Honda FOURTRAX RUBICON 2018 Owner'S Manual Download | Manualshive

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Taking Care of the Unexpected

215

Taking Care of the Unexpected

Taking Care of the Unexpected

With all the challenges you can encounter off-road, there’s a chance
that sometime something may go wrong. This section gives practical
advice to help 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 206).

General Guidelines ................................................................... 216
If Your Engine Quits or Won’t Start .......................................... 218
If the Transmission Is Not Functioning Properly ......................... 221
Emergency Gear Selection & Operation .................................... 224
If You Have a Flat Tyre .............................................................. 226
If the High Coolant Temperature Indicator Lights ...................... 229
If a Fuse Blows.......................................................................... 231
If You Crash ............................................................................. 236
If You Lose Your Key ................................................................ 237
If the Battery Is Low (or Dead)................................................... 238
If a Component Fails................................................................. 239

19 TRX500FA6 FA7 (U)-32HR68400.book Page 215 Wednesday, May 16, 2018 10:58 AM

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Summary of Contents for FOURTRAX RUBICON 2018

Page 1: ...TRX500FA6 FA7 FOURTRAX RUBICON...

Page 2: ...mation 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 wit...

Page 3: ...Honda TRX500FA6 4 4 with Power Steering TRX500FA7 4 4 with Power Steering Aluminium Wheel OWNER S MANUAL 19 TRX500FA6 FA7 U 32HR68400 book Page 2 Wednesday May 16 2018 10 58 AM...

Page 4: ...and perform all pre ride and other periodic checks detailed in this manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety information and h...

Page 5: ...any questions or if you ever need special service or repairs remember that your dealer knows your ATV best and is dedicated to your complete satisfaction Happy riding 19 TRX500FA6 FA7 U 32HR68400 book...

Page 6: ...manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a...

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

Page 8: ...ts 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 wearing a helmet and othe...

Page 9: ...intenance and adjustment items Tips 205 How to store and transport your ATV and how to be an environmentally responsible rider Taking Care of the Unexpected 215 What to do if you have a flat tyre your...

Page 10: ...Contents 19 TRX500FA6 FA7 U 32HR68400 book Page 9 Wednesday May 16 2018 10 58 AM...

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

Page 12: ...V model is 16 Children under age 16 should never operate this vehicle Always Wear a Helmet It s a proven fact helmets significantly reduce the number and severity of head injuries So always wear an ap...

Page 13: ...ractice Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice in a safe area until you build your skills and get accustomed to the ATV s size and...

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

Page 15: ...nyone who rides the vehicle should read and understand this information before riding The labels should be considered permanent parts of the vehicle If a label comes off or becomes hard to read contac...

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

Page 17: ...t capacity 573lbs 260kg Front 4 4psi 30kPa Rear 4 4psi 30kPa Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never e...

Page 18: ...rate ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS WITH DRUGS OR ALCOHOL Overloading this ATV or carrying cargo improperly can change han...

Page 19: ...ents are presented in other sections of this manual where they will be most useful Operation Component Locations 11 Indicators Displays 14 Multi function Display 20 Speed and Mileage Unit Changing 22...

Page 20: ...h 42 Headlight Switch 43 Headlight Dimmer Switch 43 Horn Button 43 Recoil Starter 44 Throttle Lever 45 Drive Mode Select Switch 46 Gearshift Switch 47 Front Brake Lever 48 Rear Brake Lever Parking Bra...

Page 21: ...switch headlight switch front brake lever gearshift switches ignition switch differential lock switch 4WD switch throttle lever horn button start over ride button drive mode select switch range select...

Page 22: ...uments Controls 12 Operation Component Locations rear cargo rack recoil starter rear brake pedal flag pole bracket front cargo rack 19 TRX500FA6 FA7 U 32HR68400 book Page 12 Wednesday May 16 2018 10 5...

Page 23: ...Instruments Controls 13 Operation Component Locations utility box accessory socket trailer hitch storage compartment 19 TRX500FA6 FA7 U 32HR68400 book Page 13 Wednesday May 16 2018 10 58 AM...

Page 24: ...r to the indicators frequently Their functions are described on the following pages 1 5 1 neutral indicator 3 8 7 6 4 2 2 reverse indicator 3 differential lock indicator 4 PGM FI indicator 8 mode sele...

Page 25: ...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 indicator comes back on and remains on un...

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

Page 27: ...ights when there is any abnormality in the PGM FI Programmed Fuel Injection system Should also light for a few seconds and then go off when the ignition switch is turned on If the indicator comes on a...

Page 28: ...cified maintenance interval is reached page 33 Speedometer Shows riding speed Fuel gauge Shows approximate fuel supply available page 25 Digital clock Shows the time hours and minutes page 27 Odometer...

Page 29: ...ulti function display Adjusts the digital clock page 27 Changes the speed and mileage units page 22 Resets the tripmeter to zero 0 page 28 This button also used to reset the maintenance tripmeter and...

Page 30: ...h the mode select button 8 Multi function Display 4WD indicator Gear position indicator LOW indicator Speedometer Maintenance minder indicator Fuel gauge Digital clock Odometer Tripmeter Coolant tempe...

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

Page 32: ...e speed and mileage units press and hold the mode select button 1 for more than 5 seconds in the odometer mode page 21 with the ATV stopped The 4WD indicator 1 shows when the 4WD mode engages page 37...

Page 33: ...Displays The LOW indicator 1 will be displayed when low L range is engaged with the ignition switch in the ON q position page 94 LOW Indicator 1 LOW indicator 1 19 TRX500FA6 FA7 U 32HR68400 book Page...

Page 34: ...ly Before riding check that the gear 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 the...

