 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 could cause loss of control or a collision and could cause the ATV to overturn When you go over obstacles always follow proper procedures as described in this owner s manual 19 TRX500FE2_31HR4850 book Page 104 Wednesday April...

Page 115: ...ontrol 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 ability to float Operating this ATV through deep or fast flowing water may cause a loss of traction and loss of control which could lead to a crash Never operate this ATV in fast flowing water or in water deeper than that ...

Page 116: ...t 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 make the brakes less effective than normal and may reduce stopping ability If necessary apply the brakes repeatedly until they dry out and operate normally If the brakes don t regain effectiveness stop your ATV and follow the procedures on page 181 19 TRX500FE2_31H...

Page 117: ...king 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 you must park your ATV on a steep incline or loose or slippery surface use the following procedure 1 While holding the brakes set the parking brake 2 Turn the ignition switch to OFF w and release the brakes 3 If the ATV b...

Page 118: ...Basic Operation Riding 108 19 TRX500FE2_31HR4850 book Page 108 Wednesday April 4 2018 11 48 AM ...

Page 119: ...rotection Agency EPA and Environment Climate Change Canada ECCC see page 246 USA only Maintenance replacement or repair of the emission control devices and systems may be performed by any ATV repair establishment or individual using parts that are certified to EPA standards Before You Service Your Honda The Importance of Maintenance 111 Maintenance Safety 112 Important Safety Precautions 113 Maint...

Page 120: ... Final Gear Oil 143 Coolant 145 Air Cleaner 153 Engine Throttle 159 Clutch System 161 Reverse Lock System 162 Spark Plug 163 Valves 166 Spark Arrester 167 Chassis Suspension 168 Brakes 171 Tires 182 Guards 189 Drivetrain Boots 191 Electrical Battery 193 Appearance Care 198 19 TRX500FE2_31HR4850 book Page 110 Wednesday April 4 2018 11 48 AM ...

Page 121: ...he 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 repair If your ATV overturns or is involved in a crash be sure your dealer inspects all major parts even if you are able to make some repairs WARNING 3WARNING Improperly maintaining this ATV or failing to correct a pro...

Page 122: ...da 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 cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task WARNING 3WARNING Failure to properly follow maintenance instructi...

Page 123: ... 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 cigarettes sparks and flames away from all fuel related parts Remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only ne...

Page 124: ...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 equipment We recommend that you have your dealer perform these tasks unless you have advanced mechanical skills and the required tools and equipment Procedures for such items in this schedule are provided in an official Hon...

Page 125: ...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 every 2 years Replacement requires mechanical skill Should be serviced by your dealer unless the owner has proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual...

Page 126: ...REGULAR Refer to page 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 159 AIR CLEANER NOTE 1 C C 153 AIR CLEANER HOUSING DRAIN TUBE NOTE 2 I I 158 SPARK PLUG I I 163 VALVE CLEARANCE I I I 166 ENGINE OIL INITIAL 100 mi 150 km 20 operating hours or 1 month R 131 ENGINE OIL FILTER REGULAR Every 600 mi 1 000 km 100 operati...

Page 127: ... 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 DRIVETRAIN BOOTS I I 191 FRONT REAR FINAL GEAR OIL R EVERY 2 YEARS I 140 143 BRAKE FLUID NOTE 3 I I 171 BRAKE SHOES WEAR NOTE 1 2 I 179 BRAKE PADS WEAR NOTE 1 2 I 174 BRAKE LIGHT SWITCH I I I 180 BRAKE SYSTEM I I I 171 REVERSE LOCK SYSTEM I I I 162 GUARDS I I 189 CLUTCH SYSTEM I I I 161 SUSPENSION I I 168 SPARK ARRESTER C C 167 NUTS B...

Page 128: ...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 anything you want to remind yourself about or mention to your dealer Miles km or months or hours ODO or HOUR Date Performed By Notes 100 150 or 1 or 20 600 1 000 or 6 or 100 1 200 2 000 or 12 or 200 1 800 3 000 or 18 or 30...

Page 129: ...parations Maintenance Component Locations front brake fluid reservoir front brake lever P R lever rear brake lever parking brake lever throttle lever reverse assist lever 19 TRX500FE2_31HR4850 book Page 119 Wednesday April 4 2018 11 48 AM ...

Page 130: ...lant reserve tank rear brake light switch air cleaner housing drain tube engine oil filter fuel fill cap front final gear oil fill cap front final gear oil drain bolt seat latch air cleaner battery fuse box main fuse 1 main fuse 2 EPS fuse rear brake pedal 19 TRX500FE2_31HR4850 book Page 120 Wednesday April 4 2018 11 48 AM ...

Page 131: ...ension spring pre load adjuster spark plug engine oil fill cap dipstick engine oil drain bolt rear final gear oil fill cap rear final gear oil drain bolt rear brake panel clutch adjuster owner s manual air pressure gauge coolant reserve tank 19 TRX500FE2_31HR4850 book Page 121 Wednesday April 4 2018 11 48 AM ...

Page 132: ...sing the tools be sure to use the rubber band 3 to fasten the tool kit and gear change tool securely An optional larger tool kit may be available Check with your dealer s parts department UNDER REAR FENDER COVER 1 2 1 tool kit 2 gear change tool 3 3 rubber band 19 TRX500FE2_31HR4850 book Page 122 Wednesday April 4 2018 11 48 AM ...

Page 133: ...over 3 The owner s manual and air pressure gauge 4 should be stored in the plastic document bag and fastened with the rubber band 5 To remove the rear fender cover see page 125 Be careful not to flood this area when washing your ATV 1 4 3 1 owner s manual 2 plastic document bag 4 air pressure gauge REAR FENDER COVER UNDERSIDE 2 5 rubber band 3 rear fender cover 5 19 TRX500FE2_31HR4850 book Page 12...

Page 134: ...pressure gauge gear change tool and tool kit 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 the backside of the tank cover 4 and hooks 5 on the frame and press the studs 6 into the grommets 7 2 Press down on the seat until locks 3 6 7 1 4 5 1 seat latch 2 seat 3 front prongs 5 hooks 6 studs 7 grommets 4 tank...

