Honda TRX500FM Owner'S Manual Download | Manualshive

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(1)

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(1) tool kit

(2) rubber band

UNDER SEAT

110

Tool Kit

Servicing Your Honda

The tools in the kit are sufficient to perform routine maintenance and
simple repairs. Any extensive work requiring additional tools should be
performed by your dealer.

The tool kit includes the following items:

standard/Phillips screwdriver
screwdriver handle
10

12 mm open end wrench

14

17 mm open end wrench

spark plug wrench and handlebar
pliers
tool case
5 mm hex wrench

The tool kit ( ) is stored under the seat (page

).

After using the tools, be sure to use the rubber band ( ) to fasten the
tool kit securely.

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Summary of Contents for TRX500FM

Page 1: ...Honda TRX500FM FPM OWNER S MANUAL Original instructions 12 03 16 11 22 24 32HR0610_002...

Page 2: ...reak in guidelines and perform all pre ride and other periodic checks detailed in this manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety...

Page 3: ...dicated to your complete satisfaction Happy riding The following codes in this manual indicate each country Australia New Zealand European direct sales The specifications may vary with each locale Aus...

Page 4: ...rating procedures and other 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 yo...

Page 5: ...nstructions A Few Words About Safety A Few Words About Safety Safety Headings Safety Section Instructions These signal words mean such as Important Safety Reminders or Important Safety Precautions suc...

Page 6: ...tion you should know plus a look at the safety related labels on your ATV The location and function of indicators and controls on your ATV and operating instructions for various controls and features...

Page 7: ...gular maintenance what you need to know before servicing your Honda an owner maintenance schedule and instructions for specific maintenance and adjustment items How to store and transport your ATV and...

Page 8: ...12 03 16 11 23 06 32HR0610_009...

Page 9: ...n and recommendations to help you ride your ATV safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your ATV Important Sa...

Page 10: ...sider to be most important The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle It s a proven fact helmets significantly reduce the number and s...

Page 11: ...s a paved or public road get off and walk your ATV across The terrain can present a variety of challenges when you ride off road Continually read the terrain for unexpected turns drop offs rocks ruts...

Page 12: ...ts and ride safely 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 an...

Page 13: ...el comes off or becomes hard to read contact your dealer for a replacement There is a specific symbol on each label The meanings of each symbol and label are as follows Read instructions contained in...

Page 14: ...ndling the battery has a proper understanding of the hazards and correct handling procedures involved Handle battery electrolyte with extreme care as it contains dilute sulfuric acid Exposure to eyes...

Page 15: ...gs and instructions Never use without proper training and instruction While riding Never ride too fast for your skills or the conditions Always use proper riding techniques for hills slopes and rough...

Page 16: ...er the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJ...

Page 17: ...lead to an accident Never exceed the maximum front cargo limit of Refer to instructions in the Owner s Manual Overloading this ATV or carrying cargo improperly can change handling stability and braki...

Page 18: ...ED type ATV Safety Towing an improperly loaded trailer can cause loss of control Read towing instructions in Owner s Manual Tow weight limit Tongue weight With four wheel drive operating any brake co...

Page 19: ...RADIATOR CAP LABEL FRONT CARRIER LABEL CE MARK BATTERY LABEL TYRE OVERLOAD WARNING LABEL 11 Labels ED type ATV Safety 12 03 16 11 24 24 32HR0610_020...

Page 20: ...LER HITCH LABEL PASSENGER WARNING LABEL GENERAL WARNING LABEL REAR CARRIER LABEL 4WD BRAKING INFORMATION LABEL AGE RECOMMENDATION WARNING LABEL 12 ATV Safety Labels ED type 12 03 16 11 24 34 32HR0610_...

Page 21: ...vehicle If a label comes off or becomes hard to read contact your dealer for replacements Your ATV comes with several labels containing important safety information Anyone who rides the vehicle should...

Page 22: ...14 Labels U type ATV Safety 12 03 16 11 24 46 32HR0610_023...

Page 23: ...15 Labels U type ATV Safety 12 03 16 11 24 59 32HR0610_024...

Page 24: ...16 ATV Safety 12 03 16 11 25 01 32HR0610_025...

Page 25: ...on this page are described in this section Instructions for other components are presented in other sections of this manual where they will be most useful cont d Operation Component Locations Indicat...