Page 35: ...e display is in when the fuel level reaches 1st segment 3 the display will automatically switch to the fuel gauge display You should refuel as soon as possible The amount of fuel remaining when the fu...

Page 36: ...k blinks you should refuel as soon as possible The amount of fuel reserve is approximately 4 9 1 29 US gal 1 08 Imp gal Fuel gauge failure If the fuel gauge E F 6 is blinking the fuel gauge function h...

Page 37: ...the display will begin advancing fast Press and hold the button for 0 5 5 5 seconds advance one minute at a time 5 5 10 5 seconds advance five minutes at a time 10 5 seconds or more advance ten minute...

Page 38: ...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 read out exceeds 999 9 To reset the tripmeter to zero press th...

Page 39: ...ormal operating temperature range is within the section between the 1st segment 3 and 4th segment 4 When coolant temperature is low the coolant temperature gauge will display Lo 5 Coolant Temperature...

Page 40: ...check the reserve tank coolant level Read pages 229 230 and do not ride the ATV until the problem has been corrected NOTICE Continuing to ride with an overheated engine can cause serious engine damag...

Page 41: ...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 read out exceeds 99 999 9 Hour...

Page 42: ...tenance minder indicator The maintenance tripmeter decreases from 1 000 km 600 miles after reset The maintenance hour meter decreases from 100 hour after reset Initial setting of the maintenance tripm...

Page 43: ...ntenance Appears at 150 km 100 miles or 20 operating hours whichever comes first Regular Maintenance Interval 1 Appears 1 000 km 600 miles or 100 operating hours after the Initial Maintenance or Regul...

Page 44: ...ear then it will blinks twice and the multi function display will temporarily show all the modes and digital segments The indicator message will disappear Reset operation will be cancelled if the mode...

Page 45: ...for the ON q position The ignition switch is also used to reset the maintenance tripmeter maintenance hour meter page 34 Ignition Switch Key Position Function ON q Electrical circuits on OFF w No ele...

Page 46: ...Features The range select lever 1 has two positions Drive D Low L See Shifting Gears page 94 Range Select Lever LEFT SIDE OF FUEL TANK 1 range select lever 1 19 TRX500FA6 FA7 U 32HR68400 book Page 36...

Page 47: ...he 4WD indicator 2 2WD mode the 4WD indicator disappears when the 2WD mode engages 4WD mode the 4WD indicator appears when the 4WD mode engages If the 4WD indicator does not appear when selecting the...

Page 48: ...cking 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 32 km h 20 mph Pushing and holding the star...

Page 49: ...the differential lock indicator will slowly flash If the differential lock indicator does not stay on when the front differential lock mode is selected steer the handlebar either to the left or right...

Page 50: ...front final gear system If this occurs the front final gear actuator will stop moving and the front final gear system will be fixed in the current position either 2WD mode 4WD mode or front different...

Page 51: ...arter 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 over ride button is pushed To activate the speed limiter over rid...

Page 52: ...he engine and it should normally remain in the RUN e position even when the engine is OFF If your ATV is stopped with the ignition switch ON q and the engine stop switch OFF r the battery will dischar...

Page 53: ...he high and low beams of the headlights and to activate the assist headlight To operate turn the switch to HI u for high beam of the headlights and activate the assist headlight LO i for low beam of t...

Page 54: ...atures The recoil starter 1 is used to start the engine when the battery is low See Using the Recoil Starter page 87 Recoil Starter RIGHT SIDE 1 recoil starter 1 19 TRX500FA6 FA7 U 32HR68400 book Page...

Page 55: ...1 with your thumb To reduce engine rpm release pressure on the throttle lever The throttle will automatically return to the closed position engine idle when you remove your thumb Throttle Lever RIGHT...

Page 56: ...select switch 1 has two positions AUTO automatic shift mode and ESP manual shift mode See Shifting Gears page 89 Drive Mode Select Switch RIGHT HANDLEBAR 1 1 drive mode select switch 19 TRX500FA6 FA7...

Page 57: ...P manual shift mode These gearshift switches are used to select the next higher or lower gear in the transmission To operate press the upshift switch 1 to engage the next higher gear or press the down...

Page 58: ...g brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see page 97 The rear brake pedal is used to slow or stop your ATV To operate depress the...

Page 59: ...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 1 P R lever 2 rear brake lever parking brake lever 1 2 LEFT HA...

Page 60: ...see page 112 To release the parking brake Squeeze the rear brake lever parking brake lever until the P R lever is released from the slot on the rear brake lever parking brake lever bracket The brakeli...

Page 61: ...er To mount a pole in the bracket 1 follow the instructions that come with the flag pole kit Flag poles are required in some riding areas Check local regulations before riding Flag Pole Bracket RIGHT...

Page 62: ...er size ball 2 as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the trailer manufacturer s instructions For load limits and operational guidelines see...

Page 63: ...ot plug in any heat generating accessory such as an automobile cigarette lighter because it can damage the socket To use the accessory socket turn the ignition switch to ON q start the engine Then tur...

Page 64: ...y 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 231 When you are done using an accessory unplug it and c...

Page 65: ...front of the utility box cover 2 To close Push down the front of the utility box cover until it locks in place Make sure that the stud 3 is locked securely in position by pulling up lightly on the fro...

Page 66: ...he 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 3 1 storage compartment 2 1 2 rear cargo rack 3...

Page 67: ...brief period After cooling down it will then return to normal PS operation The PS indicator should light when the ignition switch is turned on and remain on until the engine is started The PS indicat...

Page 68: ...Instruments Controls 58 19 TRX500FA6 FA7 U 32HR68400 book Page 58 Wednesday May 16 2018 10 58 AM...

Page 69: ...ur 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 63 No Passengers 63...

