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Honda FourTrax Foreman TRX520FM1 2020, Owner'S Manual, Page: 127 / 283

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Honda FourTrax Foreman TRX520FM1 2020 Owner'S Manual Download Page 127

Servicing Your Honda

117

Service Preparations

Maintenance Component

Locations

front brake lever

P/R lever

rear brake lever/
parking brake lever

throttle lever

front brake fluid reservoir

reverse 
assist lever

20 TRX520FM1 FM2-31HR46600.book  117 ページ  ２０１９年４月２５日　木曜日　午後６時２分

Summary of Contents for FourTrax Foreman TRX520FM1 2020

Page 1: ...REMAN 2020 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...

Page 2: ...ll illustrations are based on the TRX520FM2 model This publication includes the latest production information available before printing Honda Motor Co Ltd reserves the right to make changes at any tim...

Page 3: ...n 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 It conf...

Page 4: ...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 det...

Page 5: ...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 You...

Page 6: ...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 operati...

Page 7: ...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 t...

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

Page 9: ...ATV and how to be an environmentally responsible rider Taking Care of the Unexpected 211 What to do if you have a flat tire your engine won t start etc Technical Information 233 ID numbers technical...

Page 10: ...20 TRX520FM1 FM2 31HR46600 book 9...

Page 11: ...nt 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 ATV...

Page 12: ...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 numbe...

Page 13: ...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 ap...

Page 14: ...g 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 dr...

Page 15: ...ortant 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 or...

Page 16: ...lance 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 seriousl...

Page 17: ...ssure Maximum weight capacity 551lbs 250kg Front 4 4psi 30kPa Rear 4 4psi 30kPa Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to...

Page 18: ...hicle 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 NEVE...

Page 19: ...structions 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 an...

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

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

Page 22: ...nstruments Controls 12 Operation Component Locations rear cargo rack front cargo rack rear brake pedal recoil starter Canada only flag pole bracket front utility box 20 TRX520FM1 FM2 31HR46600 book 12...

Page 23: ...Instruments Controls 13 Operation Component Locations trailer hitch shift lever storage compartment accessory socket side utility box utility pocket 20 TRX520FM1 FM2 31HR46600 book 13...

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

Page 25: ...on 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...

Page 26: ...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 neut...

Page 27: ...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 indica...

Page 28: ...intenance 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 ac...

Page 29: ...he 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 mainten...

Page 30: ...t 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 i...

Page 31: ...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 w...

Page 32: ...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 mo...

Page 33: ...r 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 position...

Page 34: ...ess 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 re...

Page 35: ...s 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 gau...

Page 36: ...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 more...

Page 37: ...ter 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 tripmete...

Page 38: ...witch 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 C...

Page 39: ...stop the engine and check the reserve tank coolant level Read pages 221 222 and do not ride the ATV until the problem has been corrected NOTICE Continuing to ride with an overheated engine can cause s...

Page 40: ...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 exc...

Page 41: ...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 th...

Page 42: ...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 M...

Page 43: ...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 ca...

Page 44: ...urn 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 circu...

Page 45: ...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 appear...

Page 46: ...d 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 hold...

Page 47: ...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 t...

Page 48: ...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 mode...

Page 49: ...tton 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 sp...

Page 50: ...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 b...

Page 51: ...etween 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 bea...

Page 52: ...rols Features The recoil starter 1 is used to start the engine when the battery is low See Using the Recoil Starter Canada only page 86 Recoil Starter Canada only RIGHT SIDE 1 recoil starter 1 20 TRX5...

Page 53: ...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 T...

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

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

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

Page 57: ...able 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 Flag...

Page 58: ...tch 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 opera...

Page 59: ...hone 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 start...

Page 60: ...ay 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 223 When you are done using an access...

Page 61: ...ush 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 no...

Page 62: ...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 sto...

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

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

Page 65: ...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 turned on a...

Page 66: ...Instruments Controls 56 20 TRX520FM1 FM2 31HR46600 book 56...

Page 67: ...ents to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride 58 Protective Apparel 58 Rider Training 60 Age Recommendation 6...

Page 68: ...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 s...

Page 69: ...le 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 should...

Page 70: ...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 bookl...

Page 71: ...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 death...

Page 72: ...ating 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 serious...

Page 73: ...pected 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 a...

Page 74: ...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 vegeta...

