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Honda Pioneer SXS500M 2019, Owner'S Manual

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Honda Pioneer SXS500M 2019 Owner'S Manual Download Page 1

2019

2019

2019

2019

OWNER’S MANUAL

OWNER’S MANUAL

SXS500M

SXS500M

Read this manual carefully,
it contains important safety information.

Minimum recommended operator age: 16

Models sold in and used in California:
The removal or modification of evaporative 
emission-related parts on this OHRV is illegal. Violators 
may be subject to civil and/or criminal penalties as 
provided under California and federal law.

Part Number

Summary of Contents for Pioneer SXS500M 2019

Page 1: ...portant safety information Minimum recommended operator age 16 Models sold in and used in California The removal or modification of evaporative emission related parts on this OHRV is illegal Violators...

Page 2: ...uction information 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 re...

Page 3: ...2019 Honda PIONEER SXS500M OWNER S MANUAL 19 SXS500M 31HL56400 book 2...

Page 4: ...our investment we urge you to keep your vehicle well maintained Scheduled service is a must of course but it s also important to observe the break in guidelines and perform all pre drive and other per...

Page 5: ...our website at www honda com USA www powersports honda com Canada www honda ca The following codes in this manual indicate each country SXS500M The illustrations herein are based on the SXS500M A type...

Page 6: ...not possible to warn you about all hazards associated with operating or maintaining this vehicle You must use your own good judgment You will find important safety information in a variety of forms in...

Page 7: ...ty Precautions Safety Section Driver Passenger Safety beginning on page 1 Instructions how to operate this vehicle correctly and safely In addition to the above your owner s manual is full of informat...

Page 8: ...ce of wearing a seat belt helmet protective eyewear and other protective gear how to make sure you and your Honda are ready to drive plus load limits and guidelines on carrying cargo and towing a trai...

Page 9: ...numbers technical specifications and other technical facts Consumer Information 231 Information on warranties emissions controls how to get a service manual and how to contact Honda Index 237 Alphabe...

Page 10: ...Contents 19 SXS500M 31HL56400 book 9...

Page 11: ...most important information and recommendations to help you drive your Honda safely Please take a few moments to read these pages This section also shows you the location of safety labels on your vehi...

Page 12: ...er allow anyone to ride in the middle of the bench seat There is no seat belt to restrain them Wearing a seat belt and positioning it properly is your best protection against injury in a crash or roll...

Page 13: ...n be difficult especially if you are stranded far from your base To help avoid problems inspect your Honda before each use and perform all recommended maintenance Alcohol and driving don t mix Even on...

Page 14: ...weight reducing the amount of cargo you can carry and can raise the vehicle s center of gravity increasing the risk of a rollover Check with your dealer for assistance and always follow these guideli...

Page 15: ...esign or operation Such changes could seriously impair your vehicle s handling stability and braking and make it unsafe to drive We also advise you not to make any modifications or remove any equipmen...

Page 16: ...s or rides in the vehicle should read and understand this information before driving The labels should be considered permanent parts of the vehicle If a label comes off or becomes hard to read contact...

Page 17: ...Driver Passenger Safety 7 Safety Labels general warning tag shift drive select 19 SXS500M 31HL56400 book 7...

Page 18: ...Driver Passenger Safety 8 Safety Labels general warning general warning 19 SXS500M 31HL56400 book 8...

Page 19: ...Driver Passenger Safety 9 Safety Labels loading warning trailer hitch tire overload warning OSHA 19 SXS500M 31HL56400 book 9...

Page 20: ...Driver Passenger Safety 10 19 SXS500M 31HL56400 book 10...

Page 21: ...e Indicator 17 High Coolant Temperature Indicator 17 PGM FI Malfunction Indicator Lamp MIL 17 Seat Belt Indicator 17 Multi function Display 20 Speedometer Display 21 Odometer Display 22 Gear Position...

Page 22: ...Instruments Controls 12 Instruments Controls Seat Belts 44 Passenger Handhold 49 Storage Compartments 50 Accessory Power Socket 51 Trailer Hitch 52 19 SXS500M 31HL56400 book 12...

Page 23: ...light switch page 33 accessory power socket page 51 parking brake lever page 39 ignition switch page 32 drive mode select lever page 36 indicators displays page 16 shift paddles page 35 reverse lever...

Page 24: ...Instruments Controls 14 Operation Component Locations seat belt page 44 side net page 41 door page 40 passenger handhold page 49 19 SXS500M 31HL56400 book 14...

Page 25: ...Instruments Controls 15 Operation Component Locations cargo carrier page 61 trailer hitch receiver page 52 seat belt page 44 side net page 41 door page 40 19 SXS500M 31HL56400 book 15...

Page 26: ...ed on the following pages Lamp Check The indicators come on and go off sequentially when you turn the ignition switch to the ON q position If one of these indicators does not come on key ON check have...

Page 27: ...ife of the engine If this indicator comes on while you are driving stop as soon as possible turn the engine off and let it cool PGM FI Malfunction Indicator Lamp MIL This indicator comes on and stays...

Page 28: ...21 Odometer display Shows fuel gauge digital clock odometer tripmeter coolant temperature gauge hour meter maintenance tripmeter and maintenance hour meter page 22 Gear position display Shows gear po...

Page 29: ...n display will temporarily show all the modes and digital segments and initial message So you can make sure the liquid crystal display is functioning properly If any part of this display does not come...

Page 30: ...multi function display consists of the following function displays Multi function Display Speedometer display Odometer display Gear position display mode switch gear position display speedometer displ...