Page 70: ...y alcohol or drugs in your system For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gloves trousers and a long sleeved shirt or jacket whene...

Page 71: ...e gloves to help protect your hands Riding trousers with knee and hip pads a riding jersey with padded elbows and a chest shoulder protector WARNING 3WARNING Operating this ATV without wearing an appr...

Page 72: ...ontrols and feel comfortable with its size and weight Rider Training WARNING 3WARNING Operating this ATV without proper instruction could increase your risk of an accident which could lead to serious...

Page 73: ...argo racks Age Recommendation WARNING 3WARNING A child using an ATV that is not recommended for their age could lose vehicle control while riding resulting in severe injury or death A child under 16 s...

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

Page 75: ...er There may be damage or other problems you cannot see Check the following items before you get on the ATV WARNING 3WARNING Improperly maintaining this ATV or failing to correct a problem before ridi...

Page 76: ...to make sure all accessible nuts bolts and fasteners are tight Underbody Exhaust System Check for and remove any dirt vegetation or other debris that could be a fire hazard or interfere with the prop...

Page 77: ...e it moves smoothly without sticking and snaps shut automatically when it is released in all steering positions page 166 Brakes Squeeze the front and rear brake levers and step on the rear brake pedal...

Page 78: ...dlights and Headlight Dimmer Switch Check for proper function page 43 Engine Stop Switch Check for proper function page 42 Steering Check that the wheels turn properly as you steer the handlebar Move...

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

Page 80: ...gue 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 260 kg 573 lb includes the we...

Page 81: ...pe or cable to the rear rack Load cargo on the rear rack as far forward as possible Make sure cargo on the front rack does not interfere with handlebar movement Do not allow cargo to extend beyond the...

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

Page 83: ...change its design or operation Such changes could seriously impair your ATV s handling stability and braking making it unsafe to ride Removing or modifying your lights exhaust system emission control...

Page 84: ...Before Riding 74 19 TRX500FA6 FA7 U 32HR68400 book Page 74 Wednesday May 16 2018 10 58 AM...

Page 85: ...vice life refer to Break in Guidelines page 248 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 Terrain 80 Do Not Pe...

Page 86: ...r ATV 99 Making Turns 99 Skidding or Sliding 101 Riding Up Hills 102 Riding Down Hills 106 Crossing or Turning on Hills or Slopes 107 Riding Over Obstacles 109 Riding Through Water 110 Parking 112 19...

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

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

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

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

Page 91: ...y rough slippery or loose terrain could cause loss of traction or vehicle control which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain...

Page 92: ...mission will automatically return to neutral q when the ignition switch is turned to the ON q position The starter motor will operate when the transmission is in neutral or the front brake lever is pu...

Page 93: ...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 to RUN...

Page 94: ...tart over ride button with the throttle completely closed The engine will not start if the throttle is fully open because the electronic control module cuts off the fuel supply Snapping the throttle o...

Page 95: ...tle slightly if idling is unstable If the engine does not start wait 10 seconds then follow steps 1 4 again If the engine still won t start refer to If Your Engine Quits or Won t Start page 218 Your v...

Page 96: ...ttle gradually Normal Engine Stop To stop the engine make sure the transmission is in neutral by checking that the neutral indicator light is on then turn the ignition switch OFF w The engine stop swi...

Page 97: ...out slowly approximately 100 mm 4 0 in 4 Pull the grip up briskly and fully 5 After the engine starts allow the starter grip to return slowly Pull the recoil starter grip straight out so that the cord...

Page 98: ...iding condition The gear position indicator shows D for forward gears N for neutral and R for reverse Select gear position with the gear shift switches ESP manual shift mode In this mode you can shift...

Page 99: ...N R Manual 1 5 N R Two gearshift switches are located next to the left handlebar grip upshift and downshift To shift between a forward gear D or 1 neutral N or reverse R bring the ATV to complete stop...

Page 100: ...e and letting it warm up follow these procedures 1 With the transmission in neutral release the parking brake page 50 but continue to squeeze the rear brake lever parking brake lever 2 With the thrott...

Page 101: ...r position indicator shows 1 4 Release the rear brake lever parking brake lever and increase engine speed by gradually opening the throttle 5 When speed increases release the throttle and upshift to 2...

Page 102: ...utomatically downshifts to the next lower gear In ESP manual shift mode Low L range if the ground speed in 2nd gear is decreased under 5 km h 3 mph or in 3rd gear is decreased under 8 km h 5 mph or in...

Page 103: ...the normal shifting points Downshift to a lower gear before you feel the engine laboring lugging at low rpm Avoid downshifting to help slow your ATV when engine rpm is high Downshifting when engine s...

Page 104: ...nsmission may be damaged Drive D range Drive is the normal position use this range for normal riding Low L range Use this range to get more power when climbing for maximum engine braking when going do...

Page 105: ...ear brake lever parking brake lever 3 then press the downshift switch 4 once to shift into R reverse gear 5 Make sure that the reverse indicator comes on and the gear position indicator shows R WARNIN...

Page 106: ...cator shows N The transmission cannot be shifted from neutral back into reverse when the engine speed is above 2 300 min 1 rpm or speed of your ATV is above 3 km h 2 mph The transmission cannot be shi...

Page 107: ...g system provides about 70 percent of total stopping power For full braking effectiveness use both the pedal and lever simultaneously Using both braking systems will stop your ATV faster with greater...

Page 108: ...ding skills When descending a long steep grade use engine compression braking by downshifting in the ESP mode with intermittent use of both brakes Continuous brake application can overheat the brakes...

Page 109: ...differential lock mode will cause steering to be heavy and increase turning radius Making Turns WARNING 3WARNING Turning improperly can make the ATV go out of control causing a collision or overturn A...