Page 75: ...Check that all 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...

Page 76: ...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 t...

Page 77: ...odifications 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 l...

Page 78: ...e 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 25...

Page 79: ...t 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 t...

Page 80: ...nd 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 s...

Page 81: ...ndling 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 comp...

Page 82: ...Before Riding 72 20 TRX520FM1 FM2 31HR46600 book 72...

Page 83: ...mance and service life refer to Break in Guidelines page 241 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...

Page 84: ...raking 91 Riding Your ATV 93 Making Turns 93 Skidding or Sliding 95 Riding Up Hills 96 Riding Down Hills 100 Crossing or Turning on Hills or Slopes 101 Riding Over Obstacles 103 Riding Through Water 1...

Page 85: ...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 local...

Page 86: ...m 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 str...

Page 87: ...rain 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...

Page 88: ...uctions 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 result...

Page 89: ...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 slipper...

Page 90: ...noxide 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 a...

Page 91: ...page 45 2 Turn the ignition switch 1 to ON q Confirm the following The transmission is in neutral the neutral indicator 2 is ON and the gear position indicator shows N The engine stop switch 3 is set...

Page 92: ...ture 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 Snapping...

Page 93: ...dure 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 Y...

Page 94: ...ressing 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 fuel...

Page 95: ...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 batt...

Page 96: ...hen 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 tha...

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

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

Page 99: ...the reverse assist lever 2 4 While continuing to hold the P R lever squeeze the rear brake lever parking brake lever 3 then depress the shift lever once to shift into R reverse gear WARNING 3WARNING...

Page 100: ...not open the throttle suddenly or make abrupt turns 8 To stop close the throttle and gradually apply both the front and rear brakes Do not abruptly apply the rear brake by alone 9 To shift out of rev...

Page 101: ...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 ATV...

Page 102: ...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 overheat...

Page 103: ...ar 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 collisi...

Page 104: ...t 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 steeri...

Page 105: ...ring 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 w...

Page 106: ...t 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 forw...

Page 107: ...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 go...

Page 108: ...ing 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 caref...

Page 109: ...k 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 p...

Page 110: ...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 caus...

Page 111: ...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 attem...

Page 112: ...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 Compar...

Page 113: ...educe 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 caus...

Page 114: ...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 ability...

Page 115: ...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 may...

Page 116: ...pplying 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 mu...

Page 117: ...l Protection Agency EPA the California Air Resources Board CARB and Environment Climate Change Canada ECCC see page 242 USA only Maintenance replacement or repair of the emission control devices and s...

Page 118: ...al Gear Oil 138 Front Final Gear Oil 141 Coolant 143 Air Cleaner 151 Engine Throttle 157 Clutch System 159 Reverse Inhibitor System 160 Spark Plug 161 Valves 164 Spark Arrester 165 Chassis Suspension...

Page 119: ...ance 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 rep...

Page 120: ...d 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 ca...

Page 121: ...e 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 c...

Page 122: ...med 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 equipmen...

Page 123: ...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 every...

Page 124: ...e 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 157 AIR CLEANER NOTE 1 C C 151 AIR CLEANER HOUSING DRAIN TUBE NOTE 2 I...

Page 125: ...00 600 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 DRIVETRAIN BOOTS I I 189 FRONT REAR FINAL GEAR OIL R EVERY 2 YEARS I 138 141 BRAKE FLUID NOTE 3 I I 169 BRAKE SHOES WEAR NOTE 1 2...

Page 126: ...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 anythin...

Page 127: ...117 Service Preparations Maintenance Component Locations front brake lever P R lever rear brake lever parking brake lever throttle lever front brake fluid reservoir reverse assist lever 20 TRX520FM1 F...

Page 128: ...aliper coolant reserve tank battery fuse box main fuse 1 main fuse 2 EPS fuse TRX520FM2 rear brake pedal air cleaner housing drain tube rear brake light switch front final gear oil fill cap front fina...

Page 129: ...are fuse fuse puller tool kit spark arrester rear suspension spring pre load adjuster spark plug engine oil fill cap dipstick engine oil drain bolt rear brake panel clutch adjuster rear final gear oil...

Page 130: ...r cover page 123 After using the tools be sure to use the rubber band 2 to fasten the tool kit securely An optional larger tool kit may be available Check with your dealer s parts department UNDER REA...