Page 31: ...ge the mileage unit press and hold the mode switch for more than 5 seconds in odometer mode page 22 with the vehicle stopped Speedometer Blinking If the speedometer digits and seat belt indicator blin...

Page 32: ...s shown in the illustration If there are unusual indications with your SXS and mode switch is not pressed for 10 seconds a message will automatically appear in the display Odometer Display Fuel gauge...

Page 33: ...s in when the fuel level reaches only one segment remaining the display will automatically switch to the fuel gauge display You should refuel as soon as possible The amount of fuel left in the tank wi...

Page 34: ...ments Controls 24 Indicators Displays Fuel gauge failure If the fuel system has an error the fuel gauge will flash If this occurs see your dealer as soon as possible fuel gauge 19 SXS500M 31HL56400 bo...

Page 35: ...he time 1 Turn the ignition switch to ON q 2 Press and hold the mode switch in the clock mode The clock will start blinking 3 Press and hold the mode switch until the desired time appears 4 To complet...

Page 36: ...xceeds 999 999 Tripmeter The tripmeter shows the number of miles or kilometers ridden with the TRIP display since you last reset the tripmeter The tripmeter returns to 0 when the readout exceeds 999 9...

Page 37: ...ating temperature range is within the section between the H and C displays If all sections of the coolant temperature gauge including segment H and high coolant temperature indicator are on automatica...

Page 38: ...perature system has an error the coolant temperature gauge will flash and appear in the display and or the high coolant temperature indicator will turn on If this occurs see your dealer as soon as pos...

Page 39: ...icators Displays Hour meter The hour meter display shows accumulated hours while the ignition is ON q The hour meter locks at 99 999 9 when the readout exceeds 99 999 9 hour meter hour meter display 1...

Page 40: ...ndicator appears be sure to reset the maintenance minder after performing the scheduled maintenance Resetting the indicator To reset the indicator press and continue to hold the mode switch and turn t...

Page 41: ...on the gear position indicator when the transmission is not shifted into gear properly Before driving check that the gear position is properly displayed on the gear position indicator If the gear pos...

Page 42: ...re off The key can be inserted and removed only when it is in this position ON q The electrical circuits are on You can use the accessory power socket in this position START p This position is used on...

Page 43: ...ontrols The headlight switch is located on the front console to the right side of the steering wheel This switch turns the headlights and taillight on and off Headlight Switch headlight switch OFF t O...

Page 44: ...of the drive mode select lever The AT MT switch has two positions AT automatic shift mode and MT manual shift mode To select the transmission mode turn the AT MT switch to the desired position See Shi...

Page 45: ...and the downshift paddle to shift to a lower gear position and R reverse In MT mode the shift paddles are used to change gears while driving the SXS In AT mode you can drive the SXS without operating...

Page 46: ...nd 4WD To check your present drive mode look at the 4WD indicator 2WD mode The 4WD indicator will be off when the 2WD mode is engaged 4WD mode The 4WD indicator will be on when the 4WD mode is engaged...

Page 47: ...OTICE Changing drive modes while the vehicle is moving could damage the drivetrain After changing the drive mode drive several yards making right and left turns and make sure that indicators work prop...

Page 48: ...mission cannot be shifted into reverse if the SXS is moving Make sure the transmission is in neutral While pulling the reverse lever and depressing the brake pedal pull the downshift paddle left handl...

Page 49: ...ull the lever up fully To release it pull up slightly push the button at the end of the lever then lower it Before driving check that the parking brake indicator is off NOTICE Driving with the parking...

Page 50: ...oors are securely closed before driving your Honda SXS and never remove a door If a door is damaged or does not close securely see your dealer for repair or replacement Do not drive the Honda SXS with...

Page 51: ...with side net D rings and side net snap hooks To function properly the side nets should be tight If a side net is loose tighten the belts on the side net D rings Be sure the side nets are properly ad...

Page 52: ...e on page 95 1 Hook the side net snap hooks 2 Tighten the belt on the lower side net D ring and door side net D ring Side net snap hooks wear limit Inspect the side net snap hooks for wear If the side...

Page 53: ...someone to ride there Do not drive with any cargo on the center of the seat Cargo on the center of the bench seat can interfere with the driver s ability to control the vehicle and can be thrown aroun...

Page 54: ...ection against serious injuries in any type of crash so make sure all occupants always buckle up before driving Of course seat belts cannot completely protect you in every crash But in most cases seat...

Page 55: ...for one second if the vehicle is moving The speed limitation will be removed and seat belt indicator and speedometer will stop blinking after the driver follows this procedure and correctly deploys a...

Page 56: ...njuries 3 Position the lap part of the belt as low as possible across your hips then pull up on the shoulder part of the belt to make sure the lap part is snug This keeps you connected to the vehicle...

Page 57: ...e latch plate When the seat belt is subjected to intense forces during a crash or rollover part of the holder locks the belt Unlock 1 To unlatch a seat belt press the red PUSH button on the buckle 2 H...

Page 58: ...ely in your seat while keeping some tension on the belt During a crash or rollover the retractor automatically locks the belt to help restrain your body Do not put any accessories on a seat belt as th...

Page 59: ...t protective structure OPS has a handhold to give a passenger extra support when the vehicle travels over rough or bumpy terrain Passenger can also brace their feet against the floorboard Passenger Ha...

Page 60: ...Instruments Controls 50 Storage Compartments Your Honda SXS has two drink holders drink holders 19 SXS500M 31HL56400 book 50...

Page 61: ...d to power such items as a trouble light spotlight CB radio or cell phone but not a heat generating accessory such as a car cigarette lighter To use the accessory power socket the engine must be on an...

