Honda FourTrax Foreman TRX520FE2 2020 Owner'S Manual Download Page 121 | Manualshive

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Servicing Your Honda

111

Servicing Your Honda

(cont’d)

Servicing Your Honda

To help keep your ATV in good shape, this section includes a
Maintenance Schedule for required service and step-by-step
instructions for specific maintenance tasks. You’ll also find important
safety precautions, information on fuels and oils, and tips for
keeping your Honda looking good.

For information about replacing fuses, see page 228.

For information about the exhaust emission and noise requirements of
the U.S. Environmental Protection Agency (EPA), the California Air
Resources Board (CARB), 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 ............................................... 113
Maintenance Safety .................................................................. 114

Important Safety Precautions ................................................. 115

Maintenance Schedule ............................................................. 116
Maintenance Record................................................................. 120

Service Preparations

Maintenance Component Locations ......................................... 121
Tool Kit .................................................................................... 124
Owner’s Manual Storage .......................................................... 125
Seat Removal............................................................................ 126
Rear Fender Cover Removal ...................................................... 127
Tank Cover Assembly Removal ................................................. 128
Clip Removal ............................................................................ 129

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Summary of Contents for FourTrax Foreman TRX520FE2 2020

Page 1: ...2020 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 r...

Page 2: ...formation available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced...

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

Page 4: ...ed in this manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual contains a d...

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

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

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

Page 8: ...on your ATV Instruments Controls 9 The location and function of indicators and controls on your ATV and operating instructions for various controls and features Before Riding 59 The importance of wear...

Page 9: ...ur ATV and how to 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 technica...

Page 10: ...20 TRX520FE2 31HR48600 book 9...

Page 11: ...tant information and recommendations to help you ride your ATV safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your A...

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

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

Page 14: ...ing don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink and ride and don t let your friends...

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

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

Page 17: ...ent Never exceed 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 r...

Page 18: ...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 PASSENGERS WITH DRUGS OR ALCOHOL To...

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

Page 20: ...40 Headlight Switch 41 Headlight Dimmer Switch 41 Recoil Starter Canada only 42 Throttle Lever 43 Gearshift Switch 44 Reverse Switch 45 Front Brake Lever 46 Rear Brake Lever Parking Brake Lever 46 Re...

Page 21: ...tch parking brake lock 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 ge...

Page 22: ...Instruments Controls 12 Operation Component Locations rear cargo rack front cargo rack flag pole bracket rear brake pedal recoil starter Canada only front utility box 20 TRX520FE2 31HR48600 book 12...

Page 23: ...Instruments Controls 13 Operation Component Locations side utility box trailer hitch accessory socket storage compartment utility pocket 20 TRX520FE2 31HR48600 book 13...

Page 24: ...d more enjoyable 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...

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

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

Page 27: ...4 PGM FI indicator 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...

Page 28: ...maintenance interval 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...

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

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

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

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

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

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

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

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

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

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

Page 39: ...s stop the engine and check the reserve tank coolant level Read pages 226 227 and do not ride the ATV until the problem has been corrected NOTICE Continuing to ride with an overheated engine can cause...

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

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

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

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

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

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

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

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

Page 48: ...y abnormality in 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 mod...

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

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

Page 51: ...between the high 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 b...

Page 52: ...ntrols Features The recoil starter 1 is used to start the engine when the battery is low See Using the Recoil Starter Canada only page 88 Recoil Starter Canada only RIGHT SIDE 1 recoil starter 1 20 TR...

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

Page 54: ...r lower gear in the 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 89 Gearshift...

Page 55: ...ontrols Features The reverse switch 1 is used when shifting the transmission into reverse R To shift into reverse R see Riding in Reverse page 92 Reverse Switch LEFT HANDLEBAR 1 reverse switch 1 20 TR...

Page 56: ...ar brake lever parking brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see page 94 The rear brake pedal is used to slow or stop your ATV To...

Page 57: ...arking brake lock lever 1 on the rear brake lever parking brake lever 2 is used to apply the parking brake Parking Brake Lock Lever LEFT HANDLEBAR 1 parking brake lock lever 1 2 2 rear brake lever par...

Page 58: ...lever bracket For information on Parking see page 109 To release the parking brake Squeeze the rear brake lever parking brake lever until the parking brake lock lever is released from the slot on the...

Page 59: ...ilable from your dealer To mount a pole in the bracket 1 follow the instructions that come with the flag pole kit Flag poles are required in some riding areas Check local regulations before riding Fla...

Page 60: ...hitch you ll need a proper size ball 2 as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the trailer manufacturer s instructions For load limits and ope...

Page 61: ...phone etc NOTICE Do not plug in any heat generating accessory such as an automobile cigarette lighter because it can damage the socket To use the accessory socket turn the ignition switch to ON q sta...