Page 135: ...l and tool kit Removal 1 Remove the seat page 124 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 tabs 5 5 Remove the rear fender cover Installation Install the rear fender cover in the reverse order of removal 5 4 2 1 5 3 1 rubber strap 2 studs 3 grommets 4 rear fender cover 5 tabs 19 TRX500FE2_31HR4850 book Page 1...

Page 136: ... 1 Remove the seat page 124 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 the slits Installation Install the tank cover assembly in the reverse order of removal 1 2 1 3 3 1 right studs 2 tank cover assembly 3 right tabs 19 TRX500FE2_31HR4850 book Page 126 Wednesday April 4 2018 11 48 AM ...

Page 137: ...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 19 TRX500FE2_31HR4850 book Page 127 Wednesday April 4 2018 11 48 AM ...

Page 138: ... fuels see page 250 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 while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persist...

Page 139: ...4 9 ℓ 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 113 Fuel Capacity Refueling Procedure 1 2 1 fuel fill cap 2 bottom of the filler neck 19 TRX500FE2_31HR4850 book Page 129 Wednesday April 4 2018 11 48 AM ...

Page 140: ...da Genuine replacement part or equivalent NOTICE Gasoline can damage the camouflage coating Do not allow spilled gasoline to pool on camouflage colored bodywork Also do not allow gasoline soaked rags to be placed on camouflage bodywork WARNING 3WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame...

Page 141: ...ut 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 serious damage to the engine and transmission Change the engine oil as specified in the maintenance schedule on page 116 When running in very dusty conditions oil changes should be performed more frequently than specif...

Page 142: ...ircular 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 based racing oils Oil Recommendation API classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label viscosity weight SAE 10W 30 JASO T 903 standard MA su...

Page 143: ...ted 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 labeled on the oil container For example the following label shows the MA classification 1 2 1 oil code 2 oil classification 19 TRX500FE2_31HR4850 book Page 133 Wednesday April 4 2018 11 48 AM ...

Page 144: ...m 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 a total of 10 minutes 3 Stop the engine and wait 2 3 minutes 4 Remove the oil check fill door 1 by disengaging the studs 2 from the grommets and releasing the tabs 3 from the slits Checking Adding Oil 1 LEFT SIDE 1 oi...

Page 145: ... 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 fill cap dipstick Do not overfill 8 Reinstall the oil fill cap dipstick 9 Install the oil check fill door NOTICE Running the engine with an improper oil level can cause serious engine damage LEFT SIDE 4 5 6 4 oil fill ...

Page 146: ...cedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid page 212 If you do not have the skills or the tools see your dealer Change the oil with the engine warm to assure complete and rapid draining Drain the Engine Oil 1 With the ATV on level ground remove the oil check fill door page 134 and the oil fill cap dipstick fr...

Page 147: ...Filter 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 19 TRX500FE2_31HR4850 book Page 137 Wednesday April 4 2018 11 48 AM ...

Page 148: ...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 filter body near the seal Use only the Honda Genuine oil filter or a filter of equivalent quality specified for your model Using the wrong Honda filter or a non Honda filter which is not of equivalent quality may cause ...

Page 149: ... 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 ℓ 3 Reinstall the oil fill cap dipstick 4 Start the engine and let it idle for 3 5 minutes 5 Stop the engine wait 2 3 minutes and check the oil level Make sure the oil is between the upper and lower level marks on the oil fill cap dipstick If necessary add more oil bu...

Page 150: ...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 Honda shaft drive oil or equivalent Changing Oil 19 TRX500FE2_31HR4850 book Page 140 Wednesday April 4 2018 11 48 AM ...

Page 151: ...oil fill cap 2 O ring 3 drain bolt and sealing washer 4 4 After the oil has completely drained reinstall the drain bolt with a new sealing washer and tighten it to the specified torque 9 lbf ft 12 N m 1 2 kgf m 3 1 oil drain bolt 1 REAR UNDERSIDE 3 O ring 2 4 2 oil fill cap 4 sealing washer 19 TRX500FE2_31HR4850 book Page 141 Wednesday April 4 2018 11 48 AM ...

Page 152: ...ts to flow out of the oil level check hole 7 Allow oil to settle for 2 3 minutes before moving to next step to prevent overfilling 2 9 US oz 85 cm3 8 Coat a new O ring with grease and install it into the fill cap groove and tighten it to the specified torque 9 lbf ft 12 N m 1 2 kgf m 9 Install the oil level check bolt with a new sealing washer and tighten it to the specified torque 9 lbf ft 12 N m...

Page 153: ...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 Honda shaft drive oil or equivalent Changing Oil 19 TRX500FE2_31HR4850 book Page 143 Wednesday April 4 2018 11 48 AM ...

Page 154: ...able container and dispose of it in an approved manner page 212 NOTICE Improper disposal of drained fluids is harmful to the environment 6 Fill the front final gear case with the recommended oil 11 0 US oz 325 cm3 Make sure the oil level is at the lower edge of the oil fill inspection hole 5 7 Coat a new O ring with grease and install it into the fill cap groove and tighten it to the specified tor...

Page 155: ... 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 silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages Using tap water may cause engine damage The factory provides a 50 50 solution of antifreeze and water in this ATV This coolant...

Page 156: ... 113 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 temperature check the coolant level in the reserve tank 1 It should be between the UPPER 2 and LOWER 3 level marks If the reserve tank is empty or if coolant loss is excessive check for leaks and see your dealer for repair Checkin...

Page 157: ...nk 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 reinstall the reserve tank cap 7 Install the radiator cap lid FRONT 5 7 4 radiator cap lid 6 grommet 5 stud 7 reserve tank cap 6 4 19 TRX500FE2_31HR4850 book Page 147 Wednesday April 4 2018 11 48 AM ...

Page 158: ... 254 To properly dispose of drained coolant refer to You the Environment page 212 NOTICE Improper disposal of drained fluids is harmful to the environment Coolant Replacement WARNING 3WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap 19 TRX500FE2_31HR4850 ...