Page 62: ...our Honda SXS is equipped with a trailer hitch receiver that accepts a 1 1 4 inch drawbar You can purchase an approved drawbar from your Honda dealer See page 63 for page Towing a Trailer trailer hitc...

Page 63: ...eck on your vehicle It also includes important information about loading cargo Are You Ready to Drive 54 Age Size Recommendations 54 Protective Apparel 55 Get to Know Your Vehicle 56 Don t Drink Drive...

Page 64: ...eat belt properly page 44 and operate all the controls A passenger should also be tall enough to wear the seat belt properly and ride with both feet on the floor Age Size Recommendations WARNING 3WARN...

Page 65: ...les or a face shield For your safety we also recommend that you always wear boots gloves long pants and a long sleeved shirt or jacket whenever you drive Protective Apparel WARNING 3WARNING Driving or...

Page 66: ...conditions It s well known that alcohol and drugs can seriously affect a person s judgment perception and ability to safely operate any vehicle We therefore strongly recommend that you do not drive or...

Page 67: ...ur vehicle has overturned or been involved in a crash do not drive it until it has been inspected by your dealer There may be damage or other problems you cannot see WARNING 3WARNING Improperly mainta...

Page 68: ...or fumes if you smell any fuel turn the ignition switch to OFF w immediately and see your dealer Brake Fluid Check the level page 155 If it is near MIN check the brake pads for wear page 157 If the br...

Page 69: ...evenly oiled Air Cleaner Housing Drain Tube Check for deposits in the drain tube If necessary clean the tube page 137 and check the air cleaner housing Suspension Check the condition of all suspension...

Page 70: ...rly The seat belts must move smoothly when pulled out and retract on their own when released The latch plates should click securely into the buckles and release when the release buttons are pushed fir...

Page 71: ...reduce the maximum cargo weight you can carry Load Limit Maximum weight capacity 880 lb 399 kg This includes the weight of cargo occupants accessories and trailer tongue load Maximum cargo weight 450...

Page 72: ...ing Be aware that carrying tall heavy items will significantly raise the vehicle s center of gravity increasing the chance of a rollover Never let a passenger ride in the rear cargo area or hang onto...

Page 73: ...Maximum weight capacity on page 61 Total Trailer Weight Check the weight of a fully loaded trailer or estimate the total by adding the weight of the trailer as quoted by the trailer maker with the we...

Page 74: ...use a proper trailer hitch Do not tow by attaching a rope or cable to the vehicle s frame Secure all items inside the trailer so they cannot shift while driving Loading a Trailer WARNING 3WARNING Exce...

Page 75: ...r operating on different types of terrain driving with cargo and towing a trailer Basic Operation 66 Starting Stopping the Engine 66 Shifting Gears 68 Driving in Reverse 74 Selecting a Drive Mode 75 P...

Page 76: ...Make sure the doors side nets and front hood are securely closed 2 Check that any items you may be carrying are stored properly or fastened down securely 3 Fasten your seat belt Check that your passen...

Page 77: ...does not start after 5 seconds turn the key back to the OFF w position and wait about 10 seconds before turning it to START p again 4 If the engine does not start within 5 seconds or starts but stalls...

Page 78: ...AT MT switch AT mode This mode automatically shifts the gears with optimal timing according to your driving conditions The gear position indicator shows D for forward gears N for neutral and R for re...

Page 79: ...The gear position indicator will show 1 2 3 4 or 5 for forward gears N for neutral and R for reverse Holding the shift paddle does not continuously shift the gears To continue shifting release your f...

Page 80: ...e sure the gear position indicator shows D 3 Release the pressure from the brake pedal and increase engine speed by gradually pressing the accelerator pedal The transmission cannot be upshifted from n...

Page 81: ...n operating the shift paddles while AT mode is selected the D displayed in the gear position indicator changes to a gear position number 1 5 Because the gear change is temporary the vehicle automatica...

Page 82: ...When speed increases shift to 2nd gear by pulling the upshift paddle once Lifting off the throttle is recommended but not required 5 Repeat this sequence to progressively upshift to 3rd 4th and 5th to...

Page 83: ...issions control NOTICE Improper shifting can damage the engine transmission and drive train Also coasting or towing the SXS for long distance with the engine off can damage the transmission Shifting U...

Page 84: ...pulling the reverse lever and depressing the brake pedal pull the downshift paddle once to shift into R reverse gear 4 Make sure that the reverse indicator comes on 5 Release the brake pedal and rever...

Page 85: ...from one mode to another be sure the vehicle is stopped and the engine is idling See page 36 for additional information Selecting a Drive Mode 2WD This mode supplies power to the rear wheels only thi...

Page 86: ...must park on a slope block the wheels to help keep the vehicle from sliding After bringing your vehicle to a stop 1 Keep your foot on the brake pedal while you shift into neutral N 2 Set the parking b...

Page 87: ...re Driving section page 53 and the precautions below We also recommend that you complete the Recreational Off Highway Vehicle ROV E Course The free course is available at www ROHVA org The two hour RO...

Page 88: ...ing signs Control Speed Driving at excessive speed for the terrain or other conditions increases the chance of a crash or overturn Always reduce speed when driving on hilly terrain or when carrying ca...

Page 89: ...that allow good traction in sand loose dirt wet grass and other low traction surfaces These advantages come at some cost Because your vehicle is taller and rides higher off the ground it can more eas...

Page 90: ...conditions One minute you can be on firm soil and the next in soft sand or deep mud A path can quickly change from level to bumpy slope at a dangerous angle or disappear in a drop off Always keep your...

Page 91: ...top Do not drive across a steep slope with a trailer Use lower gears when towing a trailer or carrying extra cargo Making Turns The basic turning technique for Honda SXS is to drive at low speed and g...

