Honda FourTrax Rubicon TRX520FA5 2020 Owner'S Manual Download Page 225 | 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

(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 Tire............................................................... 226
If the High Coolant Temperature Indicator Lights ...................... 230
If a Fuse Blows.......................................................................... 232
If You Crash ............................................................................. 237
If You Lose Your Key ................................................................ 238
If the Battery Is Low (or Dead)................................................... 239
If a Component Fails................................................................. 240

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Summary of Contents for FourTrax Rubicon TRX520FA5 2020

Page 1: ...uxe FOURTRAX FOREMAN RUBICON FOURTRAX FOREMAN RUBICON Read this manual carefully it contains important safety information Minimum recommended operator age 16 Models sold in and used in California The...

Page 2: ...our particular model All illustrations are based on the TRX520FA6 model This publication includes the latest production information available before printing Honda Motor Co Ltd reserves the right to m...

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

Page 4: ...c 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 helpful tips To make it easy to use the manu...

Page 5: ...dealer knows your 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...

Page 6: ...r information on 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 associ...

Page 7: ...uch as ATV Safety 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...

Page 8: ...related labels on your ATV Instruments Controls 9 The location and function of indicators and controls on your ATV and operating instructions for various controls and features Before Riding 61 The imp...

Page 9: ...nd 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 tire your engine won t start etc Technical Information 241 ID n...

Page 10: ......

Page 11: ...the most important 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 l...

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

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

Page 14: ...Alcohol and riding 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 le...

Page 15: ...ls containing important 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 la...

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

Page 17: ...ead to an accident Never exceed the maximum front cargo limit of 99 lbs 45 kg Refer to instructions in the Owner s Manual WARNING Improper tire pressure or overloading can cause loss of control Loss o...

Page 18: ...R USE NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS WITH DRUGS OR ALCOHOL Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an...

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

Page 20: ...ngine Stop Switch 42 Headlight Switch 43 Headlight Dimmer Switch 43 Recoil Starter Canada only 44 Throttle Lever 45 Drive Mode Select Switch 46 Gearshift Switch 47 Reverse Switch 48 Front Brake Lever...

Page 21: ...witch rear brake lever parking brake lever engine stop switch start override button ignition switch throttle lever front brake lever 4WD switch headlight dimmer switch gearshift switches drive mode se...

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

Page 23: ...Instruments Controls 13 Operation Component Locations flag pole bracket trailer hitch storage compartment accessory socket side utility box...

Page 24: ...safer and more enjoyable Refer to the indicators frequently Their functions are described on the following pages 4 PGM FI indicator 5 high coolant temperature indicator 1 neutral indicator 2 reverse i...

Page 25: ...ndicator comes back 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 neutr...

Page 26: ...The displays are 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 F...

Page 27: ...icator there is any abnormality in the front final gear system See page 40 Lamp Check 4 PGM FI indicator Lights when there is any abnormality in the PGM FI Programmed Fuel Injection system Should also...

Page 28: ...sition page 24 LOW indicator Shows when low L range is engaged page 23 Maintenance minder indicator Shows when specified maintenance interval is reached page 33 Speedometer Shows riding speed Fuel gau...

Page 29: ...lects display in the lower parts of multi 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...

Page 30: ...art of the multi function display push the mode select button 8 Multi function Display 4WD indicator Gear position indicator LOW indicator Speedometer Maintenance minder indicator Fuel gauge Digital c...

Page 31: ...ly return to the 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 ordi...

Page 32: ...PH and MILE or KM H and KM To change the speed and mileage units press and hold the mode select button 1 for more than 5 seconds in odometer mode page 28 with the ATV stopped The 4WD indicator 1 shows...

Page 33: ...Instruments Controls 23 Indicators Displays The LOW indicator 1 will be displayed when low L range is engaged with the ignition switch in the ON q position page 97 LOW Indicator 1 LOW indicator 1...

Page 34: ...ssion is not shifted into gear properly 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...

Page 35: ...al 14 7 Regardless of what mode the display is in when the fuel level reaches only 1st segment 3 the display will automatically switch to the fuel gauge display You should refuel as soon as possible T...

Page 36: ...EL 5 blink 3 times alternately and fuel mark blinks you should refuel as soon as possible The amount of fuel reserve is approximately 1 29 US gal 4 9 Fuel gauge failure If the fuel gauge E F 6 is blin...

Page 37: ...ress and hold the 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...

Page 38: ...99 999 The tripmeter 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 read out exceeds 999 9 To...

Page 39: ...ile the ignition switch is ON q The normal operating temperature range is within the section between the 1st segment 3 and 4th segment 4 When coolant temperature is low the coolant temperature gauge w...