Page 159: ...n 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 in mud The left and center radiator grill covers must be removed to clean the radiator core Radiator Core 19 TRX500FE2_31HR4850 book Page 149 Wednesday April 4 2018 11 48 AM ...

Page 160: ...lid page 147 2 Remove the reserve tank 1 by removing the bolt 2 and clips 3 page 127 3 Release the hoses 4 from the guides 4 Hold the reserve tank being careful not to spill the coolant 4 1 3 1 reserve tank 2 bolt 3 clips LEFT FRONT 3 2 4 hoses 19 TRX500FE2_31HR4850 book Page 150 Wednesday April 4 2018 11 48 AM ...

Page 161: ... 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 FRONT 3 8 5 10 6 7 19 TRX500FE2_31HR4850 book Page 151 Wednesday April 4 2018 11 48 AM ...

Page 162: ...tor 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 removal 6 tab A FRONT 9 12 11 10 7 6 7 tab B 9 hook A 10 hook B 11 center radiator grill cover 12 radiator core 19 TRX500FE2_31HR4850 book Page 152 Wednesday April 4 2018 11 48 AM ...

Page 163: ...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 cleaner of equal quality NOTICE Using the wrong air cleaner may result in premature engine wear Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mile...

Page 164: ...r 1 Remove the seat page 124 2 Unlatch the retainer clips 1 3 Remove the air cleaner housing cover 2 Cleaning UNDER SEAT 1 2 1 retainer clips 2 air cleaner housing cover 19 TRX500FE2_31HR4850 book Page 154 Wednesday April 4 2018 11 48 AM ...

Page 165: ...ms 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 Pro Honda Foam Filter Oil or an equivalent Canada Honda Foam Filter Oil or an equivalent over the entire surface of the air cleaner Use both hands to evenly spread the oil into the air cleaner Gently squeeze out a...

Page 166: ...y 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 8 facing forward and fit the cut out of the tab 9 at the end of the air cleaner 8 UNDER SEAT 9 9 tab 8 FRONT mark 9 19 TRX500FE2_31HR4850 book Page 156 Wednesday April 4 2018 11 48 AM ...

Page 167: ...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 19 TRX500FE2_31HR4850 book Page 157 Wednesday April 4 2018 11 48 AM ...

Page 168: ...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 the deposits 3 Reinstall the drain tube securing it with the clip Air Cleaner Housing Drain Tube REAR 3 1 drain tube 3 air cleaner housing 2 1 2 clip 19 TRX500FE2_31HR4850 book Page 158 Wednesday April 4 2018 11 48 AM ...

Page 169: ... 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 closed to fully open in all steering positions Throttle Freeplay RIGHT HANDLEBAR 1 8 5 16 in 3 8 mm 2 1 throttle lever 2 rubber sleeve 3 throttle cable adjuster 4 lock nut A decrease freeplay B increase freeplay A B 3 4 1...

Page 170: ...tions 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 replaced 4 Check the throttle cable for tension or stress in all steering positions 5 Lubricate the throttle cable with a commercially available cable lubricant to prevent premature wear and corrosion Throttle Inspectio...

Page 171: ...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 engine and test ride your ATV to be sure the clutch is operating properly If you cannot get proper adjustment or the clutch does not work properly the clutch friction discs may be worn See your dealer or refer to offic...

Page 172: ...justing 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 cable for loose connections or other damage If the cable is worn or kinked have it replaced by your dealer Reverse Lock System Adjustment LEFT HANDLEBAR 1 1 dust cover 2 3 2 reverse assist lever 3 rubber sleeve 4 lock ...

Page 173: ...nk cover assembly page 126 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 Using a spark plug wrench provided in the tool kit remove the spark plug Spark Plug Recommendation standard spark plug BKR5E 11 NGK or K16PR U11 DENSO Spark Plug Inspection Replacement LEFT SIDE 1 spark plug cap 1...

Page 174: ...nd 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 if there is apparent wear or if the insulator is cracked or chipped 7 Using a wire type feeler gauge check the spark plug gap 4 If adjustment is necessary bend the side electrode carefully The gap should be 0 039 0 043 i...

Page 175: ...oosen 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 If a plug is too tight the threads may be damaged 10 Connect the spark plug cap Take care to avoid pinching any cables or wires 11 Install the remaining parts in the reverse order of removal NGK 3 4 turn after it seats...

Page 176: ...wer 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 Otherwise the valves should be adjusted by your dealer Valve Inspection intake 0 006 in 0 15 mm exhaust 0 009 in 0 23 mm 19 TRX500FE2_31HR4850 book Page 166 Wednesday April 4 2018 11 48 AM ...

Page 177: ...onment 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 spark arrester 1 Select a well ventilated area free of combustible materials and make sure the exhaust pipe is cool 2 Remove the bolt 1 3 Start the engine and rev it up approximately twenty times while momentarily creati...

Page 178: ...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 spring pre load provides a softer ride and is usually preferred for light loads and smooth terrain Higher spring pre load provides a firmer ride and is recommended for heavy loads and rough terrain Using a pin spanner wh...

Page 179: ...djuster 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 2 1 2 1 2 3 4 5 1 2 3 4 5 1 spring pre load adjuster 2 pin spanner 19 TRX500FE2_31HR4850 book Page 169 Wednesday April 4 2018 11 48 AM ...

Page 180: ... loaded Also increase spring pre load for stiffer suspension Make sure that both front shock absorbers are adjusted to the same position Always adjust the shock absorber position in sequence 1 2 3 4 5 or 5 4 3 2 1 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber 19 TRX500FE2_31HR4850 book Page 170 Wednesday April 4 2018 11 48 AM ...

Page 181: ...le riding check the brake pads for wear page 174 Worn pads should be replaced If the pads are not worn beyond the recommended limit there is probably air in the brake system See your dealer to have the air bled from the system Mechanical Drum Rear Brake If the rear brake lever parking brake lever or brake pedal freeplay does not feel within the normal range while riding check the brake shoes for w...