Page 92: ...ger your cargo and your vehicle can handle For example ask yourself Is the hill too steep Is the incline constant or are there places where it gets suddenly steeper If you run out of power you may not...

Page 93: ...peed you may begin to stall If that happens Stop the vehicle and set the parking brake If you have a passenger you may want to have them get out and move away from the vehicle If you are headed straig...

Page 94: ...vehicle s narrower track and higher center of gravity increases the chance of tipping or rolling over If you drive across a slope and an uphill wheel hits a bump or a downhill wheel drops into a hole...

Page 95: ...d good traction so you can enter the stream and exit safely The surface under the water appears to provide good traction Remember the water may hide hazards such as rocks holes mud or slippery vegetat...

Page 96: ...Basic Operation Driving Guidelines 86 19 SXS500M 31HL56400 book 86...

Page 97: ...nmental Protection Agency EPA the California Air Resources Board CARB and Environment and Climate Change Canada ECCC see page 224 USA Only Maintenance replacement or repair of the emission control dev...

Page 98: ...1 Engine Oil Filter 114 Front Final Gear Oil 124 Rear Final Gear Oil 126 Coolant 128 Air Cleaner 133 Lubrication 138 Engine Accelerator Pedal 141 Reverse Inhibitor System 143 Spark Plug 145 Spark Arre...

Page 99: ...aintenance Schedule The service intervals in this schedule are based on average operation conditions Frequent servicing of the air cleaner is especially important to help you avoid a possible costly e...

Page 100: ...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 follow However...

Page 101: ...sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around gasoline Use only non flammable solvent not gasoline to clean parts Keep cig...

Page 102: ...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 tools and e...

Page 103: ...first See Initial Maintenance on the maintenance schedule Regular Maintenance Interval 1 Appears 600 miles 1 000 km or 100 operating hours after the Initial Maintenance is performed and maintenance m...

Page 104: ...items particularly those marked and may require more technical information and tools Consult your dealer Summary of Maintenance Schedule Notes NOTES Should be serviced by your dealer unless you have...

Page 105: ...nt and snap hooks 41 Reverse inhibitor system 143 Check brake fluid Check fluid level once a month 155 Replace engine oil and oil filter 119 Inspect valve clearance Every 600 miles 1 000 km or 100 ope...

Page 106: ...0 500 600 ITEMS Month 1 12 Lubricate all hinges latches and pivots 138 Inspect the following items Suspension components Wheels 168 Driveshaft boots 169 Accelerator and brake pedals 141 158 Brake ligh...

Page 107: ...letes this record All scheduled maintenance including the 100 mile 150 km or 20 hours or 1 month initial maintenance is considered a normal owner operating cost and will be charged for by your dealer...

Page 108: ...cates something visible seat back page 107 brake pedal page 158 accelerator pedal page 141 parking brake lever page 159 Indicates something concealed tool kit gear change tool page 103 reverse lever p...

Page 109: ...olant reserve tank page 130 fuel fill cap page 112 front final gear oil filler cap front final gear oil drain plug pages 124 125 battery page 173 main fuse page 205 fuse box page 206 front hood page 1...

Page 110: ...gear oil filler cap rear final gear oil drain plug pages 126 127 air cleaner housing drain tube page 137 spark plug page 145 Indicates something visible Indicates something concealed air cleaner page...

Page 111: ...tenance Component Locations brake fluid reservoir tank page 155 front brake calipers page 157 driveshaft boots page 169 brake light switch page 160 front suspension spring pre load adjusters page 151...

Page 112: ...omponent Locations driveshaft boots page 169 rear brake caliper page 157 rear suspension spring pre load adjusters page 153 Indicates something visible Indicates something concealed center rear panel...

Page 113: ...he compartment under the seat bottom To access the tool kit and the gear change tool remove the seat bottom page 106 An optional larger tool kit may be available Check with your dealer s parts departm...

Page 114: ...it with you for easy reference Store your owner s manual in the plastic document bag under the seat bottom The owner s manual should be stored in the plastic bag Be careful not to flood this area when...

Page 115: ...r system adjustment and throttle cable adjustment to check the coolant level and for washing the radiator fan area Removal 1 Turn the knobs outward 2 Remove the prongs from the grommets 3 Remove the f...

Page 116: ...to change the engine oil filter and to access the tool kit gear change tool and owner s manual Removal 1 Open the doors page 40 2 Pull the rear of seat bottom upward then slide it slightly backward I...

Page 117: ...ange the engine oil filter to clean the air cleaner to remove the center rear panel Removal 1 Open the doors page 40 2 Pull the bottom of seat back forward then slide it slightly downward Installation...

Page 118: ...the engine oil filter to clean the air cleaner Removal 1 Remove the seat back page 107 2 Release the prongs from their grommets 3 Pull the center rear panel forward Installation 1 Insert the tabs int...

Page 119: ...moval and installation 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 120: ...D mode and set the parking brake securely Use only on a firm level surface Place a jack only at the specified jack up point Do not leave any person or cargo in the vehicle Do not place any object abov...

Page 121: ...ctane number For information on the use of oxygenated fuels see page 228 Use of lower octane gasoline can cause persistent pinging or spark knock a loud rapping noise which if severe can lead to engin...

Page 122: ...ld refuel as soon as possible Refer to Safety Precautions on page 91 1 Turn the fuel fill cap counterclockwise 2 Add fuel until the level reaches the bottom of the filler neck Avoid over filling the t...

Page 123: ...or equivalent NOTICE Gasoline can damage the camouflage coating Do not allow spilled gasoline to pool on camouflage colored bodywork Also do not allow gasoline soaked rags to be placed on camouflage b...