Page 26: ...ch Horn Button Recoil Starter Throttle Lever Reverse Selector Knob Front Brake Lever Rear Brake Lever Parking Brake Lever Rear Brake Pedal Parking Brake Flag Pole Bracket Trailer Hitch PS Electric Pow...

Page 27: ...ver headlight dimmer switch horn button front brake lever headlight switch rear brake lever parking brake lock lever engine stop switch parking brake lever 2WD 4WD select lever 19 Instruments Controls...

Page 28: ...rear brake pedal recoil starter rear cargo rack seat latch front cargo rack 20 Instruments Controls Operation Component Locations 12 03 16 11 25 33 32HR0610_029...

Page 29: ...flag pole bracket accessory socket utility box shift lever storage compartment trailer hitch 21 Instruments Controls Operation Component Locations 12 03 16 11 25 37 32HR0610_030...

Page 30: ...informed alert you to possible problems and make your riding safer and more enjoyable Refer to the indicators frequently Their functions are described on the following pages Lamp Check The high coolan...

Page 31: ...he ignition switch ON and remains on until you shift out of 4WD mode If one of these indicators does not come on when it should have your dealer check for problems Display Check When the ignition swit...

Page 32: ...any other time reduce speed and take your vehicle to your dealer as soon as possible PGM FI indicator High coolant temperature indicator Lights when coolant temperature is high enough to adversely af...

Page 33: ...dometer Shows riding speed Odometer Shows accumulated mileage page Tripmeter Shows mileage per trip page Hourmeter Shows hours and tenths of hours of engine operation page Odometer tripmeter hourmeter...

Page 34: ...indicator 3 speedometer 4 fuel gauge 5 6 3 26 Multi function Display Indicators Displays Instruments Controls The multi function display includes the following functions 1 Gear position indicator Oil...

Page 35: ...he transmission 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 th...

Page 36: ...the indicator press and hold the odometer tripmeter hourmeter select button and turn the ignition switch to ON for more than 5 seconds The indicator message will disappear If the oil is changed before...

Page 37: ...change the display from tripmeter or hourmeter to odometer press and release the odometer tripmeter hourmeter select button When selected the tripmeter shows mileage per trip while the ignition is ON...

Page 38: ...e hourmeter shows accumulated hours while the ignition is ON The hourmeter provides accurate service period information for initial and regular maintenance To change the display from odometer or tripm...

Page 39: ...gauge liquid crystal display shows the approximate fuel supply available The fuel tank capacity is When segment E and low fuel indicator flash you should refill the tank as soon as possible The amoun...

Page 40: ...y Position Function 32 Ignition Switch Controls Features Instruments Controls The ignition switch is used for starting and stopping the engine page Insert the key and turn it to the right for the ON p...

Page 41: ...is in motion and come to a complete stop before using the 2WD 4WD select lever The 2WD 4WD select lever is located on the left side of the fuel tank To select the drive mode shift the 2WD 4WD select...

Page 42: ...h to the OFF position The switch must be in the RUN position to start the engine and it should normally remain in the RUN position even when the engine is OFF When the start button is pushed the start...

Page 43: ...h is used to turn the headlights and assist headlight ON or OFF To operate turn the switch to ON or OFF Press the horn button to sound the horn The headlight dimmer switch is used to change between th...

Page 44: ...ecoil starter 1 36 Recoil Starter Controls Features Instruments Controls Using the Recoil Starter The recoil starter is used to start the engine when the battery is low See page 1 76 12 03 16 11 27 27...

Page 45: ...s Controls The throttle controls engine rpm speed To increase engine rpm press the throttle lever with your thumb To reduce engine rpm release pressure on the throttle lever The throttle will automati...

Page 46: ...e The reverse selector knob located on the rear brake lever parking brake lever is used to shift into reverse To operate with your ATV stopped and the transmission in neutral make sure the gear positi...

Page 47: ...pull the lever For information on braking techniques see page 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...

Page 48: ...g brake When using the parking brake be sure to turn the ignition switch OFF to avoid discharging the battery The lock lever on the rear brake lever parking brake lever allows it to be used as a parki...

Page 49: ...ments Controls Flag poles are required in some riding areas Check local regulations before riding Flag poles are optional equipment available from your dealer To mount a pole in the bracket follow the...

Page 50: ...located on the rear axle housing To use the hitch you ll need a proper size ball as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the trailer manufact...

Page 51: ...bile cigarette lighter because it can damage the socket The accessory socket is attached to the left side under the assist headlight You can use the accessory socket to power a trouble light spotlight...