Page 62: ...may drain the battery The accessory socket s rated capacity is DC 12 V 120 Watts 10 A or less If you exceed this limit you may blow a fuse See If a Fuse Blows page 228 When you are done using an acce...

Page 63: ...Push down the front of the side 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 side utility box cover Do...

Page 64: ...n the front of the front utility box cover until it locks in place Make sure that the studs 3 are locked securely in position by pulling up lightly on the front of the front utility box cover Do not s...

Page 65: ...s The utility pocket 1 is located on the left side cover You may store small lightweight items in the pocket Do not store valuable items in the utility pocket Utility Pocket 1 utility pocket 1 LEFT SI...

Page 66: ...1 is located below the rear cargo rack 2 To open the compartment unhook the rubber strap 3 Be careful not to flood this area when washing your ATV Storage Compartment REAR 1 storage compartment 1 3 r...

Page 67: ...cle and allow the EPS system to cool down until the PS indicator goes off After cooling down steering will return to normal EPS operation The PS indicator should light when the ignition switch is turn...

Page 68: ...Instruments Controls 58 20 TRX520FE2 31HR48600 book 58...

Page 69: ...tments to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride 60 Protective Apparel 60 Rider Training 62 Age Recommendation...

Page 70: ...ng You don t have any alcohol or drugs in your system For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved...

Page 71: ...ycle boots to help protect your feet ankles and lower legs Off road motorcycle gloves to help protect your hands Riding pants with knee and hip pads a riding jersey with padded elbows and a chest shou...

Page 72: ...e ASI For information about the ASI training course nearest you call the national toll free number 800 887 2887 USA only Other riding tips can be found in the Tips Practice Guide for the ATV Rider boo...

Page 73: ...n the front or rear cargo racks Age Recommendation WARNING 3WARNING A child using an ATV that is not recommended for their age could lose vehicle control while riding resulting in severe injury or dea...

Page 74: ...erating an ATV Consult your doctor to be sure it is safe to operate a vehicle after taking medication No Alcohol or Drugs WARNING 3WARNING Operating this ATV after consuming alcohol or drugs can serio...

Page 75: ...nspected by your dealer There may be damage or other problems you cannot see Check the following items before you get on the ATV WARNING 3WARNING Improperly maintaining this ATV or failing to correct...

Page 76: ...s Bolts Check the wheels to see that the axle nuts are tightened Use a wrench to make sure all accessible nuts bolts and fasteners are tight Underbody Exhaust System Check for and remove any dirt vege...

Page 77: ...Limits Make sure you do not exceed the load limits page 70 Cargo Check that all cargo is secure Throttle Check the freeplay and adjust if needed Press the throttle to make sure it moves smoothly witho...

Page 78: ...t before you ride Headlight and Headlight Dimmer Switch Check for proper function page 41 Engine Stop Switch Check for proper function page 40 Steering Check that the wheels turn properly as you steer...

Page 79: ...modifications that change this ATV s design and performance can also make it unsafe Also the weight of any accessories will reduce the maximum load the ATV can carry More specific information on load...

Page 80: ...gue using either a tongue jack or other support to keep the trailer level The weight of added accessories will reduce the maximum cargo weight you can carry Load Limits maximum weight capacity 551 lb...

Page 81: ...not tow by tying a rope or cable to the rear rack Load cargo on the rear rack as far forward as possible Make sure cargo on the front rack does not interfere with handlebar movement Do not allow cargo...

Page 82: ...and always follow these guidelines Make sure the accessory does not obscure any lights reduce ground clearance limit suspension travel or steering travel or interfere with operating any controls Make...

Page 83: ...handling stability and braking making it unsafe to ride We also advise you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system co...

Page 84: ...Before Riding 74 20 TRX520FE2 31HR48600 book 74...

Page 85: ...ormance and service life refer to Break in Guidelines page 245 Safe Riding Precautions 77 Off road Use Only 77 Keep Hands and Feet on Controls 78 Control Speed 79 Use Care on Unfamiliar or Rough Terra...

Page 86: ...Braking 94 Riding Your ATV 96 Making Turns 96 Skidding or Sliding 98 Riding Up Hills 99 Riding Down Hills 103 Crossing or Turning on Hills or Slopes 104 Riding Over Obstacles 106 Riding Through Water...

Page 87: ...nd manufactured for off road use only not for pavement Riding on pavement can affect handling and control You should not ride your ATV on pavement When riding off road also remember to always obey loc...

Page 88: ...rom the handlebars or one foot from the footpegs can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV WARNING 3WARNING Operating this ATV on public s...

Page 89: ...visibility and other operating conditions plus your own skills and experience Control Speed WARNING 3WARNING Operating this ATV at excessive speeds increases your chances of losing control of the ATV...

Page 90: ...tructions like hidden rocks bumps or holes in time to react Use Care on Unfamiliar or Rough Terrain WARNING 3WARNING Failure to use extra care when operating this ATV on unfamiliar terrain could resul...