Page 124: ...he best oil wears out Changing oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause...

Page 125: ...r 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 vegetable or castor...

Page 126: ...ea 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 standard...

Page 127: ...s Stop the engine and wait 2 3 minutes 3 Remove the seat bottom page 106 and fold open the rubber dust cover on the left side 4 Remove the oil filler cap dipstick from the front crankcase cover and wi...

Page 128: ...oil into the fill cap hole up to the upper level mark on the dipstick Do not overfill 7 Reinstall the oil filler cap dipstick rubber dust cover and seat bottom NOTICE Running the engine with an improp...

Page 129: ...rofessional tools such as a torque wrench and access from underneath the vehicle as well as the means for disposing of the drained fluid page 188 If you do not have the skills or the tools see your de...

Page 130: ...seat back page 107 7 Remove the center rear panel page 108 8 Remove the clips page 109 and screws from right seat bottom cover and flip it forward leaving ECU and wiring in place The oil filter can b...

Page 131: ...tall a new oil filter with the rubber seal facing out away from the engine You will see the OUT SIDE TOWARD FILTER COVER mark on the filter body near the seal Use only the Honda Genuine oil filter or...

Page 132: ...suitable container and dispose of it in an approved manner page 188 NOTICE Improper disposal of drained fluids is harmful to the environment 14 Install the right seat bottom cover by flipping it back...

Page 133: ...the seat bottom 23 Start the engine and let it idle for 3 5 minutes 24 Remove the seat bottom and fold open the rubber dust cover 25 Stop the engine and after 2 3 minutes check the oil level Make sur...

Page 134: ...er inspection hole 4 Apply a thin coat of grease to a new O ring and insert it into the oil filler cap groove 5 Install and tighten oil filler cap to the specified torque 9 lbf ft 12 N m 1 2 kgf m Oil...

Page 135: ...e 9 lbf ft 12 N m 1 2 kgf m 5 Fill the front final gear with the recommended oil 17 2 US oz 510 cm3 6 Make sure the oil level is at the lower edge of the oil filler inspection hole 7 Apply a thin coat...

Page 136: ...ller inspection hole 4 Apply a thin coat of grease to a new O ring and insert it into the oil filler cap groove 5 Install and tighten oil filler cap to the specified torque 9 lbf ft 12 N m 1 2 kgf m O...

Page 137: ...e 9 lbf ft 12 N m 1 2 kgf m 5 Fill the rear final gear with the recommended oil 5 1 US oz 150 cm3 6 Make sure the oil level is at the lower edge of the oil filler inspection hole 7 Apply a thin coat o...

Page 138: ...eze container label Use only distilled water as a part of the coolant solution Water that is high in mineral content or salt may be harmful to the aluminum engine NOTICE Using coolant with silicate in...

Page 139: ...Refer to Safety Precautions on page 91 Check the engine coolant level every day before operating your Honda SXS and add if needed 1 Make sure the vehicle is parked on a firm level surface 2 Remove the...

Page 140: ...to add coolant by removing the radiator cap 5 Add coolant to the reserve tank as required to bring the coolant level to the MAX level mark 6 After adding coolant install the reserve tank cap and inst...

Page 141: ...da Service Manual To properly dispose of drained coolant refer to You the Environment page 188 NOTICE Improper disposal of drained fluids is harmful to the environment Coolant Replacement WARNING 3WAR...

Page 142: ...our dealer if more than 20 of the radiator surface air flow is restricted Clean the radiator core after driving your Honda SXS in mud To clean the radiator core 1 Remove the front hood page 105 2 Wash...

Page 143: ...rmine the correct service interval for your driving conditions Your Honda SXS s air cleaner has very specific performance requirements Use a new Honda Genuine air cleaner specified for your model or a...

Page 144: ...er 1 Remove the seat back page 107 and center rear panel page 108 2 Unlatch the retainer clips 3 Remove the air cleaner housing cover Cleaning UNDER CARGO CARRIER air cleaner housing cover retainer cl...

Page 145: ...eaner in clean non flammable high flash point solvent such as kerosene Do not use gasoline After cleaning gently squeeze out the remaining solvent Avoid twisting or wringing the air cleaner This can t...

Page 146: ...s to evenly spread the oil into the air cleaner Gently squeeze out any excess oil To keep your hands dry place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner 12 I...

Page 147: ...spection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle 1 Remove the air cleaner housing drain tube plug by removing the clip 2 Drain the deposits 3 Rei...

Page 148: ...ording to the maintenance schedule page 96 Consult your dealer for more information about lubrication procedures Apply grease to each pivot to prevent corrosion Check for smooth movement after lubrica...

Page 149: ...as shown in the following illustration Remove the dust cover Lubricate the drive mode select lever pivot as shown in the following illustration Remove the front hood page 105 parking brake pivot UNDER...

Page 150: ...ation Lubricate the door latch spring as shown in the following illustration Open the door page 40 The left and right door latch springs can be lubricate in the same manner door latch spring LEFT SIDE...

Page 151: ...not open fully If the accelerator pedal has no play the accelerator may be hard to control and the idle speed may be erratic Check the accelerator pedal play periodically in accordance with the Perio...

Page 152: ...ut 4 Turn the adjuster to obtain the correct freeplay 5 Tighten the lock nut and reinstall the sleeve 6 After adjustment check for smooth operation of the accelerator pedal 7 Install the remaining par...

Page 153: ...ows for proper reverse gear selection and adjust the play if necessary Refer to maintenance schedule on page 95 Inspection Check freeplay of the reverse lever Freeplay 1 4 1 2 in 6 0 12 0 mm Reverse L...