Page 52: ...ket otherwise you may drain the battery The accessory socket s rated capacity is DC 12V 120 Watts 10A or less If you exceed this limit you may blow a fuse See page When you are done using an accessory...

Page 53: ...The utility box is located on the left side of the front fender You may store small lightweight items in the box Lift the D ring on the quick release fastener Turn it counterclockwise until it release...

Page 54: ...p 46 Storage Compartment Controls Features Instruments Controls The storage compartment is located below the rear cargo rack To open the compartment unhook the rubber strap Be careful not to flood thi...

Page 55: ...ring will perform as a normal non PS system during this brief period After cooling down it will then return to normal PS operation The PS indicator should light when the ignition switch is turned ON a...

Page 56: ...48 Instruments Controls 12 03 16 11 28 33 32HR0610_057...

Page 57: ...to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride Protective Apparel Rider Training Age Recommendation No Passengers N...

Page 58: ...er protective 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 trousers...

Page 59: ...1 Are You Ready to Ride Before Riding Additional Riding Gear In addition to a helmet and eye protection we also recommend Sturdy off road motorcycle boots to help protect your feet ankles and lower le...

Page 60: ...he course and the operating techniques described in the owner s manual 52 Rider Training Are You Ready to Ride Before Riding Developing your riding skills is an on going process Even if you have ridde...

Page 61: ...d you or your passenger could be injured or killed Never carry a passenger on this ATV 53 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended age for this ATV...

Page 62: ...rugs before or while operating this ATV 54 No Alcohol or Drugs Are You Ready to Ride Before Riding Alcohol drugs and ATVs don t mix Even a small amount of alcohol can impair your ability to operate an...

Page 63: ...re any problem you find is corrected A pre ride inspection is a must not only for safety but because having a breakdown or even a flat tyre can be a major inconvenience If your ATV has overturned or b...

Page 64: ...heck for damage pages Check for damage or looseness pages 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 Check for...

Page 65: ...ions page Check these items after you get on the ATV Check that all cargo is secure Check the cable housings for wear Check the fittings for looseness Replace or tighten as needed Make sure you do not...

Page 66: ...function page Check for proper function page Check that the wheels turn properly as you steer the handlebar Move the handlebar right and left and check that there is no excessive backlash Remember be...

Page 67: ...r balance and control of the ATV In addition exceeding the weight limits or carrying an unbalanced load can seriously affect your ATV s handling braking and stability Adding accessories or making modi...

Page 68: ...ply to standard equipment only Modifying your ATV using non standard equipment or riding on terrain that is not flat and smooth could further reduce these limits The weight of added accessories will r...

Page 69: ...icle 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...

Page 70: ...d tested for your ATV Because Honda cannot test all other accessories you must be personally responsible for proper selection installation and use of non Honda accessories Check with your dealer for a...

Page 71: ...ify your ATV in any way that would change its design or operation Such changes could seriously impair your ATV s handling stability and braking making it unsafe to ride Removing or modifying your ligh...

Page 72: ...64 Before Riding 12 03 16 11 30 35 32HR0610_073...

Page 73: ...to Break in Guidelines page cont d Safe Riding Precautions Off road Use Only Keep Hands and Feet on Controls Riding in Reverse Shifting Gears Using the Recoil Starter How to Stop the Engine Stalled En...

Page 74: ...ing Braking Riding Your ATV Making Turns Skidding or Sliding Riding Up Hills Riding Down Hills Crossing or Turning on Hills or Slopes Riding Over Obstacles Riding Through Water Parking 81 83 83 85 86...

Page 75: ...tion beginning on page Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice in a safe area until you build your skills and get accustomed to the...

Page 76: ...ls Safe Riding Precautions Basic Operation Riding You should never ride your ATV on public streets roads or highways even if they are not paved Drivers of street vehicles may have difficulty seeing an...

Page 77: ...road motorcycle boots Long sleeved apparel and trousers 69 Control Speed Riding Position Safety Equipment Safe Riding Precautions Basic Operation Riding Riding at excessive speed increases the chance...

Page 78: ...alert to changing terrain conditions when operating the ATV 70 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area always check the terr...

Page 79: ...f terrain Attempting wheelies jumps and other stunts increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off 71 Do Not Perform St...

Page 80: ...engine in an enclosed area such as a garage Your ATV s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death The engine stop switch i...