Page 40: ...ts If this occurs stop the engine and check the reserve tank coolant level Read pages 230 231 and do not ride the ATV until the problem has been corrected NOTICE Continuing to ride with an overheated...

Page 41: ...hours while the 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 whe...

Page 42: ...gnition switch is ON q with the maintenance minder indicator The maintenance tripmeter decreases from 600 miles 1 000 km after reset The maintenance hour meter decreases from 100 hour after reset Init...

Page 43: ...r appears in the 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 af...

Page 44: ...maintenance minder 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 op...

Page 45: ...the key and turn it to the right for the ON q position The ignition switch is also used to reset the maintenance tripmeter and the maintenance hour meter page 34 Ignition Switch Key Position Function...

Page 46: ...Instruments Controls 36 Controls Features The range select lever 1 has two positions Drive D Low L See Shifting Gears page 97 Range Select Lever LEFT SIDE OF FUEL TANK 1 range select lever 1...

Page 47: ...heck your present 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 indicat...

Page 48: ...to rotate at the same speed Because locking all four wheels together changes the way the vehicle handles and increases the amount of room necessary to turn a speed limiter restricts the speed to 20 mp...

Page 49: ...king process will 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 h...

Page 50: ...when there is any 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...

Page 51: ...start override button is pushed the starter motor will crank the engine The starter motor will not operate if the engine stop switch is in the OFF r position when the start override button is pushed T...

Page 52: ...be in the RUN e position to start the engine and it should normally remain in the RUN e position even when the engine is OFF If your ATV is stopped with the ignition switch ON q and the engine stop s...

Page 53: ...ON y or OFF t The headlight dimmer switch 2 is used to change between the high and low beams of the headlights and to activate the assist headlight To operate turn the switch to HI u for high beam of...

Page 54: ...s Controls 44 Controls Features The recoil starter 1 is used to start the engine when the battery is low See Using the Recoil Starter Canada only page 90 Recoil Starter Canada only RIGHT SIDE 1 recoil...

Page 55: ...e engine rpm press 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 r...

Page 56: ...46 Controls Features The drive mode select switch 1 has two positions AUTO automatic shift mode and ESP manual shift mode See Shifting Gears page 91 Drive Mode Select Switch 1 drive mode select switc...

Page 57: ...e 91 and Riding in Reverse page 98 ESP 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 t...

Page 58: ...s Controls 48 Controls Features The reverse switch 1 is used when shifting the transmission into reverse R To shift into reverse R see Riding in Reverse page 98 Reverse Switch 1 1 reverse switch LEFT...

Page 59: ...page 100 The rear 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 100 The rear brake pedal is used to slow or...

Page 60: ...ols Features The parking brake lock lever 1 on the rear brake lever parking brake lever 2 is used to apply the parking brake Parking Brake Lever 1 2 1 parking brake lock lever 2 rear brake lever parki...

Page 61: ...ever parking brake lever bracket For more information on Parking see page 115 To release the parking brake Squeeze the rear brake lever parking brake lever until the parking brake lock lever is releas...

Page 62: ...al equipment available 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 b...

Page 63: ...To use the hitch you ll need a proper size ball 2 as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the trailer manufacturer s instructions For load li...

Page 64: ...radio or cell phone etc NOTICE Do not plug in any heat generating accessory such as an automobile cigarette lighter because it can damage the socket To use the accessory socket turn the ignition swit...

Page 65: ...t otherwise you may drain the battery The accessory socket s rated capacity is DC 12 V 120 Watts 10 A or less If you exceed this limit you may blow a fuse See If a Fuse Blows page 232 When you are don...

Page 66: ...cover 2 To close Push down the front of the side utility box cover until it locks in place Make sure that the stud 3 is locked securely in position by pulling up lightly on the front of the side utili...

Page 67: ...close Push down 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...

Page 68: ...rage compartment 1 is located below the rear cargo rack 2 To open the compartment unhook the rubber strap 3 Be careful not to flood this area when washing your ATV Storage Compartment REAR 1 storage c...

Page 69: ...the vehicle and allow the EPS system to cool down until the PS indicator goes off After cooling down steering will return to normal EPS operation The PS indicator should light when the ignition switc...

Page 70: ...Instruments Controls 60...

Page 71: ...r ATV and adjustments to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride 62 Protective Apparel 62 Rider Training 64 Age...

Page 72: ...rotective clothing 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 an...

Page 73: ...off road motorcycle 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 a...

Page 74: ...Safety Institute 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 t...

Page 75: ...on the seat or on 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 seve...