Page 154: ...n the lock nut and turn the adjusting nut After adjustment tighten the lock nut securely and check for smooth operation of the reverse lever 2 Install the remaining parts in the reverse order of remov...

Page 155: ...nch provided in the tool kit remove the spark plug 5 Inspect the electrodes and center porcelain for deposits corrosion or carbon fouling If the corrosion or deposits are heavy replace the plug Clean...

Page 156: ...or chipped 7 Using a wire type feeler gauge check the spark plug gap If adjustment is necessary bend the side electrode carefully The gap should be 0 039 0 043 in 1 00 1 10 mm spark plug cap side elec...

Page 157: ...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 may be...

Page 158: ...r 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 159: ...stem Stop the engine and check for any sign of exhaust gas leakage Listen for exhaust leaks near the muffler which is located by the left rear wheel well Exhaust System Inspection check for exhaust le...

Page 160: ...stems adjust the amount of force required to begin compression of the spring You may adjust the spring pre load of both suspension systems Consider adjusting your suspensions pre load whenever you cha...

Page 161: ...al are limited to adjustments of the shock assembly only Refer to Safety Precautions on page 91 The spring pre load adjuster has 5 positions for different load or driving conditions Before adjusting t...

Page 162: ...st the shock absorber position in sequence 1 2 3 4 5 or 5 4 3 2 1 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber Using a pin spanner which is available from your dea...

Page 163: ...0001 Available through your dealer Position 1 for a light load and smooth terrain Position 2 standard position Positions 3 to 5 for when the SXS is more heavily loaded Also increase spring pre load fo...

Page 164: ...e brake pedal freeplay seems abnormal or the pedal feels spongy see your dealer to have the air bled from the system Refer to Safety Precautions on page 91 Push down on the brake pedal to check that t...

Page 165: ...er check the system as soon as possible NOTICE Brake fluid can damage plastic and painted surfaces Handle with care Check the fluid level on level ground 1 Slide the brake fluid reservoir tank cap cov...

Page 166: ...ontact with skin or eyes If brake fluid comes in contact with your eyes wash them out with clean water and immediately call a doctor If brake fluid comes in contact with your skin wash with clean wate...

Page 167: ...that the pads are designed to make a metallic noise during braking when they reach the wear limit Front If you hear a continuous metallic friction sound when applying the brakes the brake pads need to...

Page 168: ...ecautions on page 91 Check that the brake pedal moves smoothly and does not feel abnormally spongy Refer to the maintenance schedule on page 96 Brake Pedal Inspection CHECK THAT THE BRAKE PEDAL MOVES...

Page 169: ...d from the lever fully disengaged at stopper to when lever is pulled up and resistance is felt in lever Parking brake lever freeplay is 1 9 16 1 15 16 in 40 50 mm If adjustment is necessary have the p...

Page 170: ...htly behind the brake fluid reservoir The brake light should turn on just before the brake works Adjustment is done by holding the switch body and turning the adjusting nut Turn the nut in direction A...

Page 171: ...ow and when to check your air pressure how to inspect your tires for wear and damage and our recommendations for tire repair and replacement WARNING 3WARNING Using tires that are excessively worn impr...

Page 172: ...comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tires make your Honda SXS drive harshly are more prone to d...

Page 173: ...or 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 driving s...

Page 174: ...o look for Bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Cuts slits or cracks in the tires Replace the tire if you can see fabric or cord Nails or othe...

Page 175: ...check the condition of a tire tread measure the groove depth in the center of the tire or check the wear indicator For best performance you should replace a tire before the tread depth at the center r...

Page 176: ...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 199 A permanent repair such as an internal plu...

Page 177: ...st one tire The recommended tires for your Honda SXS are When you replace a tire remember Have the tire replaced by your Honda dealer if possible If you have a tire professionally replaced at a non Ho...

Page 178: ...Honda 168 Wheels Check that the wheel nuts are tight and there are no cracks or deformation in the wheel Inspection CHECK FOR CRACKS OR DEFORMATION CHECK THAT THE WHEEL NUTS ARE TIGHT 19 SXS500M 31HL...

Page 179: ...ons on page 91 Check the boots for tears or traces of splattered grease If necessary have your dealer replace them FRONT driveshaft boots driveshaft boots REAR front arm ball joint boots front arm bal...

Page 180: ...discharge If you have electrical accessories on your Honda SXS or do not drive frequently we recommend that you charge the battery frequently see Battery Charging page 174 If you do not expect to driv...

Page 181: ...rn brown When this stops wash it off with plain water Dry off the battery with a cloth or paper towel You will get the best storage results from removing the battery and slow charging it every 30 days...

Page 182: ...sconnect the positive terminal lead 5 Remove the battery from the battery box 6 Charge the battery see the following section unless you have been driving regularly 7 Store your battery in an easy to r...

Page 183: ...rder of removal Be sure to connect the positive terminal first then the negative terminal Make sure the clock is set to the proper time after the battery is reconnected page 25 positive terminal lead...

Page 184: ...cifically for your Honda which can be purchased from your dealer These units can be left connected for long periods without risking damage to the battery However do not intentionally leave the charger...

Page 185: ...lastic and camouflage coating on your Honda SXS If your Honda SXS is still warm from recent operation give the engine and exhaust system time to cool off Park in a shady area Washing your Honda SXS in...

Page 186: ...5 Dry your Honda SXS with a chamois or a soft towel Leaving water on the surface to air dry can cause dulling and water spots As you dry inspect for chips and scratches 6 Start the engine and let it i...

Page 187: ...paint chrome glass and clear plastic Light road grime 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 ab...