Page 81: ...indicated below Any Air Temperature The engine will not start if the throttle is fully open because the electronic control module cuts off the fuel supply Snapping the throttle or fast idling for mor...

Page 82: ...starter several times Follow the normal starting procedure 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 ag...

Page 83: ...have started the engine release the front brake lever then apply throttle gradually Normal Engine Stop To stop the engine make sure the transmission is in neutral by checking that the neutral indicat...

Page 84: ...operate the recoil starter Check that the transmission is in neutral Grasp the starter grip firmly then pull it out slowly approximately 100 mm 4 in Pull the grip up briskly and fully After the engine...

Page 85: ...fts the transmission to the next higher or lower gear in the shifting sequence The shift lever automatically returns to the horizontal position when released To upshift to a higher gear put the toe of...

Page 86: ...transmission and drivetrain Upshift to a higher gear or reduce throttle before engine rpm speed gets too high Learn the relationship between engine sound and the normal shifting points Downshift to a...

Page 87: ...brake lever parking brake lever 79 Basic Operation Riding Riding in Reverse If you need to ride in reverse make sure the area behind you is clear and only operate the ATV at low speed Bring the vehicl...

Page 88: ...verse speed limiter which helps the vehicle to maintain a safe speed while riding in reverse gear To stop close the throttle and gradually apply both the front and rear brakes Do not abruptly apply th...

Page 89: ...s 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 downshift...

Page 90: ...ion braking by downshifting 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 pedal or...

Page 91: ...manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 83 Making Turns Basic Operation Riding Riding Your ATV Learn how to turn your ATV prop...

Page 92: ...t wheel steering To make a turn from a full stop Apply the throttle gradually when you turn and start up at the same time Remember to shift your body forward to make sharp low speed turns and whenever...

Page 93: ...Riding The terrain surface can be a major factor affecting turns Skidding during a turn is more likely to occur on slippery surfaces such as snow ice mud and loose gravel If you skid on ice you may l...

Page 94: ...bility to safely climb hills largely depends on the rider s skill and judgment Begin by practicing on smooth gentle slopes As you gain experience you ll learn the hazards and your own limitations You...

Page 95: ...ill To climb a hill take 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...

Page 96: ...set the parking brake and turn the engine off Then assess the situation If the ATV starts rolling backwards before you begin braking Keep your weight uphill Carefully apply the front brakes first then...

Page 97: ...e doesn t roll backwards If the hill is not too steep and you have good footing you 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...

Page 98: ...ur weight back 90 Riding Down Hills Riding Your ATV Basic Operation Riding It s usually advisable to descend hills with the ATV pointed straight downhill Avoid angles that would cause the vehicle to l...

Page 99: ...braced against the handlebar then go down slowly with the throttle closed Use mainly the rear brake to control speed Avoid using either the front brake or rear brake hard or abruptly when riding down...

Page 100: ...ean toward the uphill side 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 slip...

Page 101: ...n this owner s manual 93 Riding Over Obstacles Riding Your ATV Basic Operation Riding Before operating in a new area check for obstacles Watch out for bumps rain ruts potholes and other obstacles in t...

Page 102: ...eatedly until they dry out and operate normally Riding through water can make the brakes less effective than normal and may reduce stopping ability After leaving the water always test both the front a...

Page 103: ...ission into neutral The brake lights are activated by applying the parking brake When using the parking brake be sure to turn the ignition switch OFF to avoid discharging the battery If you must park...

Page 104: ...96 Basic Operation Riding 12 03 16 11 34 15 32HR0610_105...

Page 105: ...You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking good For information about replacing fuses see page cont d The Importance of Mainte...

Page 106: ...e Oil Coolant Air Cleaner Throttle Clutch System Reverse Lock System Spark Plug Valves Spark Arrester Chassis Appearance Care Battery Electrical Drivetrain Boots Guards Tyres Brakes Suspension Differe...

Page 107: ...lution Careful pre ride inspections and good maintenance are especially important because your ATV is designed to be ridden over rough off road terrain To help you properly care for your ATV this sect...

Page 108: ...hese tasks with the tools provided with your ATV Other tasks that are more difficult and require special tools are best performed by professionals Removing the wheels should normally be handled only b...

Page 109: ...hing Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of a fire or explosion be ca...

Page 110: ...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 tools and...

Page 111: ...e more technical information and tools Consult your dealer In the interest of safety we recommend these items be serviced only by your dealer Service more frequently when riding in dusty areas sand or...