Page 91: ...n operating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control which could result in a crash including an overturn Do not operate on excessively rough slipp...

Page 92: ...monoxide gas which can collect rapidly in an enclosed area and cause illness or death WARNING 3WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause...

Page 93: ...ke page 47 2 Turn the ignition switch 1 to ON q Confirm the following The transmission is in neutral the neutral indicator 2 is ON and the gear position indicator shows N The engine stop switch 3 is s...

Page 94: ...rature Press the start override button with the throttle completely closed The engine will not start if the throttle is fully open because the electronic control module cuts off the fuel supply Snappi...

Page 95: ...cedure 5 If the engine starts then open the throttle slightly if idling is unstable If the engine does not start wait 10 seconds then follow steps 1 4 again If the engine still won t start refer to If...

Page 96: ...pressing the start override button Do not press the throttle lever while starting in gear The engine will not start if the throttle is fully open because the electronic control module cuts off the fu...

Page 97: ...ch to OFF w The engine stop switch should normally remain in the RUN e position even when the engine is OFF If your ATV is stopped with the engine stop switch OFF r and the ignition switch ON q the ba...

Page 98: ...then pull it out slowly approximately 4 in 100 mm 4 Pull the grip up briskly and fully 5 After the engine starts allow the starter grip to return slowly Pull the recoil starter grip straight out so t...

Page 99: ...wnshift switch 2 once To select reverse see Riding in Reverse page 92 After starting the engine and letting it warm up follow these procedures 1 With the transmission in neutral release the parking br...

Page 100: ...downshifted from 1st gear to neutral when the engine speed is above 3 100 rpm or the ground speed is above 3 mph 5 km h If the electric shift system malfunctions the transmission cannot be shifted by...

Page 101: ...ng when engine speed is near its allowable maximum may over rev the engine and possibly cause damage To prevent transmission damage do not coast or tow the ATV for long distances with the engine off R...

Page 102: ...1 then press the downshift switch 2 within 10 seconds to shift into R reverse gear You can also shift into R reverse gear by pressing and holding the downshift switch then pressing the reverse switch...

Page 103: ...ft switch 3 once To shift into 1 1st gear press and hold the reverse switch then press the upshift switch within 10 seconds You can also shift into 1 1st gear by pressing and holding the upshift switc...

Page 104: ...l rule the front braking system provides about 70 percent of total stopping power For full braking effectiveness use both the pedal and lever simultaneously Using both braking systems will stop your A...

Page 105: ...cy situation are important riding skills When descending a long steep grade use engine compression braking by downshifting with intermittent use of both brakes Continuous brake application can overhea...

Page 106: ...ebar in the front differential lock mode will cause steering to be heavy and increase turning radius Making Turns WARNING 3WARNING Turning improperly can make the ATV go out of control causing a colli...

Page 107: ...It helps to shift your body slightly forward on the seat and lean inside as you steer the handlebar Shifting weight forward allows the rear wheels to turn easier and it also improves front wheel stee...

Page 108: ...during a turn steer in the direction of the skid Avoid hard braking or accelerating until you have regained directional control Remember that steering the handlebar in the front differential lock mode...

Page 109: ...ght toward the front wheels to help keep them on the ground To do this shift your body slightly forward on the seat and lean forward For greater weight shift move your body farther forward and lean fo...

Page 110: ...in an appropriate gear and speed for the conditions Maintain a steady speed as you ascend the hill Never open the throttle suddenly or make sudden gear changes The ATV could flip over backward Never g...

Page 111: ...rking brake and turn the engine off 4 Then assess the situation If the ATV starts rolling backwards before you begin braking 1 Keep your weight uphill 2 Carefully apply the front brakes first then car...

Page 112: ...alk the ATV back down the hill Make sure your intended path is clear in case you lose control of the ATV 1 Stand with your body facing downhill beside the vehicle so you can reach the rear brake lever...

Page 113: ...ch a downhill stop and survey the terrain below Never ride past the limit of your visibility Never go down a hill at high speed Riding Down Hills WARNING 3WARNING Going down a hill improperly could ca...

Page 114: ...d on any hill with a loose surface Riding on hills or slopes is different from riding on level terrain Be careful when riding on any hill Make sure that you practice on gentle smooth slopes before att...

Page 115: ...or loose surface you may also need to steer slightly uphill to maintain a straight course across the slope Avoid crossing hills that are excessively steep slippery or rough Making Turns on Slopes Comp...

Page 116: ...reduce your speed and be prepared to stop Never try to ride over large obstacles such as large rocks or fallen logs Riding Over Obstacles WARNING 3WARNING Improperly operating over obstacles could ca...

Page 117: ...lt in emissions control system malfunction Have your ATV dealer inspect the oxygen sensor immediately after water enters the muffler Riding Through Water WARNING 3WARNING The ATV tires have some abili...