Page 182: ...ck the system 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 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 Fluid Level Inspection 19 TRX...

Page 183: ... wear page 174 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings If the hoses are worn or cracked have them replaced by your dealer Other Inspections 1 RIGHT HANDLEBAR 1 LOWER level mark 19 TRX500FE2_31HR4850 book Page 173 Wednesday April 4 2018 11 48 ...

Page 184: ...ular 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 dealer for this replacement Always inspect both pads in both the right and left front brake calipers Brake Pad Wear RIGHT FRONT Left side similar 2 1 1 wear indicator 2 edge of reference mark 1 2 19 TRX500FE2_31HR4850 boo...

Page 185: ...brake starts to take hold Freeplay measurement at the tip of the end of the pedal should be 9 16 13 16 in 15 20 mm If necessary adjust to the specified range Rear Brake Pedal Freeplay 1 RIGHT SIDE 1 rear brake pedal 9 16 13 16 in 15 20 mm 19 TRX500FE2_31HR4850 book Page 175 Wednesday April 4 2018 11 48 AM ...

Page 186: ...e the cutout on the adjusting nut is properly seated on the brake arm pin 3 2 Adjust the freeplay of the rear brake pedal Push the brake arm 4 then check the clearance between the brake arm and the brake arm pin 2 RIGHT REAR 2 brake pedal adjusting nut 3 3 brake arm pin 4 4 brake arm 19 TRX500FE2_31HR4850 book Page 176 Wednesday April 4 2018 11 48 AM ...

Page 187: ... starts to take hold Freeplay measurement at the tip of the end of the brake lever should be 9 16 13 16 in 15 20 mm If necessary adjust to the specified range Rear Brake Lever Freeplay 1 LEFT HANDLEBAR 1 rear brake lever parking brake lever 9 16 13 16 in 15 20 mm 19 TRX500FE2_31HR4850 book Page 177 Wednesday April 4 2018 11 48 AM ...

Page 188: ...rating rod at the rear of the frame Make sure the cutout on the adjusting nut is properly seated on the brake arm pin 3 2 Adjust the freeplay of the rear brake lever parking brake lever Push the brake arm 4 then check the clearance between the brake arm and the brake arm pin 2 RIGHT REAR 2 brake lever adjusting nut 3 3 brake arm pin 4 4 brake arm 19 TRX500FE2_31HR4850 book Page 178 Wednesday April...

Page 189: ...t lets you 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 1 Apply the brake control and check the movement of the arrow 1 on the brake arm 2 2 Replace the brake shoe if the arrow aligns with the reference mark 3 on the brake panel upon full application of the brake If replacement is necessar...

Page 190: ...de behind the engine from time to time Adjustment is done by turning the adjusting nut 2 Turn the nut in direction A if the switch operates too late and in direction B if the switch operates too soon Brake Light Switch Adjustment RIGHT REAR 1 rear brake light switch 1 2 A B 2 adjusting nut 19 TRX500FE2_31HR4850 book Page 180 Wednesday April 4 2018 11 48 AM ...

Page 191: ...e bottom of the rear brake panel If any water drains the brake seals must be replaced by your dealer as soon as possible 3 Install the rear brake drain bolt with a new sealing washer and tighten it to the specified torque 9 lbf ft 12 N m 1 2 kgf m Draining Water from Brakes RIGHT REAR 1 rear brake drain bolt 1 2 2 sealing washer 19 TRX500FE2_31HR4850 book Page 181 Wednesday April 4 2018 11 48 AM ...

Page 192: ...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 recommendations for tire repair and replacement WARNING 3WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this ow...

Page 193: ...lly 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 damage from surface hazards and wear unevenly Make sure the air valve caps are secure If necessary install new caps Air Pressure 19 TRX500FE2_31HR4850 book Page 183 Wednesday April 4 2018 11 48 AM ...

Page 194: ...ngs 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 since changes in altitude can affect air pressure The recommended cold tire pressures are FRONT REAR RECOMMENDED PRESSURE 4 4 psi 30 kPa 4 4 psi 30 kPa 19 TRX500FE2_31HR4850 book Page 184 Wednesday April 4 2018 11 48 AM ...

Page 195: ...so 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 or cord Nails or other foreign objects embedded in the side of the tire or tread Excessive tread wear WARNING 3WARNING Operating this ATV with improper tires or with uneven tire pressure may cause loss of control and you...

Page 196: ... 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 reaches the following limits front 3 16 in 4 mm rear 3 16 in 4 mm FRONT 3 2 1 3 16 in 4 mm REAR 1 groove depth 2 wear indicator 3 wear indicator location mark Replace NEW Replace NEW 3 16 in 4 mm 19 TRX500FE2_31HR4850 book Page 186 Wednesda...

Page 197: ...d or permanently repaired as soon as possible For more information on temporary repairs see If You Have a Flat Tire page 222 A permanent repair such as an internal plug patch can be made if a tire has only a small puncture in the tread area However you may not be able to safely carry as much weight If you choose to have a tire repaired be sure the repair work is performed by a professional If you ...

Page 198: ...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 Honda facility we recommended that you have the work checked by your dealer Tire Replacement WARNING 3WARNING Installing improper tires on your ATV can affect handling and stability This can cause a crash in which you can...

Page 199: ...ear final gear case Check the guard and plate for cracks damage or looseness at intervals shown in the Maintenance Schedule Have the engine guard and skid plate replaced if they are cracked or damaged If the guard and plate bolts are loose tighten them securely Skid Plate Engine Guard 1 1 engine guard 2 2 skid plate 19 TRX500FE2_31HR4850 book Page 189 Wednesday April 4 2018 11 48 AM ...

Page 200: ...iveshaft guards 2 for cracks damage or looseness Tighten any loose fasteners Replace the front boot guards and front driveshaft guards as required Front Boot Guards Front Driveshaft Guards 1 front boot guards 2 front driveshaft guards 2 1 FRONT 2 1 19 TRX500FE2_31HR4850 book Page 190 Wednesday April 4 2018 11 48 AM ...