Page 112: ...ITEMS FREQUENCY WHICHEVER COMES FIRST INITIAL Every 1 000 km 600 mi 100 operating hours or 12 months R INITIAL REGULAR 150 km 100 mi 20 operating hours or 1 month R MONTH HOURS MAINT INTERVAL MAINT 10...

Page 113: ...I I I I I I I I C I I 2000 1200 12 200 I I I I I I I I I I I I C I I I I I Refer to page 174 175 126 129 156 163 158 155 146 172 173 145 152 151 FREQUENCY ITEMS WHICHEVER COMES FIRST REGULAR INITIAL M...

Page 114: ...rms the maintenance completes this record All scheduled maintenance including the 150 km 100 mile or 1 month or 20 hours initial maintenance is considered a normal owner operating cost and will be cha...

Page 115: ...front brake fluid reservoir front brake lever throttle lever rear brake lever parking brake lever fuel fill cap 107 Servicing Your Honda Maintenance Component Locations 12 03 16 11 35 38 32HR0610_116...

Page 116: ...leaner housing coolant reserve tank front brake caliper front suspension spring pre load adjuster differential oil fill cap differential oil drain bolt rear brake light switch 108 Servicing Your Honda...

Page 117: ...rear suspension spring pre load adjuster engine oil fill cap dipstick gear case oil fill cap main fuse fuse box battery PS fuse owner s manual air pressure gauge spark plug TRX500FPM only 109 Servici...

Page 118: ...should be performed by your dealer The tool kit includes the following items standard Phillips screwdriver screwdriver handle 10 12 mm open end wrench 14 17 mm open end wrench spark plug wrench and ha...

Page 119: ...age for the owner s manual so you ll have it with you for easy reference Store your owner s manual in the plastic document bag underside of the seat The owner s manual and air pressure gauge should be...

Page 120: ...prongs into the hooks on the frame and press the studs into the grommets Pull the seat latch at the rear of the seat The seat must be removed for the air cleaner engine oil engine oil filter clutch s...

Page 121: ...r Honda Removal Installation Pull up the centre pin to release the lock Pull out the clip of the hole Insert the clip into the hole Press down the centre pin securely to lock the clip 1 2 1 2 1 1 2 2...

Page 122: ...at a steady engine speed under normal load change brands of petrol If pinging or spark knock persists consult your dealer Use of lower octane petrol can cause persistent pinging or spark knock a loud...

Page 123: ...r cover hole 4 filler neck 115 Fuel Capacity Refueling Procedure Fuel Servicing Your Honda Safety Precautions Fuel tank capacity including reserve Reserve capacity The tank should be refilled as soon...

Page 124: ...turn it counterclockwise Pull the breather tube out of the handlebar cover hole Add fuel until the level reaches the bottom of the filler neck Avoid over filling the tank There should be no fuel in t...

Page 125: ...st 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 seri...

Page 126: ...s that are not labeled as energy conserving on the circular API service label Your ATV does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They ma...

Page 127: ...e temperature in your 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...

Page 128: ...d if needed Unsnap and remove the left side cover Remove the seat page 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 engi...

Page 129: ...he oil level The oil level should be between the upper level mark and the lower level mark on the oil fill cap dipstick Remove the oil fill cap dipstick from the front crankcase and wipe it clean If t...

Page 130: ...or your model or a filter of equal quality This procedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid page If you do...

Page 131: ...ur Honda Install a New Engine Oil Filter cont d Place an oil drain pan under the crankcase and remove the engine oil drain bolt and sealing washer Place shop towels under the oil filter cover because...

Page 132: ...ngine oil to a new O rings and install them to the oil filter cover Then install a new oil filter Use only the Honda Genuine oil filter or a filter of equivalent quality specified for your model Using...

Page 133: ...the new sealing washer and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Reinstall the oil fill cap dipstick Start the engine and let it idle for 3...

Page 134: ...126 Oil Recommendation Changing Oil Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the gear case at normal operating temperature to assure complete and rapi...

Page 135: ...plate bolts and the skid plate Place an oil drain pan under the oil drain bolt Remove the oil fill cap and the drain bolt After the oil has completely drained reinstall the drain bolt with the new se...

Page 136: ...oil until oil start to flow out of the oil level check hole Allow oil to settle for 2 3 minutes before moving to next step to prevent overfilling Coat a new O ring with grease and install it into the...