Page 76: ...gerous while operating 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...

Page 77: ...il it has been inspected 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 fai...

Page 78: ...ges 193 Nuts 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 an...

Page 79: ...not exceed the load limits page 72 Cargo 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 sh...

Page 80: ...ealer correct it before you ride Headlights 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 prope...

Page 81: ...sories or making modifications that change this ATV s design and performance can also make it unsafe Also the weight of any accessories will reduce the maximum load the ATV can carry More specific inf...

Page 82: ...e under the tongue 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 c...

Page 83: ...e or trailer Do not tow by tying a rope or cable to the rear rack Load cargo on the rear rack as far forward as possible Make sure cargo on the front rack does not interfere with handlebar movement Do...

Page 84: ...r for assistance and always follow these guidelines Make sure the accessory does not obscure any lights reduce ground clearance limit suspension travel or steering travel or interfere with operating a...

Page 85: ...air your ATV s handling stability and braking making it unsafe to ride We also advise you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission co...

Page 86: ...Before Riding 76...

Page 87: ...oy optimum performance and service life refer to Break in Guidelines page 249 Safe Riding Precautions 79 Off road Use Only 79 Keep Hands and Feet on Controls 80 Control Speed 81 Use Care on Unfamiliar...

Page 88: ...ration Riding Braking 100 Riding Your ATV 102 Making Turns 102 Skidding or Sliding 104 Riding Up Hills 105 Riding Down Hills 109 Crossing or Turning on Hills or Slopes 110 Riding Over Obstacles 112 Ri...

Page 89: ...s are designed and manufactured for off road use only not for pavement Riding on pavement can affect handling and control You should not ride your ATV on pavement When riding off road also remember to...

Page 90: ...even one hand from 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...

Page 91: ...cle the terrain 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 con...

Page 92: ...cult to see obstructions 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 terr...

Page 93: ...e extra care when 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 excessi...

Page 94: ...w position while in reverse the transmission will automatically return to neutral N when the ignition switch is turned to the ON q position The starter motor will operate when the transmission is in n...

Page 95: ...and lock the parking brake page 50 2 Turn the ignition switch 1 to ON q Confirm the following The transmission is in neutral and the neutral indicator 2 is ON and the gear position indicator shows N T...

Page 96: ...ow Any Air Temperature With the throttle completely closed press the start override button The engine will not start if the throttle is fully open because the electronic control module cuts off the fu...

Page 97: ...al starting procedure 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 st...

Page 98: ...brake lever and pressing the start override button Do not press the throttle lever while starting in gear The engine will not start if the throttle is fully open because the electronic control module...

Page 99: ...he ignition switch 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 sw...

Page 100: ...r grip 1 firmly then pull it out slowly approximately 4 in 100 mm 4 Pull the grip up briskly and fully 5 After the engine starts allow the starter grip to return slowly Pull the recoil starter grip st...

Page 101: ...s D for forward gears N for neutral and R for reverse Select gear position with the gear shift switches In AUTO automatic shift mode you can temporarily shift up or down by using the shift switches ES...

Page 102: ...g Gear Position selection AUTO D 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...

Page 103: ...tic shift mode After starting the engine and letting it warm up follow these procedures 1 With the transmission in neutral release the parking brake page 51 but continue to squeeze the rear brake leve...

Page 104: ...once to shift into 1st gear 3 The gear 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...

Page 105: ...0 rpm In ESP manual shift mode if the ground speed decreases under a set speed see table the transmission will automatically downshift to the next lower gear If the ATV is at a complete stop 4th gear...

Page 106: ...elationship between engine sound and 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 rp...

Page 107: ...le the vehicle is moving the sub transmission 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...

Page 108: ...t into R reverse gear You can also shift into R reverse gear by pressing and holding the downshift switch 1 then pressing the reverse switch 2 within 0 5 seconds 4 Make sure that the reverse indicator...

Page 109: ...the upshift switch 3 then pressing the reverse switch 2 within 0 5 seconds The reverse switch will not operate if you operate continuously with the reverse switch pressed Release the reverse switch on...

Page 110: ...fectiveness use both the pedal and lever simultaneously Using both braking systems will stop your ATV faster with greater stability To slow or stop apply the brake lever and brake pedal smoothly while...

Page 111: ...ing by downshifting in the ESP mode with intermittent use of both brakes Continuous brake application can overheat the brakes and reduce their effectiveness Riding with your foot resting on the brake...

Page 112: ...eering the handlebar 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...

Page 113: ...urn at low speed It helps to shift your body slightly forward on the seat and lean inside as you steer the handlebar Shifting weight forward allows the rear wheels to turn easier and it also improves...