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

Page 132: ...nual air pressure gauge 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 prongs 3 in...

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

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

Page 135: ...oval 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 20...

Page 136: ...e of oxygenated fuels see page 246 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 whi...

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

Page 138: ...lockwise 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 on...

Page 139: ...est 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 ser...

Page 140: ...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 based...

Page 141: ...thin 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 label...

Page 142: ...ur 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 a...

Page 143: ...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 fil...

Page 144: ...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 210 If you do not have the skills or the tools...

Page 145: ...Engine Oil Filter cont d 2 Place an oil drain pan under the crankcase and remove the engine oil drain bolt 1 and sealing washer 2 UNDER ENGINE 2 1 engine oil drain bolt 1 2 sealing washer 20 TRX520FM...

Page 146: ...r 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 filt...

Page 147: ...r 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 en...

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

Page 149: ...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 torque...

Page 150: ...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 i...

Page 151: ...111 Change the oil with the front final gear at normal operating temperature to assure complete and rapid draining Oil Recommendation type hypoid gear oil viscosity weight SAE 80W 90 suggested oil Hon...

Page 152: ...oil into a suitable container and dispose of it in an approved manner page 210 NOTICE Improper disposal of drained fluids is harmful to the environment 6 Fill the front final gear case with the recomm...

Page 153: ...reeze 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 silicate...

Page 154: ...autions on page 111 Check the engine coolant level each day before operating your ATV and add if needed 1 Make sure the vehicle is on level ground 2 With the engine at normal operating temperature che...

Page 155: ...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 rei...

Page 156: ...ice Manual page 250 To properly dispose of drained coolant refer to You the Environment page 210 NOTICE Improper disposal of drained fluids is harmful to the environment Coolant Replacement WARNING 3W...

Page 157: ...y 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 in m...

Page 158: ...e radiator cap lid page 145 2 Remove the reserve tank 1 by removing the bolt 2 and clips 3 page 125 3 Release the hoses 4 from the guides 4 Hold the reserve tank being careful not to spill the coolant...

Page 159: ...right radiator grill cover 11 by releasing the tab A tab B tab C hook A hook B and hose 12 then remove the center radiator grill cover 13 9 3 clips 8 tab C 5 left radiator grill cover 6 tab A 7 tab B...

Page 160: ...or core 14 and radiator grill covers NOTICE Do not apply pressured water directly to the radiator core The pressured water can damage the radiator core 10 Install the removed parts in reverse order of...

Page 161: ...ne 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 clea...

Page 162: ...152 Air Cleaner 1 Remove the seat page 122 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 TRX520FM1 FM...

Page 163: ...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 clea...

Page 164: ...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 fit...

Page 165: ...Honda 155 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 TRX520FM1 FM2 31HR4...

Page 166: ...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 the...

Page 167: ...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 closed...

Page 168: ...l 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 repl...

Page 169: ...tch 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 eng...

Page 170: ...and turn the adjusting nut 5 to obtain the correct freeplay After adjustment tighten the lock nut securely 4 Return the dust cover and rubber sleeve Other Checks Check the reverse assist lever and cab...

Page 171: ...page 122 and tank cover assembly page 124 2 Clean any dirt from around the spark plug base 3 Disconnect the spark plug cap 1 Take care to avoid damaging the spark plug wire when disconnecting the cap...

Page 172: ...d 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 if th...

Page 173: ...e 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 If...

Page 174: ...f 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 Oth...

Page 175: ...ching 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 spark...

Page 176: ...d 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 sprin...

Page 177: ...ring pre load adjuster 1 has 5 positions for different load or riding conditions Use the pin spanner 2 to adjust the shock spring pre load Suspension Spring Pre Load 1 FRONT REAR 1 2 5 4 3 2 1 1 sprin...

Page 178: ...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 seq...

Page 179: ...ormal range while riding check the brake pads for wear page 172 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 de...

Page 180: ...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 i...

Page 181: ...brake pads for wear page 172 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 crack...

Page 182: ...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 dealer...

Page 183: ...ves 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 1...

Page 184: ...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 brake...

Page 185: ...efore 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 Freeplay...

Page 186: ...n 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 lever...

Page 187: ...r 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 the brake c...

Page 188: ...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 ope...

Page 189: ...asher 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 an...

Page 190: ...nctures 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 recommen...

Page 191: ...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 damage...