Page 137: ...Oil Recommendation Changing Oil Differential Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the differential at normal operating temperature to assure complete and r...

Page 138: ...ove the oil fill cap and the drain bolt After the oil has completely drained reinstall the drain bolt with the new sealing washer and tighten it to the specified torque Pour the drained oil into a sui...

Page 139: ...orrosion Use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines Check the antifreeze container label Use only...

Page 140: ...itional protection against freezing Check the cooling system frequently during freezing weather Refer to on page Check the engine coolant level each day before operating your ATV and add if needed Mak...

Page 141: ...grommets Slide the rear fender cover forward to disengage the tabs Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark Remove the rear fender cover and reser...

Page 142: ...t Coolant Servicing Your Honda Safety Precautions You the Environment Improper disposal of drained fluids is harmful to the environment Refer to on page To properly dispose of drained coolant refer to...

Page 143: ...or core Check the air passages for clogging or damage Remove insects mud or any obstruction with low water pressure Have the radiator checked by your dealer if the air flow is restricted over more tha...

Page 144: ...0 radiator core 9 10 136 Coolant Servicing Your Honda Remove the radiator grill plate Wash the radiator core and radiator grill plate Install the removed parts in reverse order of removal 5 6 7 9 10 1...

Page 145: ...irt dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your dealer can help you determine the correct service int...

Page 146: ...ainer clips 2 air cleaner housing cover 1 138 Cleaning Air Cleaner Servicing Your Honda Unlatch the retainer clips Remove the air cleaner housing cover Remove the seat page 1 2 3 1 2 112 12 03 16 11 3...

Page 147: ...solvent Avoid twisting or wringing the air cleaner This can tear the foam Inspect for tears or cracks in the foam or seams of the air cleaner Replace the air cleaner if it is damaged Allow the air cl...

Page 148: ...rface of the air cleaner assembly Install the clamp Insert the air cleaner assembly into the air cleaner housing Fasten the screw Reassemble by reversing the disassembly sequence Install the air clean...

Page 149: ...cover UNDER SEAT 2 breather joint 141 Dust Cover Air Cleaner Servicing Your Honda Do not push the dust cover too far into the breather joint If the dust cover is dirty clean it 1 2 12 03 16 11 40 03 3...

Page 150: ...accordance with the Maintenance Schedule Riding through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle Remove...

Page 151: ...s Refer to on page After adjustment check for smooth operation of the throttle lever from fully closed to fully open in all steering positions Tighten the lock nut and reinstall the sleeve Loosen the...

Page 152: ...ly closed in all steering positions If there is a problem see your dealer Inspect the condition of the throttle cable from the throttle lever down to the throttle body If the cable is kinked or chafed...

Page 153: ...may be worn See your dealer or refer to official Honda Shop Manual Turn the clutch adjuster counterclockwise until you feel slight resistance Turn the adjuster 1 4 turn clockwise then tighten the loc...

Page 154: ...ver and cable for loose connections or other damage If the cable is worn or kinked have it replaced by your dealer Refer to on page Return the dust cover and rubber sleeve Other Checks Turn over the d...

Page 155: ...Servicing Your Honda Using spark plugs with an improper heat range can cause engine damage Safety Precautions Use only the recommended type of spark plug in the recommended heat range Refer to on pag...

Page 156: ...n fouling If the corrosion or deposits are heavy replace the plug Clean a carbon or wet fouled plug with a plug cleaner if available or a wire brush Inspect the spark plug electrodes for wear The cent...

Page 157: ...ding Tighten the spark plug First tighten the plug NGK turn after it seats DENSO turn after it seats Then loosen the plug Next tighten the plug again 1 8 turn after it seats If the old plug is good 1...

Page 158: ...re mechanically proficient and have the proper tools instructions on adjusting valve clearances are given in the official Honda Shop Manual Otherwise the valves should be adjusted by your dealer Exces...

Page 159: ...ve the bolt Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel Stop the engine and a...

Page 160: ...ions pre load whenever you change 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...

Page 161: ...153 Suspension Spring Pre Load Suspension Servicing Your Honda Safety Precautions Refer to on page The spring pre load adjuster has 5 positions for different load or riding conditions Use the pin spa...

Page 162: ...V is more heavily loaded Also increase spring pre load for stiffer suspension Make sure that both front shock absorbers are adjusted to the same position Always adjust the shock absorber position in s...