Page 114: ...skids sideways during a turn steer in the direction of the skid Avoid hard braking or accelerating until you have regained directional control Remember that steering the handlebar in the front differ...

Page 115: ...u must shift weight 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 for...

Page 116: ...a running start in an appropriate gear and speed for the conditions Maintain a steady speed as you ascend the hill Never open the throttle suddenly or make sudden gear changes The ATV could flip over...

Page 117: ...utral set the parking 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 brake...

Page 118: ...may be able to walk the ATV back down the hill Make sure your intended path is clear in case you lose control of the ATV 1 Stand with your body facing downhill beside the vehicle so you can reach the...

Page 119: ...de As you approach 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 imp...

Page 120: ...veness is reduced 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 s...

Page 121: ...e On a slippery or loose surface you may also need to steer slightly uphill to maintain a straight course across the slope Avoid crossing hills that are excessively steep slippery or rough Making Turn...

Page 122: ...ach any obstacle reduce your speed and be prepared to stop Never try to ride over large obstacles such as large rocks or fallen logs Riding Over Obstacles WARNING 3WARNING Improperly operating over ob...

Page 123: ...sensor and result 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...

Page 124: ...ed obstacles and slippery rocks 4 Avoid getting the spark plug or air cleaner wet as this would cause the engine to stop 5 After leaving the water always test both the front and rear brakes Riding thr...

Page 125: ...ght is activated by applying the parking brake When using the parking brake be sure to turn the ignition switch to OFF w to avoid discharging the battery Parking on a Steep Incline or a Loose or Slipp...

Page 126: ...Basic Operation Riding 116...

Page 127: ...quirements of the U S Environmental Protection Agency EPA the California Air Resources Board CARB and Environment Climate Change Canada ECCC see page 250 USA only Maintenance replacement or repair of...

Page 128: ...res Fluids Filters Fuel 136 Engine Oil Filter 139 Rear Final Gear Oil 148 Front Final Gear Oil 151 Coolant 153 Air Cleaner 161 Engine Throttle 167 Spark Plug 169 Valves 172 Spark Arrester 173 Chassis...

Page 129: ...rovides a Maintenance 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...

Page 130: ...normally be handled 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 fo...

Page 131: ...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 gasoline Use only non flammable solvent not gasoline to...

Page 132: ...dule can be performed 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...

Page 133: ...ur dealer Summary 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 condition...

Page 134: ...GULAR Refer to page MAINT MAINT INTERVAL mi 100 600 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 FUEL LINE I THROTTLE OPERATION I 167 AIR CLEANER NOTE 1 C C 161 AIR CLEANER HOUSING D...

Page 135: ...RST INITIAL REGULAR Refer to page MAINT MAINT INTERVAL mi 100 600 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 DRIVETRAIN BOOTS I I 194 FRONT REAR FINAL GEAR OIL R EVERY 2 YEARS I 14...

Page 136: ...eduled maintenance 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...

Page 137: ...ng Your Honda 127 Service Preparations Maintenance Component Locations front brake fluid reservoir front brake lever fuel fill cap throttle lever parking brake lock lever rear brake lever parking brak...

Page 138: ...spring pre load adjuster front brake caliper rear brake light switch rear brake pedal engine oil filter air cleaner front final gear oil fill cap front final gear oil drain bolt rear brake lever parki...

Page 139: ...fuse 1 main fuse 2 EPS fuse TRX520FA6 FA7 rear suspension spring pre load adjuster spark plug engine oil dipstick rear final gear oil fill cap rear final gear oil drain bolt coolant reserve tank spar...

Page 140: ...compartment page 58 After using the tool kit or the gear change tool be sure to use the rubber band 3 to fasten the tool kit and the gear change tool securely An optional larger tool kit may be avail...

Page 141: ...ver 3 The owner s manual air pressure gauge 4 40 A spare fuse 5 and fuse puller 6 should be stored in the plastic document bag and fastened with the rubber band 7 To remove the rear fender cover see p...

Page 142: ...bly to access the owner s manual air pressure gauge 40 A spare fuse and fuse puller Removal 1 Pull the seat latch 1 at the rear of the seat 2 Slide the seat 2 back and lift it Installation 1 Insert th...

Page 143: ...pressure gauge 40 A spare fuse and fuse puller Removal 1 Remove the seat page 132 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...

Page 144: ...il filter and spark plug maintenance Removal 1 Remove the seat page 132 2 Carefully remove the right studs 1 and left studs from the grommets 3 Remove the tank cover assembly 2 by releasing the right...