Page 192: ...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 since...

Page 193: ...s 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 co...

Page 194: ...e 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 lim...

Page 195: ...he tire replaced or permanently repaired as soon as possible For more information on temporary repairs see If You Have a Flat Tire page 217 A permanent repair such as an internal plug patch can be mad...

Page 196: ...place 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 Honda...

Page 197: ...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 cra...

Page 198: ...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 Gua...

Page 199: ...ns on page 111 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...

Page 200: ...oots Refer to Safety Precautions on page 111 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...

Page 201: ...ge 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 195 If you do not expect to ride your ATV for...

Page 202: ...results from removing the battery and slow charging it every 30 days see Battery Charging page 195 Before you remove the battery be sure to read all the information that follows as well as the informa...

Page 203: ...der cover page 123 4 Release the rings and remove the rubber band 1 5 Disconnect the negative terminal lead 2 from the battery 3 first then disconnect the positive terminal lead 4 6 Remove the battery...

Page 204: ...ery 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 revers...

Page 205: ...ifically 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 charger...

Page 206: ...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 int...

Page 207: ...h 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 wate...

Page 208: ...t 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 abrasi...

Page 209: ...ATV s color code page 235 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 to...

Page 210: ...Servicing Your Honda 200 20 TRX520FM1 FM2 31HR46600 book 200...

Page 211: ...Honda and how to be an environmentally responsible ATV owner Preparing for a Ride 202 What to Take to the Riding Area 202 What to Take on the Trail 203 Transporting Your Honda 204 Storing Your Honda...

Page 212: ...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 encounter...

Page 213: ...ur 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 and...

Page 214: ...end 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...

Page 215: ...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 down...

Page 216: ...airs 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 yo...

Page 217: ...perform the following Remove the spark plug cap from the spark plug page 161 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 in...

Page 218: ...er 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 upr...

Page 219: ...four months change the engine oil page 134 3 If your ATV has been stored for more than two months ask your dealer to drain and replace the fuel 4 Charge the battery page 195 as required Install the ba...

Page 220: ...ay 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 protective...

Page 221: ...you deal with a wide range of problems Take time to read this section before you ride Also review the tips in Preparing for a Ride page 202 General Guidelines 212 If Your Engine Quits or Won t Start...

Page 222: ...iding 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 you...

Page 223: ...e 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 made...

Page 224: ...ing 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 overr...

Page 225: ...dead battery Charge the battery page 195 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 Start...

Page 226: ...el mixture See your dealer sooty exhaust rich fuel mixture See your dealer detonates or pings under load If applicable switch to the recommended octane gasoline page 126 or change your brand of gasoli...

Page 227: ...n 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 your...

Page 228: ...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 rep...

Page 229: ...r 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 an...

Page 230: ...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 w...

Page 231: ...ak 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 radiat...

Page 232: ...cessary add the recommended oil page 132 to the upper level mark If you must leave your ATV to get oil secure it as much as possible Start the engine and check that the coolant temperature gauge and h...

Page 233: ...e 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 located under t...

Page 234: ...ve the rear fender cover page 123 4 To access the main fuse 1 2 remove the fuse cover 3 5 To access the main fuse 2 4 remove the fuse box cover 5 6 Pull the main fuse 1 out If the main fuse 1 is blown...

Page 235: ...lips with fuse puller on the underside of the rear fender cover page 121 If the fuse is blown replace it with a spare fuse 8 of the same rating If you do not have a replacement fuse with the proper ra...

Page 236: ...g the fuse 2 Remove the seat page 122 3 Remove the rear fender cover page 123 4 To access the EPS fuse 1 remove the fuse cover 2 If the EPS fuse is blown see your dealer for this service 5 Install the...

Page 237: ...mporarily 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 installed...

Page 238: ...ect 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 damag...

Page 239: ...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 the...

Page 240: ...recommended If you can t charge the battery or it appears unable to hold a charge contact your dealer Canada only Your ATV will operate even if the battery is low or dead as long as the engine is run...

Page 241: ...hat 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 If...

Page 242: ...Taking Care of the Unexpected 232 20 TRX520FM1 FM2 31HR46600 book 232...

Page 243: ...ontains dimensions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 234 Specifications 236 Break in Guidelines 241 Em...

Page 244: ...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 145 The engine number 2 is stampe...

Page 245: ...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 Labe...