Page 163: ...er freeplay does not feel within the normal range while riding check the brake pads for wear page Worn pads should be replaced If the pads are not worn beyond the recommended limit there is probably a...

Page 164: ...aler add the recommended fluid Do not add or replace brake fluid except in an emergency If you do add fluid have your dealer check the system as soon as possible Wipe up spills immediately Avoid brake...

Page 165: ...ur dealer Make sure there are no fluid leaks Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks It should be above the LOWER level mark If the level...

Page 166: ...ng conditions The pads will wear faster in wet or muddy conditions Inspect the pads visually during all regular service intervals to determine the pad wear Always inspect both pads in both the right a...

Page 167: ...ake Pedal Freeplay Brakes Servicing Your Honda Measure the distance the rear brake pedal moves before the brake starts to take hold Freeplay measurement at the tip of the end of the pedal should be If...

Page 168: ...edal adjusting nut located on the brake operating rod at the rear of the frame Make sure the cutout on the adjusting nut is properly seated on the brake arm pin Adjust the freeplay of the rear brake p...

Page 169: ...ke Lever Freeplay Brakes Servicing Your Honda If necessary adjust to the specified range Inspection Measure the distance the rear brake lever parking brake lever moves before the brake starts to take...

Page 170: ...of the frame Make sure the cutout on the adjusting nut is properly seated on the brake arm pin Adjust the freeplay of the rear brake lever parking brake lever Push the brake arm then check the cleara...

Page 171: ...e movement of the arrow on the brake arm The rear brake is equipped with an external brake wear indicator that lets you check brake wear without disassembly Application of the brake control causes the...

Page 172: ...tions Refer to on page Rear Brake Only Check the operation of the rear brake light switch at the right side behind the engine from time to time Adjustment is done by turning the adjusting nut Turn the...

Page 173: ...to on page Make sure the engine is OFF and the parking brake is set Remove the rear brake drain bolt from the bottom of the rear brake panel If any water drains the brake seals must be replaced by yo...

Page 174: ...proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tyres Although the tyres are designed specifically for off road use th...

Page 175: ...are more prone to damage from surface hazards and wear unevenly Make sure the air valve caps are secure If necessary install new caps Always check air pressure when your tyres are cold If you check a...

Page 176: ...n service stations This will minimize the possibility of tyre damage from overinflation If you use a high pressure system at a service station add air in small amounts and check the pressure increase...

Page 177: ...f you hit a pothole or other hard object while riding stop as soon as you safely can and carefully inspect the tyres for damage Tread Wear For best performance you should replace a tyre before the tre...

Page 178: ...rably without any cargo and have the tyre replaced or permanently repaired as soon as possible For more information on temporary repairs see page A permanent repair such as an internal plug patch can...

Page 179: ...to match the performance capabilities of your ATV and provide the best combination of handling braking and comfort It is best to replace all four tyres however if that is not possible you must replace...

Page 180: ...they are cracked or damaged If the guard and plate bolts are loose tighten them securely The skid plate protects the rear final gear case Check the guard and plate for cracks damage or looseness at i...

Page 181: ...Guards Guards Servicing Your Honda Safety Precautions Check the front boot guards and front driveshaft guards for cracks damage or looseness Tighten any loose fasteners Replace the front boot guards...

Page 182: ...aft Boots Yoke Joint Boot Drivetrain Boots Servicing Your Honda Safety Precautions Refer to on page Check the rubber propeller shaft boots and rubber yoke joint boot for damage or leaking grease If ne...

Page 183: ...nt Driveshaft Boots Drivetrain Boots Servicing Your Honda Safety Precautions Refer to on page Check the rubber driveshaft boots for cuts damage or leaking grease If necessary have your dealer replace...

Page 184: ...e current from the battery even when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your ATV or do not ride frequently we recommend th...

Page 185: ...g Refer to on page If you plan to store your ATV we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life If you do not remove the b...

Page 186: ...the ignition switch is OFF Remove the seat page Remove the rear fender cover page Release the rings and remove the rubber band Disconnect the negative terminal lead from the battery first then discon...

Page 187: ...reverse order of removal Be sure to connect the positive terminal first then the negative terminal Make sure all bolts and other fasteners are secure Charge the battery see following section Remove t...

Page 188: ...ng a charger 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 intent...

Page 189: ...sh detergents or chemical solvents that could damage the metal paint and plastic on your ATV If your ATV is still warm from recent operation give the engine and exhaust system time to cool off Park in...