Page 145: ...Honda 135 Clip Removal 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 th...

Page 146: ...ormation on the use of oxygenated fuels see page 254 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 pingi...

Page 147: ...al 14 7 Reserve capacity 1 29 US gal 4 9 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 12...

Page 148: ...cap clockwise until it clicks If you replace the fuel fill cap use a Honda Genuine replacement part or equivalent NOTICE Gasoline can damage the matte and camouflage coating Do not allow spilled gasol...

Page 149: ...s life Even the best oil wears out Changing oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient...

Page 150: ...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 detergent vegetab...

Page 151: ...riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the...

Page 152: ...vel 1 Park your ATV on a firm level surface 2 Start the engine in a well ventilated area and let it idle for 3 5 minutes If the air temperature is below 10 C 50 F let the engine idle for an additional...

Page 153: ...t crankcase cover and wipe it clean 6 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 l...

Page 154: ...rom the front right crankcase cover and 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 Inst...

Page 155: ...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 the engine warm to assure complete and rapid drain...

Page 156: ...ew oil filter with the rubber seal 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...

Page 157: ...specified torque 18 lbf ft 25 N m 2 5 kgf m 2 Fill the crankcase with the recommended grade oil approximately 4 0 US qt 3 8 3 Reinstall the engine oil fill cap and dipstick 4 Start the engine and let...

Page 158: ...ecautions on page 121 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...

Page 159: ...2 O ring 3 drain bolt and sealing washer 4 4 After the oil has completely drained reinstall the drain bolt with a new sealing washer and tighten it to the specified torque 9 lbf ft 12 N m 1 2 kgf m 5...

Page 160: ...3 Make sure the oil level is at the lower edge of the oil fill inspection hole 5 7 Coat a new O ring with grease and install it into the fill cap groove and tighten it to the specified torque 9 lbf ft...

Page 161: ...ecautions on page 121 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...

Page 162: ...Pour the drained oil into a suitable container 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 ca...

Page 163: ...es Check the antifreeze 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 cool...

Page 164: ...fer to Safety Precautions on page 121 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 operati...

Page 165: ...ays add coolant to the reserve tank Do not attempt to add coolant by removing the radiator cap 5 Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark 6 After...

Page 166: ...fficial Honda Service Manual page 258 To properly dispose of drained coolant refer to You the Environment page 214 NOTICE Improper disposal of drained fluids is harmful to the environment Coolant Repl...

Page 167: ...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 TRX520FA5 The right left and cente...

Page 168: ...plate 1 Remove the radiator cap lid page 155 2 Remove the reserve tank 1 by removing the bolt 2 and clips 3 page 135 3 Release the hoses 4 from the guides 4 Hold the reserve tank being careful not to...

Page 169: ...X520FA5 only Remove the 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 LEFT FRONT 3 clips 5 left radiator gri...

Page 170: ...ok B 9 Wash the radiator 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 par...

Page 171: ...n help you determine 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 mo...

Page 172: ...162 Air Cleaner 1 Remove the seat page 132 2 Unlatch the spring hooks 1 and retainer clips 2 3 Remove the air cleaner housing cover 3 Cleaning UNDER SEAT 1 spring hooks 3 air cleaner housing cover 1 3...

Page 173: ...ears 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 th...

Page 174: ...13 Insert the air 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 faci...

Page 175: ...Servicing Your Honda 165 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...

Page 176: ...uire more frequent 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 hous...

Page 177: ...djuster 3 2 Loosen 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...

Page 178: ...fully closed in all steering positions If there is a problem see your dealer 3 Inspect the condition of the throttle cable from the throttle lever down to the throttle body If the cable is kinked or c...

Page 179: ...emove the seat page 132 and tank cover assembly page 134 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 disconn...

Page 180: ...have a flat tip and sharp edges and the side electrode 3 should not be eroded If the electrodes and insulator tip appear unusually fouled or burned we suggest that you contact your dealer 6 Discard th...

Page 181: ...a First tighten the plug b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose the piston...

Page 182: ...will cause loss of power and possibly damage the valves For those who are mechanically proficient and have the proper tools instructions on adjusting valve clearances are given in the official Honda...

Page 183: ...ur engine from reaching 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...

Page 184: ...ge your normal load 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...

Page 185: ...on page 121 The spring pre load adjuster 1 has 5 positions for different load or riding conditions Use the pin spanner 2 to adjust the shock spring pre load Suspension Spring Pre Load 1 FRONT REAR 2 1...

Page 186: ...o 5 for when the ATV is more heavily loaded Also increase spring pre load for stiffer suspension Make sure that both shock absorbers are adjusted to the same position Always adjust the shock absorber...