Page 118: ...or air cleaner wet as this would cause the engine to stop 5 After leaving the water always test both the front and rear brakes Riding through water can make the brakes less effective than normal and m...

Page 119: ...applying the parking brake When using the parking brake be sure to turn the ignition switch to OFF w to avoid discharging the battery Parking on a Steep Incline or a Loose or Slippery Surface If you...

Page 120: ...Basic Operation Riding 110 20 TRX520FE2 31HR48600 book 110...

Page 121: ...ection Agency EPA the California Air Resources Board CARB and Environment Climate Change Canada ECCC see page 246 USA only Maintenance replacement or repair of the emission control devices and systems...

Page 122: ...Rear Final Gear Oil 142 Front Final Gear Oil 145 Coolant 147 Air Cleaner 155 Engine Throttle 161 Clutch System 163 Spark Plug 164 Valves 167 Spark Arrester 168 Chassis Suspension 169 Brakes 172 Tires...

Page 123: ...enance Schedule The service intervals in this schedule are based on average riding conditions Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine r...

Page 124: ...led only by a Honda technician or other qualified mechanic Instructions are included in this manual only to assist in emergency service Some of the most important safety precautions follow However we...

Page 125: ...ake sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around gasoline Use only non flammable solvent not gasoline to clean parts Keep...

Page 126: ...ormed with basic mechanical skills and hand tools Procedures for these items are provided in this manual Other items involve more extensive procedures and may require special training tools and equipm...

Page 127: ...y of Maintenance Schedule Notes Procedures NOTES 1 Service more frequently when riding in dusty areas sand or snow 2 Service more frequently after riding in very wet or muddy conditions 3 Replace ever...

Page 128: ...age MAINT MAINT INTERVAL mi 100 600 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 FUEL LINE I THROTTLE OPERATION I 161 AIR CLEANER NOTE 1 C C 155 AIR CLEANER HOUSING DRAIN TUBE NOTE 2...

Page 129: ...MAINT MAINT INTERVAL mi 100 600 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 DRIVETRAIN BOOTS I I 192 FRONT REAR FINAL GEAR OIL R EVERY 2 YEARS I 142 145 BRAKE FLUID NOTE 3 I I 172...

Page 130: ...ce including the 100 mile 150 km or 1 month or 20 hours initial maintenance is considered a normal owner operating cost and will be charged for by your dealer Use the space under Notes to record anyth...

Page 131: ...onda 121 Service Preparations Maintenance Component Locations front brake fluid reservoir front brake lever parking brake lock lever rear brake lever parking brake lever throttle lever 20 TRX520FE2 31...

Page 132: ...brake caliper coolant 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 c...

Page 133: ...uspension 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 ma...

Page 134: ...page 127 After using 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 depart...

Page 135: ...s manual air pressure gauge 4 40 A spare fuse 5 and fuse puller 6 should be stored in the plastic document bag and fastened with the rubber band 7 To remove the rear fender cover see page 127 Be caref...

Page 136: ...ir pressure gauge gear change tool tool kit fuse puller and 40 A spare fuse 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...

Page 137: ...tool tool kit 40 A spare fuse and fuse puller Removal 1 Remove the seat page 126 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 di...

Page 138: ...intenance Removal 1 Remove the seat page 126 2 Carefully remove the right studs 1 and left studs from the grommets 3 Remove the tank cover assembly 2 by releasing the right tabs 3 and left tabs from t...

Page 139: ...emoval Removal 1 Pull up the center pin to release the lock 2 Pull out the clip of the hole Installation 1 Insert the clip into the hole 2 Press down the center pin securely to lock the clip 1 2 1 2 2...

Page 140: ...use of oxygenated 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 w...

Page 141: ...city 1 29 US gal 4 9 When there is only one segment left in the fuel gauge page 24 fuel will be low and you should refuel as soon as possible Refer to Safety Precautions on page 115 Fuel Capacity Refu...

Page 142: ...clockwise until it clicks If you replace the fuel fill cap use a Honda Genuine replacement part or equivalent NOTICE Gasoline can damage the camouflage coating Do not allow spilled gasoline to pool o...

Page 143: ...best oil wears out Changing oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause s...

Page 144: ...ls displaying a circular API energy conserving or resource conserving service label on the container They may affect lubrication and clutch performance Do not use non detergent vegetable or castor bas...

Page 145: ...within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is lab...

Page 146: ...your ATV on a firm level surface 2 Start the engine in a well ventilated area and let it idle for 3 5 minutes If the air temperature is below 10 C 50 F let the engine idle for an additional 5 minutes...

Page 147: ...d the lower level mark 6 on the oil fill cap dipstick 7 If the oil level is near or below the lower level mark then add the specified oil into the fill cap hole up to the upper level mark on the oil f...

Page 148: ...e damage This procedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid page 212 If you do not have the skills or the too...

Page 149: ...a 139 Engine Oil 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 20 TRX520FE2...