Page 110: ...ur body slightly forward on the seat and lean inside as you steer the handlebar Shifting weight forward allows the rear wheels to turn easier and it also improves front wheel steering To make a turn f...

Page 111: ...n the direction of the skid Avoid hard braking or accelerating until you have regained directional control Remember that steering the handlebar in the front differential lock mode will cause steering...

Page 112: ...wheels to help keep them on the ground To do this shift your body slightly forward on the seat and lean forward For greater weight shift move your body farther forward and lean forward Riding Up Hills...

Page 113: ...r and speed for the conditions Maintain a steady speed as you ascend the hill Never open the throttle suddenly or make sudden gear changes The ATV could flip over backward Never go over the top of any...

Page 114: ...gine off 4 Then assess the situation If the ATV starts rolling backwards before you begin braking 1 Keep your weight uphill 2 Carefully apply the front brakes first then carefully apply the rear brake...

Page 115: ...the hill Make sure your intended path is clear in case you lose control of the ATV 1 Stand with your body facing downhill beside the vehicle so you can reach the rear brake lever parking brake lever...

Page 116: ...d survey the terrain below Never ride past the limit of your visibility Never go down a hill at high speed Riding Down Hills WARNING 3WARNING Going down a hill improperly could cause loss of control o...

Page 117: ...a loose surface Riding on hills or slopes is different from riding on level terrain Be careful when riding on any hill Make sure that you practice on gentle smooth slopes before attempting to ride on...

Page 118: ...may also need to steer slightly uphill to maintain a straight course across the slope Avoid crossing hills that are excessively steep slippery or rough Making Turns on Slopes Compared to riding on lev...

Page 119: ...d be prepared to stop Never try to ride over large obstacles such as large rocks or fallen logs Riding Over Obstacles WARNING 3WARNING Improperly operating over obstacles could cause loss of control o...

Page 120: ...ystem malfunction Have your ATV dealer inspect the oxygen sensor immediately after water enters the muffler Riding Through Water WARNING 3WARNING The ATV tyres have some ability to float Operating thi...

Page 121: ...id getting the spark plug or air cleaner wet as this would cause the engine to stop 5 After leaving the water always test both the front and rear brakes Riding through water can make the brakes less e...

Page 122: ...gnition switch OFF w If it is necessary to start the engine when your ATV in gear and is stopped on a grade rock the vehicle back and forth to allow shifting the transmission into neutral The brakelig...

Page 123: ...re 1 While holding the brakes set the parking brake 2 Turn the ignition switch to OFF w and release the brakes 3 If the ATV begins to move either while sitting on it or after you dismount find a bette...

Page 124: ...Basic Operation Riding 114 19 TRX500FA6 FA7 U 32HR68400 book Page 114 Wednesday May 16 2018 10 58 AM...

Page 125: ...for keeping your Honda looking good For information about replacing fuses see page 231 Before You Service Your Honda The Importance of Maintenance 117 Maintenance Safety 118 Important Safety Precautio...

Page 126: ...ont Final Gear Oil 150 Coolant 152 Air Cleaner 160 Engine Throttle 166 Reverse Inhibitor System 168 Spark Plug 169 Valves 172 Spark Arrester 173 Chassis Suspension 174 Brakes 177 Tyres 186 Guards 192...

Page 127: ...ervice intervals in this schedule are based on average riding conditions Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair If your ATV ove...

Page 128: ...echnician or other qualified mechanic Instructions are included in this manual only to assist in emergency service Some of the most important safety precautions follow However we cannot warn you of ev...

Page 129: ...so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around petrol Use only non flam...

Page 130: ...c mechanical skills and hand tools Procedures for these items are provided in this manual Other items involve more extensive procedures and may require special training tools and equipment We recommen...

Page 131: ...f Maintenance Schedule Notes Procedures NOTES 1 Service more frequently when riding in dusty areas sand or snow 2 Service more frequently after riding in very wet or muddy conditions 3 Replace every 2...

Page 132: ...MAINT INTERVAL Refer to page ITEMS km 150 1000 2000 mi 100 600 1200 MONTH 1 6 12 NOTE HOURS 20 100 200 FUEL LINE I THROTTLE OPERATION I 166 AIR CLEANER NOTE 1 C C 160 164 AIR CLEANER HOUSING DRAIN TUB...

Page 133: ...150 1000 2000 mi 100 600 1200 MONTH 1 6 12 NOTE HOURS 20 100 200 DRIVETRAIN BOOTS I I 193 FRONT REAR FINAL GEAR OIL R EVERY 2 YEARS I 147 150 RANGE SELECT SYSTEM I BRAKE FLUID NOTE 3 I I 177 180 BRAKE...

Page 134: ...km 100 mile or 1 month or 20 hours initial maintenance is considered a normal owner operating cost and will be charged for by your dealer Use the space under Notes to record anything you want to remin...

Page 135: ...aintenance Component Locations front brake fluid reservoir reverse assist lever front brake lever rear brake lever parking brake lever throttle lever P R lever fuel fill cap 19 TRX500FA6 FA7 U 32HR684...

Page 136: ...latch rear brakelight switch air cleaner rear brake caliper front brake calipers front final gear oil fill cap front final gear oil drain bolt engine oil filter rear brake lever parking brake lever ad...

Page 137: ...cleaner housing drain tube spark arrester rear final gear oil fill cap rear final gear oil drain bolt owner s manual air pressure gauge 40 A spare fuse battery fuse box main fuse 1 main fuse 2 PS fuse...

Page 138: ...nt to perform routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your dealer The tool kit and gear change tool includes the following items sta...

Page 139: ...al air pressure gauge 4 and 40 A spare fuse 5 should be stored in the plastic document bag and fastened with the rubber band 6 To remove the rear fender cover see page 131 Be careful not to flood this...