Page 201: ...Check the propeller shaft boots 1 and yoke joint boot 2 for cuts damage or leaking grease If necessary have your dealer replace them Propeller Shaft Boots Yoke Joint Boot 1 1 propeller shaft boots 2 yoke joint boot 2 19 TRX500FE2_31HR4850 book Page 191 Wednesday April 4 2018 11 48 AM ...

Page 202: ...afety Precautions on page 113 Check the driveshaft boots 1 for cuts damage or leaking grease If necessary have your dealer replace them Front Driveshaft Boots FRONT 1 1 driveshaft boots 19 TRX500FE2_31HR4850 book Page 192 Wednesday April 4 2018 11 48 AM ...

Page 203: ...electrical accessories on your ATV or do not ride frequently we recommend that you charge the battery frequently see Battery Charging page 197 If you do not expect to ride your ATV for at least two weeks we recommend you remove the battery or at least disconnect the battery cables negative cable first If you plan to store your ATV see Battery Storage page 194 If your battery seems weak and or is l...

Page 204: ...moving the battery and slow charging it every 30 days see Battery Charging page 197 Before you remove the battery be sure to read all the information that follows as well as the information on the battery label Battery Storage WARNING 3WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the battery to explode with enough force to kill or seriousl...

Page 205: ...125 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 battery taking care not to drop the terminal nuts 5 3 1 rubber band 2 negative terminal lead 4 positive terminal lead 5 terminal nuts UNDER REAR FENDER COVER 2 4 1 5 3 battery 19 TRX500FE2_31HR4850 book Page 195 Wednesday ...

Page 206: ...tallation 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 reverse order of removal Be sure to connect the positive terminal first then the negative terminal 4 Make sure all bolts and other fasteners are secure 5 Install the removed parts in reverse order of removal After the bat...

Page 207: ...ur 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 charger connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat an ATV battery and cause premature damage Battery Cha...

Page 208: ...rom 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 intensify the sun s brightness Spotting is also more likely because surface water can dry before you have time to wipe it off Clean your ATV regularly to protect surface finishes We recommend the use of a low pressure ...

Page 209: ...an 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 water spots As you dry inspect for chips and scratches 7 Remove the cover or the plug from exhaust outlet Then start the engine and let it idle for several minutes The engine heat will help dry moist areas 8 As a precau...

Page 210: ...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 abrasive cloth Heavy grime Oil leaks Brake dust Use a spray cleaner degreaser If necessary rub with a sponge Rinse and dry Apply a spray cleaner polish and wipe with a non abrasive cloth Dull corroded chrome or aluminum A...

Page 211: ...e page 239 when you buy touch up paint If the frame has a chip that exposes the metal first apply primer to prevent corrosion and then apply the touch up paint Several thin layers of touch up paint are better than one thick coat The exhaust pipe and muffler are stainless steel but may become stained by mud or dust To remove mud or dust use a wet sponge and a liquid kitchen abrasive then rinse well...

Page 212: ...Servicing Your Honda 202 19 TRX500FE2_31HR4850 book Page 202 Wednesday April 4 2018 11 48 AM ...

Page 213: ...to be an environmentally responsible ATV owner Preparing for a Ride 204 What to Take to the Riding Area 204 What to Take on the Trail 205 Transporting Your Honda 206 Storing Your Honda 208 Preparation for Storage 209 Removal from Storage 211 You the Environment 212 19 TRX500FE2_31HR4850 book Page 203 Wednesday April 4 2018 11 48 AM ...

Page 214: ...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 encounter see Taking Care of the Unexpected which begins on page 213 We recommend that you always take water food a first aid kit and your owner s manual Other items you should consider loading on your truck or trailer inclu...

Page 215: ... 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 and know how to use them Also be sure to follow the loading guidelines and weight limit page 68 What to Take on the Trail 19 TRX500FE2_31HR4850 book Page 205 Wednesday April 4 2018 11 48 AM ...

Page 216: ...ommend 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 hazard Follow these procedures 1 Set the parking brake 19 TRX500FE2_31HR4850 book Page 206 Wednesday April 4 2018 11 48 AM ...

Page 217: ...inary 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 are tight and the vehicle is secure 1 3 2 1 front carry pipe 2 rear cargo rack 3 trailer hitch 19 TRX500FE2_31HR4850 book Page 207 Wednesday April 4 2018 11 48 AM ...

Page 218: ...orgotten 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 you perform the following procedures to keep your ATV in top condition These storage procedures will reduce the deterioration that can occur during storage 19 TRX500FE2_31HR4850 book Page 208 Wednesday April 4 2018 11...

Page 219: ...lowing Remove the spark plug cap from the spark plug page 163 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 into the cylinder and cover the spark plug hole with a piece of cloth With the engine stop switch in the RUN e position press the start override button several times to crank the engine and distribute the oil Reinstal...

Page 220: ...h 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 upright position for extended periods of time The ATV should be stored with all four tires on the ground This can damage the vehicle and leaking gasoline could be a hazard WARNING 3WARNING The battery gives off explosi...

Page 221: ...nge the engine oil page 136 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 197 as required Install the battery 5 Perform a pre ride inspection page 63 then test ride your ATV at low speeds Removal from Storage 19 TRX500FE2_31HR4850 book Page 211 Wednesday April 4 2018 11 48 AM ...

Page 222: ...hoose Sensible Cleaners Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s protective ozone layer Don t throw cleaning solvents away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil ...

Page 223: ...ad this section before you ride Also review the tips in Preparing for a Ride page 204 General Guidelines 214 If Your Engine Quits or Won t Start 216 If the Shift Switches Do Not Function 219 Emergency Gear Selection Operation 220 If You Have a Flat Tire 222 If the High Coolant Temperature Indicator Lights 226 If a Fuse Blows 228 If You Crash 233 If You Lose Your Key 234 If the Battery Is Low or De...

Page 224: ... 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 you decide what to do If a problem is relatively minor and you have the tools supplies and skills to make a permanent repair you may be able to fix it on the trail and continue riding Or you may be able to make a tempo...