Page 187: ...fluid leaks If the right brake 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...

Page 188: ...do add fluid have 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...

Page 189: ...eck the fluid level It should be above 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...

Page 190: ...he LOWER level mark check the brake pads for wear page 177 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 Che...

Page 191: ...the pads visually 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 replac...

Page 192: ...r Honda 182 Brakes Check the wear indicator 1 If the wear indicator aligns with the reference mark 2 both pads must be replaced see your dealer for this replacement RIGHT REAR 2 1 2 reference mark 1 w...

Page 193: ...ear brake lever parking brake lever 1 moves before the brake starts to take hold Freeplay measurement at the tip of the end of the brake lever should be 1 1 3 16 in 25 30 mm 3 If necessary adjust to t...

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

Page 195: ...t the right side behind the engine from time to time Adjustment is done by turning the adjusting nut 2 Hold the rear brake light switch and turn the nut in direction A if the switch operates too late...

Page 196: ...e not immune to punctures Always select your riding area with care The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damag...

Page 197: ...ad life and riding 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 mor...

Page 198: ...ridden for a few 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...

Page 199: ...the tire pressures 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 ca...

Page 200: ...Wear To check the condition of a tire tread measure the groove depth 1 in the center of the tire or check the wear indicator 2 For best performance you should replace a tire before the tread depth at...

Page 201: ...y cargo and have the tire replaced or permanently repaired as soon as possible For more information on temporary repairs see If You Have a Flat Tire page 226 A permanent repair such as an internal plu...

Page 202: ...originals Never replace just one tire The recommended tires for your ATV are When you replace a tire remember Have the tire replaced by your dealer if possible If you have a tire professionally replac...

Page 203: ...ront driveshafts The rear driveshaft guards 5 protect the rubber driveshaft boots and the rear driveshafts Check the guards and plate for cracks damage or looseness at intervals shown in the Maintenan...

Page 204: ...21 Check the rubber driveshaft boots 1 rubber propeller shaft boots 2 and rubber yoke joint boot 3 for cuts damage or leaking grease If necessary have your dealer replace them 1 1 rubber driveshaft bo...

Page 205: ...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 199 If you do not expect to...

Page 206: ...the best storage results from removing the battery and slow charging it every 30 days see Battery Charging page 199 Before you remove the battery be sure to read all the information that follows as w...

Page 207: ...ve the rear fender cover page 133 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 Rem...

Page 208: ...ng section once every 30 days Installation 1 Check that the battery rubber 5 for damage If necessary replace the battery rubber 2 Make sure the battery rubber is properly installed 3 Reinstall the bat...

Page 209: ...er 1 designed specifically 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...

Page 210: ...s or chemical solvents that could damage the metal paint plastic and camouflage coating on your ATV Honda SxS If your ATV is still warm from recent operation give the engine and exhaust system time to...

Page 211: ...or heavy grime If necessary use a mild cleaner degreaser to remove the grime 5 After washing rinse your ATV thoroughly with plenty of clean water to remove any residue Detergent residue can corrode al...

Page 212: ...lish and wipe paint 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...

Page 213: ...uminum 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...

Page 214: ...ially available spray cleaner polish or quality liquid or paste wax to finish the job Use only a non abrasive polish or wax made specifically for motorcycles or automobiles Apply the polish or wax acc...

Page 215: ...ort and store your Honda and how to be 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 S...

Page 216: ...clubs and off road 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 y...

Page 217: ...u might go from your base camp or help and how experienced you or your companions are in making repairs If you decide to take some tools spare parts or other supplies on the trail be sure you can carr...

Page 218: ...hen you transport your ATV we recommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle an...

Page 219: ...le from 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 t...

Page 220: ...hat way needed repairs 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...

Page 221: ...g in the cylinder perform the following 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 cc of c...

Page 222: ...f the floor 10 Cover 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...

Page 223: ...red for more than four months change the engine oil page 145 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 199 as requi...

Page 224: ...performance and may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosp...

Page 225: ...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...

Page 226: ...If you continue riding you could cause more damage and endanger your own safety After stopping take time to assess the situation Carefully inspect your ATV to identify the problem then consider your...

Page 227: ...time to assess the situation and your options before deciding what to do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have perma...

Page 228: ...ve a problem starting 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 pre...

Page 229: ...ttery lead low or dead battery Charge the battery page 199 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 de...

Page 230: ...fuel mixture See your dealer sooty exhaust rich fuel mixture See your dealer detonates or pings under load If applicable switch to the recommended octane gasoline page 136 or change your brand of gas...