Page 140: ...l air pressure gauge 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 into the backside of the t...

Page 141: ...fuse Removal 1 Remove the seat page 130 2 Unhook the rubber strap 1 3 Firmly pull the studs 2 from the grommets 3 4 Slide the rear fender cover 4 forward to disengage the tabs 5 5 Remove the rear fend...

Page 142: ...Removal 1 Remove the seat page 130 2 Carefully remove the right studs 1 and left studs from the grommets 3 Remove the tank cover assembly 2 by releasing the right tabs 3 and left tabs from the slits I...

Page 143: ...up the centre 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 centre pin securely to lock the clip 1 2 1 2 19 TRX500FA6 FA7 U 32H...

Page 144: ...se of Petrol Containing Alcohol see page 249 Use of lower octane petrol can cause persistent pinging or spark knock a loud rapping noise which if severe can lead to engine damage Light pinging experie...

Page 145: ...1 08 Imp gal When there is only one segment left in the fuel gauge page 25 fuel will be low and you should refuel as soon as possible Refer to Safety Precautions on page 119 Fuel Capacity Refuelling P...

Page 146: ...After refuelling turn the fuel fill cap clockwise securely If you replace the fuel fill cap use only a Honda Genuine replacement part WARNING 3WARNING Petrol is highly flammable and explosive You can...

Page 147: ...hanging oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the...

Page 148: ...n Do not use API SH or higher oils 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 d...

Page 149: ...range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is labeled on the oil conta...

Page 150: ...urface 2 Start the engine in a well ventilated area and let it idle for 3 5 minutes If the air temperature is below 10 C 50 F let the engine idle for an additional 5 minutes a total of 10 minutes 3 St...

Page 151: ...Insert the dipstick without screwing it in then remove the dipstick and check the oil level The oil level should be between the upper level mark 6 and the lower level mark 7 on the dipstick LEFT SIDE...

Page 152: ...nd add the specified oil into the fill cap hole up to the upper level mark on the dipstick Do not over fill 8 Reinstall the engine oil fill cap and dipstick 9 Install the tank cover assembly 10 Instal...

Page 153: ...ical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid page 214 If you do not have the skills or the tools see your dealer Change the oil with...

Page 154: ...er 2 Place an oil drain pan under the crankcase and remove the engine oil drain bolt 1 and sealing washer 2 2 1 1 engine oil drain bolt 2 sealing washer UNDER ENGINE 19 TRX500FA6 FA7 U 32HR68400 book...

Page 155: ...5 facing inward toward the engine Make sure the spring 6 and the OUT SIDE TOWARDS FILTER COVER mark 7 faces away from the engine toward the oil filter cover Use only the Honda Genuine oil filter or a...

Page 156: ...lbf ft 2 Fill the crankcase with the recommended grade oil approximately 3 8 4 0 US qt 3 3 Imp qt 3 Reinstall the engine oil fill cap 4 Start the engine and let it idle for 3 5 minutes 5 Stop the eng...

Page 157: ...page 119 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 Changing Oil...

Page 158: ...4 4 After the oil has completely drained reinstall the drain bolt with a new sealing washer and tighten it to the specified torque 12 N m 1 2 kgf m 9 lbf ft 5 Pour the drained oil into a suitable con...

Page 159: ...the lower edge of the oil fill inspection hole 5 7 Coat a new O ring with grease and install it into the fill cap groove and tighten it to the specified torque 12 N m 1 2 kgf m 9 lbf ft REAR 1 1 oil...

Page 160: ...page 119 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 Changing Oi...

Page 161: ...iner and dispose of it in an approved manner page 214 NOTICE Improper disposal of drained fluids is harmful to the environment 6 Fill the front final gear case with the recommended oil 325 cm3 11 0 US...

Page 162: ...lled water as a part of the coolant solution Water that is high in mineral content or salt may be harmful to the aluminium engine NOTICE Using coolant with silicate inhibitors may cause premature wear...

Page 163: ...119 Check the engine coolant level each day before operating your ATV and add if needed 1 Make sure the vehicle is on level ground 2 With the engine at normal operating temperature check the coolant...

Page 164: ...o not attempt to add coolant by removing the radiator cap 5 Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark 6 After adding coolant reinstall the reserve...

Page 165: ...operly dispose of drained coolant refer to You the Environment page 214 NOTICE Improper disposal of drained fluids is harmful to the environment Coolant Replacement WARNING 3WARNING Removing the radia...

Page 166: ...th low water pressure Have the radiator checked by your dealer if the air flow is restricted over more than 20 of the radiator surface Clean the radiator core after riding the ATV in mud The left and...

Page 167: ...lid page 154 2 Remove the reserve tank 1 by removing the bolt 2 and clips 3 page 133 3 Release the hoses 4 from the guides 4 Hold the reserve tank being careful not to spill the coolant LEFT FRONT 1 r...

Page 168: ...t radiator grill cover 5 by releasing the tab A 6 tab B 7 tab C 8 hook A 9 and hook B 10 LEFT FRONT 3 clips 3 8 5 6 9 10 5 left radiator grill cover 6 tab A 7 tab B 8 tab C 9 hook A 10 hook B 7 19 TRX...

Page 169: ...r grill covers NOTICE Do not apply pressured water directly to the radiator core The pressured water can damage the radiator core 9 Install the removed parts in reverse order of removal FRONT 6 tab A...

Page 170: ...ice interval for your riding conditions Your ATV s air cleaner has very specific performance requirements Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal qualit...

Page 171: ...page 130 2 Unlatch the spring hooks 1 and retainer clips 2 3 Remove the air cleaner housing cover 3 Cleaning UNDER SEAT 2 1 2 retainer clips 3 air cleaner housing cover 1 spring hooks 2 3 19 TRX500FA6...