Page 188: ...chip that exposes the metal first apply primer to prevent corrosion and then apply the touch up paint Several thin layers of touch up paint are better than one thick coat Refer to Safety Precautions...

Page 189: ...Honda and how to be an environmentally responsible Honda SXS owner Preparing for a Drive 180 What to Take to the Operating Area 180 What to Take on the Trail 181 Transporting Your Honda 182 Storing Y...

Page 190: ...only the Ministry of Natural Resources Canada only driver s clubs and off road magazines are good sources of information Along with your Honda SXS and personal safety gear you should take along some...

Page 191: ...ht go from help and how experienced you or your companions are in making repairs If you decide to take some tools spare parts or other supplies on the trail be sure you can carry them safely and know...

Page 192: ...sporting Your Honda Do not tow your Honda SXS behind a car or other vehicle except on a trailer Follow these procedures 1 Set the parking brake and the drive mode select lever in 4WD 19 SXS500M 31HL56...

Page 193: ...own straps are available 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 Honda SXS 3 Rock the vehicle back...

Page 194: ...SA only For more information about storage refer to the Honda Winter Storage Guide available from your dealer Canada only For more information about storage visit our website at www honda ca and look...

Page 195: ...to the fuel injector 4 To prevent rusting in the cylinder perform the following Remove the seat back page 107 and center rear panel page 108 and disconnect the spark plug cap from the spark plug Remov...

Page 196: ...a minimum of daily temperature variation 9 Place your Honda SXS on blocks to lift all tires off the floor 10 Cover your Honda SXS with a porous material Avoid using plastic or similar non breathing co...

Page 197: ...an four months change the engine oil page 119 3 If your Honda SXS has been stored for more than two months ask your dealer to drain and replace the fuel 4 Charge the battery page 174 as required Insta...

Page 198: ...may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your Honda SXS Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s pro...

Page 199: ...Also review the tips in Preparing for a Drive page 180 General Guidelines 190 If Your Engine Quits or Won t Start 192 If the Shift Paddles Do Not Function 195 If the Transmission Is Not Functioning Pr...

Page 200: ...ontinue driving if you have a flat tire or you hear an unusual noise or your Honda SXS just doesn t feel right If you continue driving you could cause more damage and endanger your own safety After st...

Page 201: ...situation and your options before deciding what to do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have permanent repairs made a...

Page 202: ...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 SXS won t start listen as you turn the ignition key to...

Page 203: ...lp see your dealer faulty starter motor If all possible causes are negative the starter motor may be faulty See your dealer SYMPTOM Starter motor works but the engine won t start POSSIBLE CAUSE WHAT T...

Page 204: ...sooty exhaust rich fuel mixture See your dealer detonates or pings under load If applicable switch to the recommended octane gasoline page 111 or change your brand of gasoline If the problem persists...

Page 205: ...ignition switch to the OFF w position 3 After the engine stops turn the ignition switch to the ON q position 4 Pull the upshift paddle then the downshift paddle and check that they are functioning 5 I...

Page 206: ...he 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 SXS inspected by your dealer When the is bl...

Page 207: ...utral go to step 6 If the transmission is not in neutral fold open the rubber dust cover and use the gear change tool to shift to neutral so you will be able to start the engine Refer to How to Shift...

Page 208: ...forth and try again If the transmission still will not shift invert the gear change tool and try again Return the gear change tool to its under seat bottom on the left side Do not attempt to shift ge...

Page 209: ...on as possible have the tire permanently repaired by your dealer Any tire that cannot be repaired should be replaced Whenever the Honda SXS is to be operated far from service facilities or available t...

Page 210: ...uts 3 Raise the front or rear wheels off the ground page 110 4 Remove the wheel nuts 5 Remove the wheel Avoid getting grease oil or dirt on the disc or pad surfaces when removing and installing each w...

Page 211: ...hten the wheel nuts on the wheel then lower the Honda SXS to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque 98 lbf ft 133 N m 13 6 kgf m If...

Page 212: ...s 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 flow...

Page 213: ...leak Check the oil level If necessary add the recommended oil page 115 to the upper level mark If you must leave your Honda SXS to get oil secure it as much as possible Start the engine and check tha...

Page 214: ...da SXS stops working the first thing you should check for is a blown fuse Check all the fuses before looking elsewhere for another possible cause of the problem Replace any blown fuses and check compo...

Page 215: ...ng or replacing the fuses 2 To access the main fuse remove the battery cover page 172 3 Remove the fuse cover 4 Pull the main fuse out If it is blown install the spare main fuse Spare main fuse is loc...

Page 216: ...of the same rating Spare fuses are located in the fuse box 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 on...

Page 217: ...emporarily If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses that were installe...

Page 218: ...running turn it off and look it over carefully inspect it for fluid leaks check the tightness of critical nuts and bolts securing such parts as the steering wheel control levers brakes and wheels If t...

Page 219: ...d 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 SXS They may have it listed in their records If th...

Page 220: ...your hands after handling However when there is no option other than jump starting follow the instructions given below NOTICE If a battery sits in extreme cold the electrolyte inside can freeze Attemp...

Page 221: ...onnect the negative side on the other end of the jumper cable to the upper muffler cover 5 After starting the engine remove the negative sides of the jumper cable from the vehicle and the battery Then...

Page 222: ...you have with you If any component in the brake system is damaged you may have reduced or limited stopping power If you decide to continue driving back to your base do so cautiously and at a very low...

Page 223: ...tched properly the maximum vehicle speed will be limited to no more than 15 mph 24 km h by the seat belt speed limiting system page 45 Also the seat belt indicator and speedometer digits blink Make su...