Page 231: ...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 When the is blink...

Page 232: ...the transmission system has malfunctioned Use the following procedure to manually override the clutch of the transmission 1 Shift the transmission into 2nd gear 2 Apply the parking brake page 51 3 Tur...

Page 233: ...eft front fender Using a screwdriver turn the emergency valve 5 all the way in With the engine running slowly open the throttle to move the ATV forward 7 See your dealer as soon as possible When the b...

Page 234: ...e 130 4 Check the neutral indicator 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 e...

Page 235: ...the vehicle back and forth and try again 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 shif...

Page 236: ...provides a plug an installation tool tire cement and an instruction sheet Follow the instructions provided with the repair kit to make a temporary repair As soon as possible have the tire permanently...

Page 237: ...flat tire The ATV 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...

Page 238: ...utions on page 121 Removal 1 Park your ATV on a firm level surface Emergency Wheel Removal Installation 1 2 Wheel nuts 47 lbf ft 64 N m 6 5 kgf m Wheel nuts 62 lbf ft 84 N m 8 6 kgf m TRX520FA5 FA6 St...

Page 239: ...or rapid pad wear after reassembly Installation 1 Position the wheel 2 Position each wheel nut so that the tapered side faces the wheel rim 2 3 Hand tighten the wheel nuts on the wheel then lower the...

Page 240: ...cates a coolant leak Shut the engine off and wait until the steaming stops Look for a leak but don t touch the engine or radiator system Let everything cool off first Check for any restriction of air...

Page 241: ...he oil level If necessary add the recommended oil page 142 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 tempe...

Page 242: ...n fuse 1 Check all the fuses before looking elsewhere for another possible cause of the problem Replace any blown fuses and check component operation The main fuse and the circuit fuses are located un...

Page 243: ...seat page 132 3 Remove the rear fender cover page 133 4 To access the main fuse 1 2 remove the fuse cover 3 5 To access the main fuse 2 4 remove the fuse box cover 5 6 Pull the main fuse 1 2 out If th...

Page 244: ...of its retaining clips with fuse puller on the underside of the rear fender cover page 131 If the fuse is blown replace it with a spare fuse 8 of the same rating If you do not have a replacement fuse...

Page 245: ...ecking the fuse 2 Remove the seat page 132 3 Remove the rear fender cover page 133 4 To access the EPS fuse 1 remove the EPS fuse box cover 2 If the EPS block fuse is blown install the spare fuse page...

Page 246: ...can do without temporarily If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses t...

Page 247: ...ely carefully inspect 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 th...

Page 248: ...lose your key and 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 th...

Page 249: ...ine is not running it may be started using the recoil starter 1 Turn the ignition switch to the ON q position 2 Check if the transmission is in neutral by moving the vehicle back and forth 3 If the tr...

Page 250: ...he damage is and what tools and supplies you have with you If any component of the brake system is damaged you may be able to ride carefully back to your base using the other brake components for slow...

Page 251: ...tion contains dimensions 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...

Page 252: ...placement parts 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 155 The engine nu...

Page 253: ...e color label 1 is attached on the left side of the frame The color code is helpful when ordering replacement parts You may record the color and code in the Quick Reference section at the rear of this...

Page 254: ...ank capacity 3 88 US gal 14 7 including reserve fuel tank reserve 1 29 US gal 4 9 engine oil capacity after disassembly 4 6 US qt 4 4 after draining 3 8 US qt 3 6 after draining oil filter change 4 0...

Page 255: ...m capacity 1 7 US qt 1 6 Capacities passenger capacity operator only maximum weight capacity 573 lb 260 kg rider all cargo and accessories Engine Specifications displacement 31 6 cu in 518 cm3 bore st...

Page 256: ...final reduction front 3 230 rear 3 153 transmission ratio 1st 3 058 2nd 2 157 3rd 1 588 4th 1 181 5th 0 848 reverse 3 996 final drive shaft Chassis Suspension caster 1 trail 0 04 in 1 mm tire size fro...

Page 257: ...t headlight 12 V 50 W brake tail light LED neutral indicator LED reverse indicator LED high coolant temperature indicator LED PGM FI indicator LED differential lock indicator LED PS Electric Power Ste...

Page 258: ...kgf m rear final gear oil drain bolt 9 lbf ft 12 N m 1 2 kgf m rear final gear oil fill cap 9 lbf ft 12 N m 1 2 kgf m front final gear oil drain bolt 9 lbf ft 12 N m 1 2 kgf m front final gear oil fi...

Page 259: ...es Help assure your 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 ra...

Page 260: ...cable exhaust emissions 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 fr...