Page 150: ...ver 4 Reposition the spring 7 to the crankcase cover and install a new oil filter with the rubber seal 8 facing out away from the engine You will see the OUT SIDE TOWARDS FILTER COVER mark 9 on the fi...

Page 151: ...her and tighten it to the specified torque 18 lbf ft 25 N m 2 5 kgf m 2 Fill the crankcase with the recommended grade oil approximately 3 2 US qt 3 0 3 Reinstall the oil fill cap dipstick 4 Start the...

Page 152: ...e 115 Change the oil with the rear final gear at normal operating temperature to assure complete and rapid draining Oil Recommendation type hypoid gear oil viscosity weight SAE 80W 90 suggested oil Ho...

Page 153: ...t 1 3 Remove the 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 torqu...

Page 154: ...il until oil starts 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...

Page 155: ...e 115 Change the oil with the front final gear at normal operating temperature to assure complete and rapid draining Oil Recommendation type hypoid gear oil viscosity weight SAE 80W 90 suggested oil H...

Page 156: ...d oil into a suitable 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 reco...

Page 157: ...ifreeze container label Use only distilled water as a part of the coolant solution Water that is high in mineral content or salt may be harmful to the aluminum engine NOTICE Using coolant with silicat...

Page 158: ...ecautions on page 115 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 c...

Page 159: ...to the reserve tank Do not attempt to add coolant by removing the radiator cap 5 Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark 6 After adding coolant r...

Page 160: ...rvice Manual page 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...

Page 161: ...or any obstruction with low water pressure Have the radiator checked by your dealer if the air flow is restricted over more than 20 of the radiator surface Clean the radiator core after riding the ATV...

Page 162: ...the radiator cap lid page 149 2 Remove the reserve tank 1 by removing the bolt 2 and clips 3 page 129 3 Release the hoses 4 from the guides 4 Hold the reserve tank being careful not to spill the coola...

Page 163: ...he clips 6 Remove the left radiator grill cover 5 by releasing the tab A 6 tab B 7 tab C 8 hook A 9 and hook B 10 9 3 clips 8 tab C 5 left radiator grill cover 6 tab A 7 tab B 9 hook A 10 hook B LEFT...

Page 164: ...r core 12 and radiator grill covers NOTICE Do not apply pressured water directly to the radiator core The pressured water can damage the radiator core 9 Install the removed parts in reverse order of r...

Page 165: ...mine the correct service interval for your riding conditions Your ATV s air cleaner has very specific performance requirements Use a new Honda Genuine air cleaner specified for your model or an air cl...

Page 166: ...da 156 Air Cleaner 1 Remove the seat page 126 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 20 TRX520FE2...

Page 167: ...n the foam or seams of the air cleaner Replace the air cleaner if it is damaged 9 Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not fully absorb the oil 10 Pour cl...

Page 168: ...r cleaner assembly into the air cleaner housing 14 Fasten the screw 15 Reassemble by reversing the disassembly sequence Install the air cleaner housing cover with the FRONT mark 8 facing forward and f...

Page 169: ...ur Honda 159 Air Cleaner Do not push the dust cover 1 too far into the breather joint 2 If the dust cover is dirty clean it Dust Cover UNDER SEAT 1 2 1 dust cover 2 breather joint 20 TRX520FE2 31HR486...

Page 170: ...nt inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle 1 Remove the drain tube 1 by removing the clip 2 under the air cleaner housing 3 2 Drain th...

Page 171: ...en the lock nut 4 3 Turn the adjuster to obtain the correct freeplay 4 Tighten the lock nut and reinstall the sleeve 5 After adjustment check for smooth operation of the throttle lever from fully clos...

Page 172: ...all steering positions If there is a problem see your dealer 3 Inspect the condition of the throttle cable from the throttle lever down to the throttle body If the cable is kinked or chafed have it re...

Page 173: ...lutch adjuster 2 counterclockwise until you feel slight resistance 5 Turn the adjuster 1 4 turn clockwise then tighten the lock nut to hold the adjuster in this position 6 After adjustment start the e...

Page 174: ...age 126 and tank cover assembly page 128 2 Clean any dirt from around the spark plug base 3 Disconnect the spark plug cap 1 Take care to avoid damaging the spark plug wire when disconnecting the cap 4...

Page 175: ...tip and sharp edges and the side electrode 3 should not be eroded If the electrodes and insulator tip appear unusually fouled or burned we suggest that you contact your dealer 6 Discard the spark plug...

Page 176: ...the plug b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose the piston may be damaged I...

Page 177: ...of power and possibly damage the valves For those who are mechanically proficient and have the proper tools instructions on adjusting valve clearances are given in the official Honda Service Manual O...

Page 178: ...eaching the environment The use of safety glasses is recommended for this procedure Because of the possible fire hazard check that there are no combustible materials in the area before purging the spa...