Page 225: ... 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 made as soon as possible Do not continue riding if you are hurt or your ATV is not in safe riding condition Additional recommendations for specific problems follow 19 TRX500FE2_31HR4850 book Page 215 Wednesday April 4 20...

Page 226: ...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 override button If you don t hear the starter motor turning refer to the Starter motor doesn t operate symptom If you can hear the starter motor working normally refer to the Starter motor works but the engine won t star...

Page 227: ...arge the battery page 197 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 Starter motor works but the engine won t start POSSIBLE CAUSE WHAT TO DO out of fuel Fill the fuel tank flooded engine See Flooded Engine page 83 loose or unconnected spark plug cap Install the spark plug cap securely If...

Page 228: ...your dealer sooty exhaust rich fuel mixture See your dealer detonates or pings under load If applicable switch to the recommended octane gasoline page 128 or change your brand of gasoline If the problem persists see your dealer afterfires backfires See your dealer pre ignition runs on after ignition switched OFF See your dealer SYMPTOM Engine starts but runs poorly or dies when hot POSSIBLE CAUSE ...

Page 229: ...shift into neutral and restart the engine If one or both switches are not functioning see Emergency Gear Selection Operation page 220 When the engine is stopped and the ignition switch is ON q 1 Turn the ignition switch to the OFF w position 2 Turn the ignition switch to the ON q position 3 Press both shift switches and check that they are functioning 4 If both switches are functioning shift into ...

Page 230: ... step 6 If the transmission is not in neutral use the gear change tool to shift to neutral so you will be able to start the engine Refer to How to Shift Gears Manually page 221 6 Apply the parking brake 7 Press the start override button to start the engine 8 Select the gear you want For running on level ground 3rd or 4th gear For mountainous roads 2nd or 3rd gear Refer to How to Shift Gears Manual...

Page 231: ...th the secondary spindle If the transmission does not shift rock the vehicle back and forth and try again And then if not shift again the surface of the gear change tool invert and turn the gear change tool Return the gear change tool to under the rear fender cover Do not attempt to shift gears manually using the gear change tool while riding If the transmission is shifted manually when the electr...

Page 232: ... possible have the tire permanently repaired by your dealer Any tire that cannot be repaired should be replaced Whenever the ATV is to be operated far from service facilities or available transportation we recommend that you carry a tire pump and a repair kit with the vehicle If the leak is more serious or a temporary repair doesn t hold the tire must be replaced The tire will also need to be repl...

Page 233: ...mporary tire repair can be risky If 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 19 TRX500FE2_31HR4850 book Page 223 Wednesday April 4 2018 11 48 AM ...

Page 234: ...e 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 removing and installing each wheel Any contamination can cause poor brake performance or rapid pad wear after reassembly Emergency Wheel Removal Installation 1 1 2 1 wheel nuts 2 wheel rim 19 TRX500FE2_31HR4850 book Page 224 W...

Page 235: ...he wheel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque 47 lbf ft 64 N m 6 5 kgf m If a torque wrench was not used for installation see your dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capability 19 TRX500FE2_31HR4850 book Page 225 Wednesday April 4 2018 11 48 AM...

Page 236: ...ine 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 radiator If there s no obvious problem leave the engine on so the fan and coolant circulating system can continue working Monitor the coolant temperature gauge and high coolant temperature indicator The indicator may turn...

Page 237: ... recommended oil page 134 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 high coolant temperature indicator goes off If you are able to resume riding continue to monitor the coolant temperature gauge and high coolant temperature indicator frequently If there is an oil leak do not ride the...

Page 238: ...k 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 are located under the rear fender cover The EPS Electric Power Steering block fuse is located under the rear fender cover Recommended Fuses main fuse 1 40 A main fuse 2 10 A other fuses 30 A 20 A 3 10 A EPS Electric Power Steer...

Page 239: ...125 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 fuses out If the main fuse 1 is blown see your dealer for this service If the main fuse 2 is blown install the spare fuse 6 7 Install the fuse cover 2 main fuse 1 5 fuse box cover 3 6 6 spare fuse UNDER REAR FENDER COVER 5 3 fuse cover 4 4 main fuse 2 2 19 TRX500FE2_3...

Page 240: ...rating If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating NOTICE Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electrical system 9 Install the fuse box cover 10 Install the rear fender cover 11 Install the seat 8 7 7 circuit fuses 8 spare fuses 19 TRX500FE2_31HR4850 book Page 230 Wednesday ...

Page 241: ...at page 124 3 Remove the rear fender cover page 125 4 To access the EPS fuse block 1 remove the fuse cover 2 If the EPS fuse block is blown see your dealer for this service 5 Install the fuse cover 6 Install the rear fender cover 7 Install the seat 1 UNDER REAR FENDER COVER 1 EPS fuse 2 2 fuse cover 19 TRX500FE2_31HR4850 book Page 231 Wednesday April 4 2018 11 48 AM ...

Page 242: ...u 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 the replacement fuse of the same rating burns out in a short time there is probably a serious electrical problem on your ATV Leave the blown fuse in that circuit and have your ATV checked by your dealer 19 TRX50...

Page 243: ...r 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 damage or you are unsure about possible damage but decide to try riding the ATV back to your base ride slowly and cautiously Sometimes crash damage is hidden or not immediately apparent When you get home thoroughly check...

Page 244: ...g 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 they don t transport your ATV to them or the nearest dealer The dealer will probably have to remove the ignition switch assembly to find the key number so they can make a key for you 1 1 key number 19 TRX500FE2_31HR485...

Page 245: ...using the recoil starter 1 Turn the ignition switch to the ON q position 2 Check if the transmission is in neutral by moving the vehicle back and forth 3 If the transmission is in neutral the vehicle will move easily Go to step 6 If the transmission is not in neutral the vehicle will not move 4 Remove the gear change tool from under of the rear fender cover page 122 5 Use the gear change tool to s...

Page 246: ...upplies 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 If you damage a throttle cable or other critical component your ATV may be unsafe to ride Carefully assess the damage and make any repairs that you can But if there is any doubt it s best to be conservative and safe 1...