Page 172: ...or cracks in 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...

Page 173: ...the air cleaner housing 14 Fasten the screw 15 Reassemble by reversing the disassembly sequence Install the air cleaner housing cover with the FRONT mark 9 facing forward and fit the cut out of the t...

Page 174: ...ner 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 dust cover 2 breather joint 2 1 19 TRX500FA6 FA7 U 32HR68400 book Page 16...

Page 175: ...sits can be seen in the drain tube the tube must be cleaned before starting the vehicle 1 Remove the drain tube 1 by removing the clip 2 under the air cleaner housing 3 2 Drain the deposits 3 Reinstal...

Page 176: ...urn the adjuster to obtain the correct freeplay 4 Tighten the lock nut and reinstall the sleeve 5 After adjustment check for smooth operation of the throttle lever from fully closed to fully open in a...

Page 177: ...s If there is a problem see your dealer 3 Inspect the condition of the throttle cable from the throttle lever down to the throttle body If the cable is kinked or chafed have it replaced 4 Check the th...

Page 178: ...ing nut 5 to obtain the correct freeplay After adjustment tighten the lock nut securely 4 Return the dust cover and rubber sleeve Other Checks Check the reverse assist lever and cable for loose connec...

Page 179: ...over assembly page 132 2 Clean any dirt from around the spark plug base 3 Disconnect the spark plug cap 1 Take care to avoid damaging the spark plug wire when disconnecting the cap 4 Using a spark plu...

Page 180: ...he side electrode 3 should not be eroded If the electrodes and insulator tip appear unusually fouled or burned we suggest that you contact your dealer 6 Discard the spark plug if there is apparent wea...

Page 181: ...n the plug c Next tighten the plug again 1 8 turn after it seats NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose the piston may be damaged If a plug is too tight...

Page 182: ...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 Shop Manual Otherwise the...

Page 183: ...tible materials and make sure the exhaust pipe is cool 2 Remove the bolt 1 3 Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocki...

Page 184: ...ing cargo accessories or when riding conditions change The way you ride your ATV and the type of ride you want to experience can also influence your suspension needs Lower spring pre load provides a s...

Page 185: ...ter 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 FRONT REAR 1 spring pre load adjuster 2 pin spanner 1...

Page 186: ...loaded Also increase spring pre load for stiffer suspension Make sure that both shock absorbers are adjusted to the same position Always adjust the shock absorber position in sequence 1 2 3 4 5 or 5 4...

Page 187: ...ke lever or brake pedal freeplay does not feel within the normal range while riding check the brake pads for wear page 181 Worn pads should be replaced If the pads are not worn beyond the recommended...

Page 188: ...he system as soon as possible NOTICE Brake fluid can damage plastic and painted surfaces Handle with care Wipe up spills immediately Avoid brake fluid contact with skin or eyes If it comes in contact...

Page 189: ...e the LOWER level mark 1 If the level is at or below the LOWER level mark check the brake pads for wear page 181 Worn brake pads should be replaced If the pads are not worn have your brake system insp...

Page 190: ...ads for wear page 181 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks Make sure there are no fluid leaks Check for deterioration or cracks in the...

Page 191: ...ular service intervals to determine the pad wear Check the wear indicator 1 If the wear indicator aligns with the edge of the reference mark 2 both pads must be replaced see your dealer for this repla...

Page 192: ...icator 3 If the wear indicator aligns with the reference mark 4 both pads must be replaced see your dealer for this replacement RIGHT REAR 3 wear indicator 4 reference mark 4 3 19 TRX500FA6 FA7 U 32HR...

Page 193: ...1 moves before the brake starts to take hold Freeplay measurement at the tip of the end of the brake lever should be 25 30 mm 1 0 1 2 in 3 If necessary adjust to the specified range Rear Brake Lever F...

Page 194: ...t on the adjusting nut is properly seated on the brake arm pin 3 Check that the brake lever and brake pedal assemblies are positioned properly and the securing bolts are tight Make sure that the brake...

Page 195: ...rom time to time Adjustment is done by turning the adjusting nut 2 Hold the rear brakelight switch and turn the nut in direction A if the switch operates too late and in direction B if the switch oper...

Page 196: ...er to Safety Precautions on page 119 Properly inflated tyres provide the best combination of handling tread life and riding comfort Generally underinflated tyres wear unevenly adversely affect handlin...

Page 197: ...will be higher If you let air out of warm tyres to match the recommended cold tyre pressures the tyres will be underinflated Be sure to check tyre pressure at the riding site since changes in altitude...

Page 198: ...ook for Bumps or bulges in the side of the tyre or the tread Replace any tyre that has a bump or bulge Cuts slits or cracks in the tyres Replace the tyre if you can see fabric or cord Nails or other f...

Page 199: ...tread measure the groove depth 1 in the centre of the tyre or check the wear indicator 2 For best performance you should replace a tyre before the tread depth at the centre reaches the following limi...

Page 200: ...permanently repaired as soon as possible For more information on temporary repairs see If You Have a Flat Tyre page 226 A permanent repair such as an internal plug patch can be made if a tyre has onl...

Page 201: ...The recommended tyres for your ATV are When you replace a tyre remember Have the tyre replaced by your dealer if possible If you have a tyre professionally replaced at a non Honda facility we recomme...

Page 202: ...guards 5 protect the rubber driveshaft boots and the rear driveshafts Check the guards and plate for cracks damage or looseness at intervals shown in the Maintenance Schedule Have the guards and skid...

Page 203: ...1 rubber propeller shaft boots 2 and rubber yoke joint boot 3 for cuts damage or leaking grease If necessary have your dealer replace them 1 rubber driveshaft boots 3 rubber yoke joint boot 2 REAR 2 r...