Page 246: ...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 o...

Page 247: ...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 in...

Page 248: ...r 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 tire...

Page 249: ...adlight 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 Power Steerin...

Page 250: ...ain 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 m...

Page 251: ...r 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 a...

Page 252: ...sions 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 C...

Page 253: ...mponents 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 emi...

Page 254: ...nd 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 com...

Page 255: ...LOWING 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 maint...

Page 256: ...his 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 conta...

Page 257: ...ur 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 of...

Page 258: ...Technical Information 248 20 TRX520FM1 FM2 31HR46600 book 248...

Page 259: ...Information This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 250 Warranty Coverage 251 Warranty Service 252 Contacting Honda 253 Yo...

Page 260: ...elp you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician but most mechanically capable owners should find them easy...

Page 261: ...bsite 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 as...

Page 262: ...f 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 to...

Page 263: ...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 CA...

Page 264: ...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 from...

Page 265: ...Consumer Information 255 20 TRX520FM1 FM2 31HR46600 book 255...

Page 266: ...e 58 appearance care 196 authorized manuals 250 B bank angle sensor ignition cut off system 83 battery 191 brake light switch adjustment 178 brakes cables 177 draining water from 179 fluid 169 front b...

Page 267: ...care 196 climbing hills 96 clip 125 clutch system 159 color label 235 compartment owner s manual 121 tool kit 120 component fails 231 consumer information 249 controls features 34 coolant temperature...

Page 268: ...ting 80 stop switch 40 stopping 85 won t start 214 environment 210 EPS Electric Power Steering TRX520FM2 55 exhaust system cleaning 64 purging 165 F final gear oil front 141 rear 138 flag pole bracket...

Page 269: ...223 G gap spark plug 161 237 gasohol 246 gasoline 126 gear shifting 87 guards 187 H headlight dimmer switch 41 headlight switch 41 high coolant temperature indicator 14 17 221 hills crossing or turnin...

Page 270: ...tenance minder indicator 20 31 neutral indicator 14 17 PGM FI indicator 14 17 PS Electric Power Steering indicator TRX520FM2 14 17 reverse indicator 14 17 inspection pre ride 63 K key lost 229 number...

Page 271: ...al service 250 maximum weight limit 68 modifications 71 multi function display 20 N neutral indicator 14 17 noise emission control system 245 numbers serial 234 O obstacles riding over 103 odometer 27...

Page 272: ...er shaft boots yoke joint boot 189 protective apparel 58 R rear fender cover removal 123 rear final gear oil 138 recoil starter Canada only 42 86 removal rear fender cover 123 seat 122 tank cover asse...

Page 273: ...precautions 111 labels 5 riding precautions 75 schedule maintenance 112 seat removal 122 serial numbers 234 service customer 253 manuals 250 warranty 252 shifting gears 87 side utility box 51 skid pl...

Page 274: ...ge ATV 206 owner s manual 121 suspension adjustment 166 spring pre load 167 switch 4WD 35 differential lock 36 engine stop 40 headlight 41 headlight dimmer 41 ignition 34 T tank cover assembly removal...

Page 275: ...ider 60 transporting your ATV 204 tripmeter 27 trouble unexpected 211 troubleshooting starting 214 turning on hills or slopes 101 on level ground 93 U utility box front utility box 52 side utility box...

Page 276: ...ndex W warning labels 5 warranty coverage 251 extended 251 service 252 washing your ATV 197 water draining from brakes 179 riding through 104 weight limit 68 wheel removal 219 20 TRX520FM1 FM2 31HR466...

Page 277: ...n be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly repairs are Engine...

Page 278: ...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 TRX520FM1 FM2 31HR46600 book 269...

Page 279: ...rakes reverse assist lever switches steering Fuel Capacity unleaded gasoline pump octane number 86 or higher 3 88 US gal 14 7 reserve 1 29 US gal 4 9 Engine Oil Capacity API Service Classification SG...

Page 280: ...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 equivalent...

Page 281: ...36 differential lock indicator lights when the front differential lock mode engages 36 start override button 39 e RUN engine stop switch 40 r OFF engine stop switch 40 y ON headlight switch 41 t OFF...

Page 282: ...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 service...

Page 283: ...PRINTED IN USA WPCXXXX 2019 XX L 00X31 HR4 6600 31HR4660...

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