Page 247: ...ons capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 238 Specifications 240 Break in Guidelines 245 Emission Control Systems 246 Oxygenated Fuels 250 19 TRX500FE2_31HR4850 book Page 237 Wednesday April 4 2018 11 48 AM ...

Page 248: ...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 147 The engine number 2 is stamped on the upper side of the rear crankcase Serial Numbers FRONT 1 1 VIN REAR 2 engine number 2 19 TRX500FE2_31HR4850 book Page 238 Wednesday April 4 2018 11 48 AM ...

Page 249: ...e 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 Label Code LEFT SIDE 1 1 color label 19 TRX500FE2_31HR4850 book Page 239 Wednesday April 4 2018 11 48 AM ...

Page 250: ...ing reserve fuel tank reserve 1 29 US gal 4 9 ℓ engine oil capacity after disassembly 3 5 US qt 3 3 ℓ after draining 3 1 US qt 2 9 ℓ after draining oil filter change 3 2 US qt 3 0 ℓ engine oil recommendation API Service Classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 stro...

Page 251: ...6 ℓ Capacities passenger capacity operator only maximum weight capacity 551 lb 250 kg rider all cargo and accessories Engine Specifications displacement 29 0 cu in 475 cm3 bore stroke 3 62 2 81 in 92 0 71 5 mm compression ratio 9 5 1 spark plug standard BKR5E 11 NGK or K16PR U11 DENSO spark plug gap 0 039 0 043 in 1 00 1 10 mm valve clearance cold intake 0 006 in 0 15 mm exhaust 0 009 in 0 23 mm i...

Page 252: ...ssion 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 2 trail 0 2 in 6 mm tire size front AT25 8 1211 MAXXIS M975 tire size rear AT25 10 1211 MAXXIS M978 tire pressure front rear cold front 4 4 psi 30 kPa rear 4 4 psi 30 kPa 19 TRX500FE2_31HR4850 book Page 242 Wednesday April 4 2018 11 48 AM ...

Page 253: ... 12 V 45 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 Power Steering indicator LED Fuses main 1 40 A main 2 10 A other 30 A 20 A 3 10 A EPS Electric Power Steering 40 A 19 TRX500FE2_31HR4850 book Page 243 Wednesday April 4 2018 11 48 AM ...

Page 254: ...ft 12 N m 1 2 kgf m rear final gear oil fill cap 9 lbf ft 12 N m 1 2 kgf m rear final gear oil level check bolt 9 lbf ft 12 N m 1 2 kgf m front final gear oil drain bolt 9 lbf ft 12 N m 1 2 kgf m front final gear oil fill cap 9 lbf ft 12 N m 1 2 kgf m rear brake drain bolt 9 lbf ft 12 N m 1 2 kgf m wheel nuts 47 lbf ft 64 N m 6 5 kgf m 19 TRX500FE2_31HR4850 book Page 244 Wednesday April 4 2018 11 ...

Page 255: ...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 and constant rpm operation 19 TRX500FE2_31HR4850 book Page 245 Wednesday April 4 2018 11 48 AM ...

Page 256: ...ife 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 Canada only The Vehicle Emission Control Information Label 2 is attached on the left side of the frame LEFT FRONT 1 2 vehicle emission control information label Canada only LEFT SIDE 2 1 vehicle emission control information label 19 TRX...

Page 257: ... carbon monoxide oxides of nitrogen and hydrocarbons Exhaust Emission Control System The exhaust emission control system includes a PGM FI system and oxygen sensor No adjustment to this system should be made although periodic inspection of the components is recommended The exhaust emission control system is separate from the crankcase emission control system Crankcase Emission Control System The e...

Page 258: ...onomy 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 competition If you modify your engine for use in sanctioned competition events you must deface or destroy the emission control information label If you loan sell or give your competition modified Honda ATV to someone e...

Page 259: ...E FOLLOWING 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 maintenance Removing or disabling any emissions compliance component or replacing any compliance component with a non compliant component Fuel Permeation Emission Control System This vehicle complies ...

Page 260: ... 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 containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol Do not use gasoline containing more than 10 ethanol by volume The use of gasoline containing a higher percentage e ...

Page 261: ...el 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 of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Oxygenated fuels can damage paint and plastic Be careful not to spill fuel when filling ...

Page 262: ...Technical Information 252 19 TRX500FE2_31HR4850 book Page 252 Wednesday April 4 2018 11 48 AM ...

Page 263: ...s section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 254 Warranty Coverage 255 Warranty Service 256 Contacting Honda 257 Your Honda Dealer 258 19 TRX500FE2_31HR4850 book Page 253 Wednesday April 4 2018 11 48 AM ...

Page 264: ...pare 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 easy to use if they have the proper tools and observe proper safety standards Special Honda tools are necessary for some procedures Order On Line www helminc com Order Toll Free 1 888 CYCLE93 1 888 292 5393 NOTE For ...

Page 265: ...nda 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 associated with using the ATV Your warranty coverage will not be voided if you choose to perform your own maintenance However you should have the proper tools and service information and be mechanically qualified Fail...

Page 266: ...n 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 to talk to the Service Manager of your dealer Sometimes in spite of the best intentions of all concerned a misunderstanding may occur If you aren t satisfied with your dealer s handling of the situation we suggest you ...

Page 267: ...mment 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 CA 90509 2200 mailstop 100 4C 7B telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsimile 877 939 0909 E mail honda_cr ch hond...

Page 268: ...anada 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 parts department The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage USA only Your Honda dealer can inform you about competition and other riding events in your a...

Page 269: ...Consumer Information 259 19 TRX500FE2_31HR4850 book Page 259 Wednesday April 4 2018 11 48 AM ...

Page 270: ... care 198 authorized manuals 254 B bank angle sensor ignition cut off system 83 battery 193 brake light switch adjustment 180 brakes cables 179 draining water from 181 fluid 171 front brake lever 45 pad wear 174 P R lever 46 rear brake lever freeplay 177 rear brake lever parking brake lever 45 rear brake pedal 45 rear brake pedal freeplay 175 shoe wear 179 braking 91 19 TRX500FE2_31HR4850 book Pag...