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

Page 205: ...ng 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 information on the battery...

Page 206: ...elease the rings and remove the rubber band 1 5 Disconnect the negative terminal lead 2 from the battery 3 first then disconnect the positive terminal lead 4 6 Remove the battery taking care not to dr...

Page 207: ...ation 1 Check that the battery rubber 6 for damage If necessary replace the battery rubber 2 Make sure the battery rubber is properly installed 3 Reinstall the battery in the reverse order of removal...

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

Page 209: ...e the engine and exhaust system time to cool off Park in a shady area Washing your ATV in bright sunlight may cause the finish to fade because water droplets intensify the sun s brightness Spotting is...

Page 210: ...on the surface to air dry can cause dulling and water spots As you dry inspect for chips and scratches 7 Remove the cover or the plug from exhaust outlet Then start the engine and let it idle for sev...

Page 211: ...lear plastic Light road grimes Spray any difficult to reach or very dirty areas with a spray cleaner degreaser Rinse and dry Apply a spray cleaner polish and wipe with a non abrasive cloth Heavy grime...

Page 212: ...may corrode from contact with dirt mud or road salt Clean the wheels after riding through any of these substances Use a wet sponge and mild detergent Avoid stiff brushes steel wool or cleaners contai...

Page 213: ...mud or dust use a wet sponge and a liquid kitchen abrasive then rinse well with clean water Dry with chamois or a soft towel If necessary remove heat stains by using a commercially available fine text...

Page 214: ...Servicing Your Honda 204 19 TRX500FA6 FA7 U 32HR68400 book Page 204 Wednesday May 16 2018 10 58 AM...

Page 215: ...e an environmentally responsible ATV owner Preparing for a Ride 206 What to Take to the Riding Area 206 What to Take on the Trail 207 Transporting Your Honda 208 Storing Your Honda 210 Preparation for...

Page 216: ...ools and supplies in case you have a problem For some of the difficulties you might encounter see Taking Care of the Unexpected which begins on page 215 We recommend that you always take water food a...

Page 217: ...p and how experienced you or your companions are in making repairs If you decide to take some tools spare parts or other supplies on the trail be sure you can carry them safely and know how to use the...

Page 218: ...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 petrol could be a hazard F...

Page 219: ...not recommended because it can stretch under load Using tie down straps in any other areas can damage your ATV 3 Rock the vehicle back and forth to make sure the tie down straps are tight and the vehi...

Page 220: ...efore storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again We suggest you perform the following procedures to keep your ATV in top condition These...

Page 221: ...g Remove the spark plug cap from the spark plug page 169 Remove the spark plug Do not connect the spark plug to the spark plug cap Pour a tablespoon 15 20 cm3 of clean engine oil into the cylinder and...

Page 222: ...perature variation 9 Place your ATV on blocks to lift all tyres off the floor 10 Cover your ATV with a porous material Avoid using plastic or similar non breathing coated materials that restrict air f...

Page 223: ...the engine oil page 143 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 battery 5 Perform a p...

Page 224: ...se Sensible Cleaners Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s protective ozone layer Don t...

Page 225: ...ection before you ride Also review the tips in Preparing for a Ride page 206 General Guidelines 216 If Your Engine Quits or Won t Start 218 If the Transmission Is Not Functioning Properly 221 Emergenc...

Page 226: ...se more damage and endanger your own safety After stopping take time to assess the situation Carefully inspect your ATV to identify the problem then consider your options before you decide what to do...

Page 227: ...r options before deciding what to do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have permanent repairs made as soon as possible...

Page 228: ...perience 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 over ride button If you d...

Page 229: ...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 Starter motor works but...

Page 230: ...ur dealer sooty exhaust rich fuel mixture See your dealer detonates or pings under load If applicable switch to the recommended octane petrol page 134 or change your brand of petrol If the problem per...

Page 231: ...top the ATV 2 Turn the ignition switch to the OFF w position 3 After the engine stops turn the ignition switch to the ON q position 4 Press both shift switches and check that they are functioning 5 If...

Page 232: ...ition 3 After the engine stops turn the ignition switch to the ON q position 4 Check the gear position indicator If these efforts do not restore proper operation have your ATV inspected by your dealer...

Page 233: ...e 49 3 Turn the ignition switch to the OFF w position 4 Loosen the screw 1 and release the lock plate 2 5 Locate the emergency valve access hole 4 inside the left front fender Using a screwdriver turn...

Page 234: ...If the transmission is in neutral go to step 5 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 Ma...

Page 235: ...gain Return the gear change tool to the storage location Do not attempt to shift gears manually using the gear change tool while riding If the transmission is shifted manually when the electric shift...

Page 236: ...sible have the tyre permanently repaired by your dealer Any tyre that cannot be repaired should be replaced Whenever the ATV is to be operated far from service facilities or available transportation w...

Page 237: ...se the front or rear wheels off the ground and place a support block under the vehicle 4 Remove the wheel nuts Emergency Wheel Removal Installation 1 1 2 1 wheel nuts 2 wheel rim TRX500FA6 Steel wheel...

Page 238: ...side faces the wheel rim 2 3 Hand tighten the wheel nuts on the wheel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque...

Page 239: ...ine off and wait until the steaming stops Look for a leak but don t touch the engine or radiator system Let everything cool off first Check for any restriction of air flow to the radiator If there s n...

Page 240: ...ommended oil page 138 to the upper level mark If you must leave your ATV to get oil secure it as much as possible Start the engine and check that the coolant temperature gauge and high coolant tempera...

Page 241: ...e fuses before looking elsewhere for another possible cause of the problem Replace a blown fuse and check component operation The main fuse and the circuit fuses are located under the rear fender cove...