Page 179: ...oad by adding or subtracting cargo accessories or when riding conditions change The way you ride your ATV and the type of ride you want to experience can also influence your suspension needs Lower spr...

Page 180: ...spring pre load adjuster 1 has 5 positions for different load or riding conditions Use the pin spanner 2 to adjust the shock spring pre load Suspension Spring Pre Load 1 FRONT REAR 2 1 2 1 2 3 4 5 1 2...

Page 181: ...V is more heavily 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 s...

Page 182: ...normal range while riding check the brake pads for wear page 175 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...

Page 183: ...e your dealer check 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...

Page 184: ...he brake pads for wear page 175 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 cra...

Page 185: ...ly during all regular service intervals to determine the pad wear Check the wear indicator 1 If the wear indicator aligns with the edge of the reference mark 2 both pads must be replaced see your deal...

Page 186: ...moves before the 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...

Page 187: ...he 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 pedal Push the brake arm 4 then check the clearance between the bra...

Page 188: ...before the brake 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 Freepla...

Page 189: ...on the brake operating rod at the rear of the frame Make sure the cutout on the adjusting nut is properly seated on the brake arm pin 3 2 Adjust the freeplay of the rear brake lever parking brake lev...

Page 190: ...brake wear indicator that 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 th...

Page 191: ...1 at the right side 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 o...

Page 192: ...washer 2 from the 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...

Page 193: ...punctures Always select your riding area with care The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recomm...

Page 194: ...ng comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tires make your ATV ride harshly are more prone to damag...

Page 195: ...w miles the readings will be higher If you let air out of warm tires to match the recommended cold tire pressures the tires will be underinflated Be sure to check tire pressure at the riding site sinc...

Page 196: ...res you should also look for Bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Cuts slits or cracks in the tires Replace the tire if you can see fabric or...

Page 197: ...ire tread measure the groove depth 1 in the center of the tire or check the wear indicator 2 For best performance you should replace a tire before the tread depth at the center reaches the following l...

Page 198: ...the tire replaced 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 m...

Page 199: ...replace just one tire The recommended tires for your ATV are When you replace a tire remember Have the tire replaced by your dealer if possible If you have a tire professionally replaced at a non Hond...

Page 200: ...2 protects the rear 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 c...

Page 201: ...ds 1 and front driveshaft 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 G...

Page 202: ...ions on page 115 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 propelle...

Page 203: ...Boots Refer to Safety Precautions on page 115 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 boo...

Page 204: ...arge If you have electrical accessories on your ATV or do not ride frequently we recommend that you charge the battery frequently see Battery Charging page 198 If you do not expect to ride your ATV fo...

Page 205: ...e results from removing the battery and slow charging it every 30 days see Battery Charging page 198 Before you remove the battery be sure to read all the information that follows as well as the infor...

Page 206: ...er cover page 127 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...

Page 207: ...nce every 30 days Installation 1 Check that the battery rubber 6 for damage If necessary replace the battery rubber 2 Make sure the battery rubber is properly installed 3 Reinstall the battery in the...

Page 208: ...ecifically for your Honda which can be purchased from your dealer These units can be left connected for long periods without risking damage to the battery However do not intentionally leave the charge...

Page 209: ...V is still warm from recent operation give the engine and exhaust system time to cool off Park in a shady area Washing your ATV in bright sunlight may cause the finish to fade because water droplets i...

Page 210: ...ith plenty of clean water to remove any residue Detergent residue can corrode alloy parts 6 Dry your ATV with a chamois or a soft towel Leaving water on the surface to air dry can cause dulling and wa...

Page 211: ...int chrome glass and clear plastic Light road grimes Spray any difficult to reach or very dirty areas with a spray cleaner degreaser Rinse and dry Apply a spray cleaner polish and wipe with a non abra...

Page 212: ...r ATV s color code 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...

Page 213: ...ur Honda and how 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 Hond...

Page 214: ...ad magazines are good sources of information Along with your ATV and riding gear you should take along some tools and supplies in case you have a problem For some of the difficulties you might encount...

Page 215: ...your base camp or help and how experienced you or your companions are in making repairs If you decide to take some tools spare parts or other supplies on the trail be sure you can carry them safely an...

Page 216: ...t your ATV we recommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking gasoli...

Page 217: ...m your dealer Ordinary rope is not recommended because it can stretch under load Using tie down straps in any other areas can damage your ATV 3 Rock the vehicle back and forth to make sure the tie dow...

Page 218: ...epairs won t be forgotten and it will be easier to get your ATV running again For more information about storage refer to the Honda Winter Storage Guide available from your dealer USA only We suggest...

Page 219: ...r perform the following Remove the spark plug cap from the spark plug page 164 Remove the spark plug Do not connect the spark plug to the spark plug cap Pour a tablespoon 15 20 cc of clean engine oil...

Page 220: ...over your ATV with a porous material Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate NOTICE Do not store your ATV in an u...

Page 221: ...n four months change the engine oil page 138 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 198 as required Install the...