Page 271: ...ng hills 96 clip 127 clutch system 161 color label 239 compartment owner s manual 123 tool kit 122 component fails 236 consumer information 253 controls features 34 coolant temperature gauge 28 crash if you 233 crossing or turning on hills or slopes 102 customer service 257 D differential lock switch 36 digital clock 26 dimmer switch headlight 41 dipstick 135 19 TRX500FE2_31HR4850 book Page 261 We...

Page 272: ... 131 pinging 128 starting 80 stop switch 40 stopping 85 won t start 216 environment 212 exhaust system cleaning 64 purging 167 F final gear oil front 143 rear 140 flag pole bracket 48 flat tire 222 flooded engine 83 front boot guards 190 front differential lock 36 front driveshaft boots 192 front driveshaft guards 190 19 TRX500FE2_31HR4850 book Page 262 Wednesday April 4 2018 11 48 AM ...

Page 273: ...241 gasohol 250 gasoline 128 gear shifting 87 gearshift switch 44 guards 189 H headlight dimmer switch 41 headlight switch 41 high coolant temperature indicator 14 17 226 hills crossing or turning on slopes 102 riding down hills 101 riding up hills 97 stopping on hills 99 Honda service manual 254 Honda contacting 255 dealer 258 19 TRX500FE2_31HR4850 book Page 263 Wednesday April 4 2018 11 48 AM ...

Page 274: ...ance minder indicator 20 31 neutral indicator 14 17 PGM FI indicator 14 17 PS Electric Power Steering indicator 14 17 reverse indicator 14 17 inspection pre ride 63 K key lost 234 number 234 kit tool 122 L labels safety 5 lamp check 15 limit weight 68 load limits 68 loading guidelines 69 lubrication engine oil 131 front final gear oil 143 rear final gear oil 140 19 TRX500FE2_31HR4850 book Page 264...

Page 275: ...254 maximum weight limit 68 modifications 71 multi function display 20 N neutral indicator 14 17 noise emission control system 249 numbers serial 238 O obstacles riding over 104 odometer 27 oil engine 131 front final gear 143 rear final gear 140 operation component locations 11 owner s manual storage 123 oxygenated fuels 250 19 TRX500FE2_31HR4850 book Page 265 Wednesday April 4 2018 11 48 AM ...

Page 276: ... 191 protective apparel 58 EPS Electric Power Steering 55 R rear fender cover removal 125 rear final gear oil 140 recoil starter Canada only 42 86 removal rear fender cover 125 seat 124 tank cover assembly 126 reverse assist cable 162 assist lever 162 gear shifting into 87 indicator 14 17 riding in 88 P R lever 46 rider training 60 19 TRX500FE2_31HR4850 book Page 266 Wednesday April 4 2018 11 48 A...

Page 277: ...11 labels 5 riding precautions 75 schedule maintenance 112 seat removal 122 serial numbers 238 service customer 257 manuals 254 warranty 256 shifting gears 87 skid plate 189 skidding or sliding 96 spark arrester 167 spark knock 126 spark plug 163 specifications 240 speed limiter over ride 36 speedometer 18 20 stalled engine 84 19 TRX500FE2_31HR4850 book Page 267 Wednesday April 4 2018 11 48 AM ...

Page 278: ...torage ATV 208 owner s manual 123 suspension adjustment 168 spring pre load 169 switch 4WD 35 differential lock 36 downshift 44 86 engine stop 40 headlight 41 headlight dimmer 41 ignition 34 upshift 44 87 T tank cover assembly removal 126 throttle cable 159 160 lever 43 159 160 19 TRX500FE2_31HR4850 book Page 268 Wednesday April 4 2018 11 48 AM ...

Page 279: ...delines 69 weight limits 68 training rider 60 transporting your ATV 206 tripmeter 27 trouble unexpected 213 troubleshooting starting 216 turning on hills or slopes 102 on level ground 94 U utility box 52 utility pocket 53 V valve clearance 166 vehicle identification no VIN 238 W warning labels 5 19 TRX500FE2_31HR4850 book Page 269 Wednesday April 4 2018 11 48 AM ...

Page 280: ...arranty coverage 255 extended 255 service 256 washing your ATV 199 water draining from brakes 181 riding through 105 weight limit 68 wheel removal 224 19 TRX500FE2_31HR4850 book Page 270 Wednesday April 4 2018 11 48 AM ...

Page 281: ...xpensive 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 Air cleaner dirty leaking because of improper installation poor seal Record important information on the following page How To Avoid Costly Repairs 19 TRX500FE2_31HR4850 book P...

Page 282: ...Reference Quick Reference Engine No VIN Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 19 TRX500FE2_31HR4850 book Page 277 Wednesday April 4 2018 11 48 AM ...

Page 283: ...t lever switches steering Fuel Capacity unleaded gasoline pump octane number 86 or higher 3 88 US gal 14 7 ℓ reserve 1 29 US gal 4 9 ℓ Engine Oil Capacity API Service Classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 stroke oil or equivalent after draining 3 1 US qt 2 9 ℓ a...

Page 284: ...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 equivalent distilled water Fuses main 1 40 A main 2 10 A other 30 A 20 A 3 10 A PS Electric Power Steering 40 A 19 TRX500FE2_31HR4850 book Page 279 Wednesday April 4 2018 11 48 AM ...

Page 285: ... 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 OFF headlight switch 41 u HI headlight dimmer switch 41 i LO headlight dimmer switch 41 a upshift switch gearshift switch 44 s downshift switch gearshift switch 44 parking brake reverse lever P R lever P parking brake R riding in reverse 46 19 TRX500FE2_31H...

Page 286: ...nown 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 service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle 19 TRX500FE2_31HR4850 book Pag...

Page 287: ...PRINTED IN USA WPCXXXX 2018 XX 19 00X31 HR4 8500 31HR4850 ...

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