Page 242: ...o access the main fuse 1 2 remove the fuse cover 3 5 To access the main fuse 2 4 remove the fuse box cover 5 6 Pull the main fuses out If the main fuse 1 is blown install the spare fuse page 129 If th...

Page 243: ...ng If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating NOTICE Replacing a fuse with one that has a higher rating greatly increases the chance o...

Page 244: ...130 3 Remove the rear fender cover page 131 4 To access the PS fuse 1 remove the PS fuse box cover 2 If the PS fuse is blown install the spare fuse page 129 5 Install the PS fuse box cover 6 Install...

Page 245: ...place a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses that were installed If the replacement...

Page 246: ...mage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor damage or you are unsure...

Page 247: ...you don t know your key number call the dealer where you purchased your Honda ATV They may have it listed in their records If they don t transport your ATV to them or the nearest dealer The dealer wi...

Page 248: ...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 neutral the...

Page 249: ...ies you have with you If any component of the brake system is damaged you may be able to ride carefully back to your base using the other brake components for slowing or stopping If you damage a throt...

Page 250: ...Taking Care of the Unexpected 240 19 TRX500FA6 FA7 U 32HR68400 book Page 240 Wednesday May 16 2018 10 58 AM...

Page 251: ...imensions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 242 Specifications 244 Break in Guidelines 248 Petrol Cont...

Page 252: ...stamped on the front of the frame Remove the radiator cap lid page 154 VIN ______________________________________________________ The engine number 2 is stamped on the upper side of the rear crankcas...

Page 253: ...s helpful when ordering replacement parts Record the colour and code here for your reference COLOUR__________________________________________________ CODE _____________________________________________...

Page 254: ...embly 4 4 4 6 US qt 3 9 Imp qt after draining 3 6 3 8 US qt 3 2 Imp qt after draining oil filter change 3 8 4 0 US qt 3 3 Imp qt engine oil recommendation API Service Classification SG or higher excep...

Page 255: ...ndard BKR5E 11 NGK or K16PR U11 DENSO spark plug gap 1 00 1 10 mm 0 039 0 043 in valve clearance cold intake 0 15 mm 0 006 in exhaust 0 23 mm 0 009 in idle speed 1 400 100 min 1 rpm Power Transmission...

Page 256: ...kPa 4 4 psi Electrical battery GYZ16H 12 V 16 Ah 10 HR generator 0 595 kW 5 000 min 1 rpm Lights headlight 12 V 35 35 W 2 assist headlight 12 V 50 W brakelight taillight LED neutral indicator LED rev...

Page 257: ...m 1 2 kgf m 9 lbf ft rear final gear oil drain bolt 12 N m 1 2 kgf m 9 lbf ft rear final gear oil fill cap 12 N m 1 2 kgf m 9 lbf ft front final gear oil drain bolt 12 N m 1 2 kgf m 9 lbf ft front fin...

Page 258: ...ability and performance by paying extra attention to how you ride during the first operating day or 25 km 15 miles During this period avoid full throttle starts rapid acceleration and constant rpm ope...

Page 259: ...hanol even if it has cosolvents and corrosion inhibitors Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the warranty Honda cannot endorse the us...

Page 260: ...bank angle sensor ignition cut off system 85 battery 194 brakelight switch adjustment 185 brakes cable 184 fluid 177 front brake lever 48 pad wear 181 parking 49 rear brake lever freeplay 183 rear br...

Page 261: ...manual 129 storage 56 tool kit 128 component fails 239 controls features 35 coolant temperature gauge 29 crash if you 236 crossing or turning on hills or slopes 107 D differential lock switch 38 digit...

Page 262: ...art 218 environment 214 exhaust system cleaning 66 purging 173 F final gear oil front 150 rear 147 flag pole bracket 51 flat tyre 226 flooded engine 85 front boot guards 192 front differential lock 38...

Page 263: ...88 gearshift switch 47 guards 192 H headlight dimmer switch 43 headlight switch 43 high coolant temperature indicator 14 17 229 hills crossing or turning on slopes 107 riding down hills 106 riding up...

Page 264: ...dicator 14 17 PGM FI indicator 14 17 PS Electric Power Steering indicator 14 17 reverse indicator 14 17 inspection pre ride 65 K key lost 237 number 237 kit tool 128 L labels safety 5 lamp check 15 le...

Page 265: ...weight limit 70 modifications 73 multi function display 20 N neutral indicator 17 numbers serial 242 O obstacles riding over 109 odometer 28 oil engine 137 front final gear 150 rear final gear 147 ope...

Page 266: ...tric Power Steering 57 R range select lever 36 rear driveshaft boots 193 rear driveshaft guards 192 rear fender cover removal 131 rear final gear oil 147 recoil starter 44 removal rear fender cover 13...

Page 267: ...bels 5 riding precautions 77 schedule maintenance 120 seat removal 130 serial numbers 242 shifting gears 88 skid plates 192 skidding or sliding 101 spark arrester 173 spark knock 134 spark plug 169 sp...

Page 268: ...4WD 37 differential lock 38 downshift 47 88 drive mode select 46 engine stop 42 headlight 43 headlight dimmer 43 ignition 35 upshift 47 88 T tank cover assembly removal 132 throttle cable 166 lever 45...

Page 269: ...on level ground 99 tyres air pressure 186 flat 226 repairing 190 replacing 191 tread conditions 188 U utility box 55 V valve clearance 172 vehicle identification no VIN 242 W warning labels 5 washing...

Page 270: ...19 TRX500FA6 FA7 U 32HR68400 book 265...

Page 271: ...32HR6840 00X32 HR6 8400 WPGXXXX 2018 XX 19 PRINTED IN USA U...

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