Page 222: ...may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s protectiv...

Page 223: ...s Take time to read 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 Funct...

Page 224: ...riding you could cause more damage and endanger your own safety After stopping take time to assess the situation Carefully inspect your ATV to identify the problem then consider your options before y...

Page 225: ...the situation and your options before deciding what to do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have permanent repairs mad...

Page 226: ...rting the engine or experience poor engine performance the following information may help you If you can t correct the problem see your dealer If your ATV won t start listen as you press the start ove...

Page 227: ...r dead battery Charge the battery page 198 If charging doesn t help see your dealer faulty starter motor If all possible causes are negative the starter motor may be faulty See your dealer SYMPTOM Sta...

Page 228: ...fuel mixture See your dealer sooty exhaust rich fuel mixture See your dealer detonates or pings under load If applicable switch to the recommended octane gasoline page 130 or change your brand of gaso...

Page 229: ...are functioning 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 switc...

Page 230: ...in neutral go to 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 Appl...

Page 231: ...hexagonal hole with 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 tu...

Page 232: ...an installation tool tire cement and an instruction sheet Follow the instructions provided with the repair kit to make a temporary repair As soon as possible have the tire permanently repaired by you...

Page 233: ...V will be hard to handle and if the tire comes off the rim it may lock up the wheel and cause you to crash WARNING 3WARNING Riding your ATV with a temporary tire repair can be risky If the temporary r...

Page 234: ...ear wheels off the ground and place a support block under the vehicle 4 Remove the wheel nuts 5 Remove the wheel Avoid getting grease oil or dirt on the front brake disc or pad surfaces when removing...

Page 235: ...e wheel nuts on the wheel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque 47 lbf ft 64 N m 6 5 kgf m If a torque wrench...

Page 236: ...leak Shut the engine off and wait until the steaming stops Look for a leak but don t touch the engine or radiator system Let everything cool off first Check for any restriction of air flow to the radi...

Page 237: ...necessary add the recommended oil page 136 to the upper level mark If you must leave your ATV to get oil secure it as much as possible Start the engine and check that the coolant temperature gauge and...

Page 238: ...blown fuse 1 Check all the fuses before looking elsewhere for another possible cause of the problem Replace any blown fuses and check component operation The main fuse and the circuit fuses are locate...

Page 239: ...Remove the rear fender cover page 127 4 To access the main fuse 1 2 remove the fuse cover 3 5 To access the main fuse 2 4 remove the fuse box cover 5 6 Pull the main fuse 1 out If the main fuse 1 is...

Page 240: ...clips with fuse puller on the underside of the rear fender cover page 125 If the fuse is blown replace it with a spare fuse 8 of the same rating If you do not have a replacement fuse with the proper...

Page 241: ...he fuse 2 Remove the seat page 126 3 Remove the rear fender cover page 127 4 To access the EPS fuse 1 remove the fuse cover 2 If the EPS fuse is blown see your dealer for this service 5 Install the fu...

Page 242: ...temporarily If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses that were install...

Page 243: ...spect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor dam...

Page 244: ...nd aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer where you purchased your Honda ATV They may have it listed in their records If t...

Page 245: ...t may be started 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 neu...

Page 246: ...what tools and supplies you have with you If any component of the brake system is damaged you may be able to ride carefully back to your base using the other brake components for slowing or stopping...

Page 247: ...contains dimensions 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...

Page 248: ...s You may record these numbers in the Quick Reference section at the rear of this manual The VIN 1 is stamped on the front of the frame Remove the radiator cap lid page 149 The engine number 2 is stam...

Page 249: ...is attached on the left side of the frame The color code is helpful when ordering replacement parts You may record the color and code in the Quick Reference section at the rear of this manual Color La...

Page 250: ...8 US gal 14 7 including reserve fuel tank reserve 1 29 US gal 4 9 engine oil capacity after disassembly 3 5 US qt 3 3 after draining 3 1 US qt 2 9 after draining oil filter change 3 2 US qt 3 0 engine...

Page 251: ...S qt 1 6 Capacities passenger capacity operator only maximum weight capacity 551 lb 250 kg rider all cargo and accessories Engine Specifications displacement 31 6 cu in 518 cm3 bore stroke 3 78 2 81 i...

Page 252: ...ear 3 154 transmission ratio 1st 4 230 2nd 2 388 3rd 1 608 4th 1 178 5th 0 848 reverse 5 743 final drive shaft Chassis Suspension caster 2 trail 0 2 in 5 mm tire size front AT25 8 1211 MAXXIS M975 tir...

Page 253: ...assist headlight 12 V 50 W brake tail light LED neutral indicator LED reverse indicator LED high coolant temperature indicator LED PGM FI indicator LED differential lock indicator LED PS Electric Pow...

Page 254: ...drain bolt 9 lbf ft 12 N m 1 2 kgf m rear final gear oil fill cap 9 lbf ft 12 N m 1 2 kgf m 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...