Page 261: ...spection of the components is recommended The exhaust emission control system is separate from the crankcase emission control system Evaporative Emission Control System USA 50 States meets California...

Page 262: ...nce driveability and poor fuel economy Federal regulations prohibit removing or disabling a device or element of design that may affect your engine s emission performance unless your ATV will be used...

Page 263: ...PERING ARE THE FOLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part of the intake system La...

Page 264: ...rovinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates for non road vehicles ETHANOL ethyl or grain alcohol up to 10 by volume You may...

Page 265: ...lastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resultin...

Page 266: ...ls that come near it Park your ATV away from high grasses dry leaves or other flammables A defective catalytic converter contributes to air pollution and can impair your engine s performance Follow th...

Page 267: ...ormation Consumer Information This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 258 Warranty Coverage 259 Warranty Service 260 Conta...

Page 268: ...rvice Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician but most mechanically capable owners shou...

Page 269: ...t posted on our website at www honda ca It is important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage does not apply to normal wear o...

Page 270: ...you the results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the rep...

Page 271: ...ealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address Motorcycle Division American Honda Motor Co Inc P O Bo...

Page 272: ...Honda accessories 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 produc...

Page 273: ...187 American Honda contacting 261 apparel protective 62 appearance care 200 authorized manuals 258 B bank angle sensor ignition cut off system 87 battery 195 brake light switch adjustment 185 brakes c...

Page 274: ...eaning appearance care 200 climbing hills 105 clip 135 color label 243 compartment owner s manual 131 storage 58 tool kit 130 component fails 240 consumer information 257 controls features 35 coolant...

Page 275: ...EPS 59 emission control systems 250 engine flooded 87 guard 193 number 242 oil 139 pinging 136 starting 84 stop switch 42 stopping 89 won t start 218 environment 214 EPS Electric Power Steering TRX520...

Page 276: ...efueling 137 reserve fuel supply 137 tank capacity 137 fuses 232 G gap spark plug 169 245 gasohol 254 gasoline 136 gear shifting 91 gearshift switch 47 guards 193 H headlight dimmer switch 43 headligh...

Page 277: ...ear position indicator 24 high coolant temperature indicator 14 17 230 LOW indicator 20 23 maintenance minder indicator 32 neutral indicator 14 17 PGM FI indicator 14 17 PS Electric Power Steering ind...

Page 278: ...component locations 127 hour meter 31 importance 119 minder indicator 32 precautions 121 record 126 safety 120 schedule 122 tripmeter 32 manual service 258 maximum weight limit 72 mode button 14 19 mo...

Page 279: ...ngers no carrying 65 pavement no riding on 79 pinging engine 136 plug spark 169 pre ride inspection 67 problems unexpected 216 propeller shaft boots 194 protective apparel 62 R range select lever 36 r...

Page 280: ...ion 77 clothing 62 over obstacles 112 precautions 79 preparing for 206 safety 2 safety precautions 79 through water 113 S safety important precautions 121 labels 5 riding precautions 79 schedule maint...

Page 281: ...ng on a hill 107 start override button 41 starting engine 84 troubleshooting 218 stop switch engine 42 stopping engine 89 storage ATV 210 owner s manual 131 suspension adjustment 174 spring pre load 1...

Page 282: ...ad conditions 189 190 tool kit 130 trailer hitch 53 trailer towing operational guidelines 73 weight limits 72 training rider 64 transmission range select 97 transporting your ATV 208 tripmeter 28 trou...

Page 283: ...lve clearance 172 vehicle identification no VIN 242 W warning labels 5 warranty coverage 259 extended 259 service 260 washing your ATV 201 water riding through 113 weight limit 72 wheel removal 228 Y...

Page 284: ......

Page 285: ......

Page 286: ...e of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly r...

Page 287: ...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...

Page 288: ...rts cables lights throttle brakes switches steering Fuel Capacity unleaded gasoline pump octane number 86 or higher 3 88 US gal 14 7 reserve 1 29 US gal 4 9 Engine Oil Capacity API Service Classificat...

Page 289: ...a Rear 4 4 psi 30 kPa Spark Plugs standard BKR5E 11 NGK or K16PR U11 DENSO Coolant ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Honda HP Coolant or an equiv...

Page 290: ...lights when the front differential lock mode engages 40 start override button 41 e RUN engine stop switch 42 r OFF engine stop switch 42 y ON headlight switch 43 t OFF headlight switch 43 u HI headlig...

Page 291: ...thalates and lead 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...

Page 292: ...PRINTED IN USA WPCXXXX 2019 XX L 00X31 HR6 6500 31HR6650...

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