Page 224: ...Taking Care of the Unexpected 214 19 SXS500M 31HL56400 book 214...

Page 225: ...nsions capacities and other technical data plus information on government requirements and how to break in your Honda SXS Vehicle Identification 216 Specifications 218 Break in Guidelines 223 Emission...

Page 226: ...ment parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN is stamped on the left side of the frame located under the cargo carrier The engine number is...

Page 227: ...ight front side of the frame The color code is helpful when ordering replacement parts You may record the color and code in the Quick Reference section at the rear of this manual Remove the front hood...

Page 228: ...on unleaded gasoline pump octane number of 86 or higher fuel tank capacity 4 07 US gal 15 4 engine oil capacity after disassembly 3 5 US qt 3 3 after draining 3 1 US qt 2 9 after draining oil filter c...

Page 229: ...2 5 US qt 2 4 Capacities passenger capacity operator and one passenger maximum weight capacity 880 lb 399 kg operator passenger all cargo and accessories Engine Specifications displacement 29 0 cu in...

Page 230: ...nt 4 077 rear 4 077 transmission ratio 1st 3 615 2nd 2 388 3rd 1 608 4th 1 178 5th 0 875 reverse 3 716 final drive shaft Chassis Suspension caster 5 trail 1 0 in 26 mm tire size front 24X8 00 12 NHS M...

Page 231: ...light 12 V 37 5 W x 2 brake tail light LED neutral indicator LED reverse indicator LED high coolant temperature indicator LED PGM FI malfunction indicator lamp MIL LED parking brake indicator LED seat...

Page 232: ...m engine oil filter cover bolts 9 lbf ft 12 N m 1 2 kgf m front final gear oil drain plug 9 lbf ft 12 N m 1 2 kgf m front final gear oil filler cap 9 lbf ft 12 N m 1 2 kgf m rear final gear oil drain...

Page 233: ...assure your Honda SXS s future reliability and performance by paying extra attention to how you drive during the first operating day or 15 miles 25 km During this period avoid full throttle starts an...

Page 234: ...Honda off road utility vehicle comply with applicable emissions standards during its useful life when operated and maintained according to the instructions provided The Vehicle Emission Control Inform...

Page 235: ...ic inspection 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 Califo...

Page 236: ...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 Honda off road utility vehicle will be...

Page 237: ...LLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part of the intake system Lack of proper main...

Page 238: ...e this information to be posted on the pump The following are the EPA approved percentages of oxygenates for non road vehicles ETHANOL ethyl or grain alcohol up to 10 by volume You may use gasoline co...

Page 239: ...c 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 resulting fro...

Page 240: ...ar it Park your SXS 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 these guidelines...

Page 241: ...er Information This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 232 Warranty Coverage 233 Warranty Service 234 Contacting Honda 235...

Page 242: ...ervice 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 sho...

Page 243: ...website at www honda ca It is important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage does not apply to normal wear or deterioration...

Page 244: ...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 repair it is...

Page 245: ...If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance...

Page 246: ...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 247: ...ting 235 apparel protective 55 appearance care 175 AT MT switch 34 authorized manuals 232 B battery 170 brakes fluid 154 pad wear 157 parking brake lever 39 parking brake lever freeplay 159 pedal insp...

Page 248: ...ure gauge 27 crash if you 208 crossing a hill 84 customer service 235 D differential oil front final gear 124 126 digital clock 25 dipstick 117 doors 40 drive mode select lever 36 driveshaft boots 169...

Page 249: ...ent 188 F flat tire 199 four wheel drive indicator 31 fuel gauge 23 fuel fill cap 112 oxygenated 228 recommendation 111 tank capacity 112 fuses 204 G gap spark plug 146 219 gasohol 228 gasoline 111 ge...

Page 250: ...ion switch 32 indicators gear position indicator 31 high coolant temperature indicator 17 202 neutral indicator 17 parking brake indicator 17 PGM FI malfunction indicator lamp MIL 17 reverse indicator...

Page 251: ...hedule 92 manual service 232 maximum weight limit 3 61 modifications 5 multi function display 20 N neutral indicator 17 noise emission control systems 227 numbers serial 216 O obstacles avoiding 84 od...

Page 252: ...lerator 141 pinging engine 111 plug spark 145 pre drive inspection 58 problems unexpected 190 protective apparel 55 R removal seat 106 reverse indicator 17 reverse lever 38 74 S safety driving precaut...

Page 253: ...fications 218 speedometer 21 speedometer display 21 starting engine 66 troubleshooting 192 stopping engine 66 storage owner s manual 104 SXS 184 suspension adjustment 151 152 spring pre load 151 153 s...

Page 254: ...our Honda 182 tripmeter 26 trouble unexpected 189 troubleshooting starting 192 turning on level ground 81 V vehicle identification no VIN 216 W warning labels 6 warranty coverage 233 extended 233 serv...

Page 255: ...can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly repairs are Engi...

Page 256: ...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 19 SXS500M 31HL56400 book 253...

Page 257: ...line pump octane number 86 or higher 4 07 US gal 15 4 Engine Oil Capacity API Service Classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API se...

Page 258: ...cold Front 10 psi 70 kPa Rear 10 psi 70 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...

Page 259: ...ntrols section SYMBOL COMPONENT SEE PAGE p START ignition switch 32 q ON ignition switch 32 w OFF ignition switch 32 t OFF headlight switch 33 y ON headlight switch 33 Up right shift paddle 35 Down le...

Page 260: ...d 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 necessary s...

Page 261: ...WPCXXXX 2018 XX 19 PRINTED IN USA 00X31 HL5 6400 31HL5640...

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