Page 255: ...our ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts rapid acceleration...

Page 256: ...issions standards during its useful life when operated and maintained according to the instructions provided The Vehicle Emission Control Information Label 1 is attached on the left front of the frame...

Page 257: ...components is recommended The exhaust emission control system is separate from the crankcase emission control system Evaporative Emission Control System USA 50 states meets California An evaporative e...

Page 258: ...and poor fuel economy Federal regulations prohibit removing or disabling a device or element of design that may affect your engine s emission performance unless your ATV will be used exclusively in c...

Page 259: ...OLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part of the intake system Lack of proper mai...

Page 260: ...this information to be posted on the pump The following are the EPA approved percentages of oxygenates for non road vehicles ETHANOL ethyl or grain alcohol up to 10 by volume You may use gasoline con...

Page 261: ...your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use o...

Page 262: ...Technical Information 252 20 TRX520FE2 31HR48600 book 252...

Page 263: ...r Information This 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...

Page 264: ...l can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician but most mechanically capable owners should find the...

Page 265: ...website at www honda ca It is important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage does not apply to normal wear or deterioration...

Page 266: ...of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the repair it is best t...

Page 267: ...If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance...

Page 268: ...es and products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available fro...

Page 269: ...Consumer Information 259 20 TRX520FE2 31HR48600 book 259...

Page 270: ...appearance care 199 authorized manuals 254 B bank angle sensor ignition cut off system 85 battery 194 brake light switch adjustment 181 brakes cables 180 draining water from 182 fluid 172 front brake...

Page 271: ...e care 199 climbing hills 99 clip 129 clutch system 163 color label 239 compartment owner s manual 125 tool kit 124 component fails 236 consumer information 253 controls features 34 coolant temperatur...

Page 272: ...90 number 238 oil 133 pinging 130 starting 82 stop switch 40 stopping 87 won t start 216 environment 212 exhaust system cleaning 66 purging 168 F final gear oil front 145 rear 142 flag pole bracket 49...

Page 273: ...apacity 131 fuses 228 G gap spark plug 164 241 gasohol 250 gasoline 130 gear shifting 89 gearshift switch 44 guards 190 H headlight dimmer switch 41 headlight switch 41 high coolant temperature indica...

Page 274: ...on indicator 18 23 high coolant temperature indicator 14 17 226 maintenance minder indicator 20 31 neutral indicator 14 17 PGM FI indicator 14 17 PS Electric Power Steering indicator 14 17 reverse ind...

Page 275: ...er 31 importance 113 minder indicator 20 31 precautions 115 record 120 safety 114 schedule 116 tripmeter 31 manual service 254 maximum weight limit 70 modifications 73 multi function display 20 N neut...

Page 276: ...ent no riding on 77 pinging engine 130 plug spark 164 pre ride inspection 65 problems unexpected 214 propeller shaft boots yoke joint boot 192 protective apparel 60 EPS Electric Power Steering 57 R re...

Page 277: ...6 precautions 77 preparing for 204 safety 2 safety precautions 77 through water 107 S safety important precautions 115 labels 5 riding precautions 77 schedule maintenance 116 seat removal 126 serial n...

Page 278: ...override button 39 starting engine 82 troubleshooting 216 stop switch engine 40 stopping engine 87 storage ATV 208 owner s manual 125 suspension adjustment 169 spring pre load 170 switch 4WD 35 diffe...

Page 279: ...iler towing operational guidelines 71 weight limits 70 training rider 62 transporting your ATV 206 tripmeter 27 trouble unexpected 213 troubleshooting starting 216 turning on hills or slopes 104 on le...

Page 280: ...Index W warning labels 5 warranty coverage 255 extended 255 service 256 washing your ATV 200 water draining from brakes 182 riding through 107 weight limit 70 wheel removal 224 20 TRX520FE2 31HR48600...

Page 281: ...can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly repairs are Engin...

Page 282: ...Quick Reference Quick Reference Engine No VIN Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 20 TRX520FE2 31HR48600 book 277...

Page 283: ...s throttle brakes switches steering Fuel Capacity unleaded gasoline pump octane number 86 or higher 3 88 US gal 14 7 reserve 1 29 US gal 4 9 Engine Oil Capacity API Service Classification SG or higher...

Page 284: ...Rear 4 4 psi 30 kPa Spark Plugs standard BKR5E 11 NGK or K16PR U11 DENSO Coolant ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Honda HP Coolant or an equival...

Page 285: ...rential lock indicator lights when the front differential lock mode engages 36 start override button 39 e RUN engine stop switch 40 r OFF engine stop switch 40 y ON headlight switch 41 t OFF headlight...

Page 286: ...d which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary servic...

Page 287: ...PRINTED IN USA WPCXXXX 2019 XX L 00X31 HR4 8600 31HR4860...

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