Page 190: ...a mild cleaner degreaser to remove the grime After washing rinse your ATV thoroughly with plenty of clean water to remove any residue Detergent residue can corrode alloy parts Dry your ATV with a cham...

Page 191: ...ner polish and wipe with a non abrasive cloth Apply a high quality chrome aluminum polish and wipe with a non abrasive cloth Dull corroded chrome or aluminum Heavy grime Oil leaks Brake dust Light roa...

Page 192: ...cifically for motorcycles or automobiles Apply the polish or wax according to the instructions on the container The exhaust pipe and muffler are stainless steel but may become stained by mud or dust T...

Page 193: ...Honda and how to be an environmentally responsible ATV owner Preparing for a Ride What to Take to the Riding Area What to Take on the Trail Transporting Your Honda Storing Your Honda Preparation for...

Page 194: ...ht encounter see which begins on page We recommend that you always take water food a first aid kit and your owner s manual Other items you should consider loading on your truck or trailer include a to...

Page 195: ...how far you 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 y...

Page 196: ...he transmission in gear Follow these procedures When 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 uprig...

Page 197: ...the areas shown Suitable tie down 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 ATV...

Page 198: ...correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again We suggest you perform the following procedures to keep your ATV i...

Page 199: ...in the cylinder perform the following Remove the spark plug cap from the spark plug Remove the spark plug Do not connect the spark plug to the spark plug cap Pour a tablespoon 15 20 cm of clean engine...

Page 200: ...ing temperatures and direct sunlight Slow charge the battery page once a month Wash and dry your ATV Wax all painted surfaces Inflate the tyres to their recommended pressures page Store your ATV in an...

Page 201: ...d for more than two months ask your dealer to drain and replace the fuel Perform a pre ride inspection page then test ride your ATV at low speeds Charge the battery page as required Install the batter...

Page 202: ...e they also reduce engine performance and may be illegal Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosp...

Page 203: ...e to help you deal with a wide range of problems Take time to read this section before you ride Also review the tips in page General Guidelines If Your Engine Quits or Won t Start If You Have a Flat T...

Page 204: ...the tools supplies and skills to make a permanent repair you may be able to fix it on the trail and continue riding Or you may be able to make a temporary repair that allows you to slowly ride back t...

Page 205: ...the situation and your options before deciding what to do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have permanent repairs mad...

Page 206: ...use of the problem may be a simple operational oversight If you have a problem starting the engine or experience poor engine performance the following information may help you If you can t correct the...

Page 207: ...SYMPTOM If all possible causes are negative the starter motor may be faulty See your dealer faulty starter motor Charge the battery page If charging doesn t help see your dealer low or dead battery b...

Page 208: ...or change your brand of petrol If the problem persists see your dealer afterfires backfires See your dealer pre ignition runs on after ignition switched OFF See your dealer SYMPTOM WHAT TO DO POSSIBL...

Page 209: ...repair As soon as possible have the tyre permanently repaired by your dealer Any tyre that cannot be repaired should be replaced Whenever the ATV is to be operated far from service facilities or avail...

Page 210: ...id getting grease oil or dirt on the front brake disc or pad surfaces when removing and installing each wheel Any contamination can cause poor brake performance or rapid pad wear after reassembly Remo...

Page 211: ...rim Hand tighten the wheel nuts on the wheel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque If a torque wrench was no...

Page 212: ...Shut the engine off and wait until the steaming stops Look for a leak but don t touch the engine or radiator system Let everything cool off first Check for any restriction of air flow to the radiator...

Page 213: ...on and check the high coolant temperature indicator If the indicator doesn t turn off do not ride The engine needs repair Transport your ATV to your dealer page If the temperature drops to normal chec...

Page 214: ...rcuit or overload If something electrical on your ATV 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...

Page 215: ...ss Pull the main fuse out If it is blown install the spare main fuse To access the main fuse remove the fuse box cover Remove the seat page To prevent an accidental short circuit turn the ignition swi...

Page 216: ...em Circuit Fuse Access To check or replace a circuit fuse pull the old fuse out of its retaining clips If the fuse is blown replace it with a spare fuse of the same rating If you do not have a replace...

Page 217: ...ignition switch OFF before checking the fuse Remove the seat page Remove the rear fender cover page To access the PS fuse remove the PS fuse box cover If the PS fuse is blown see your dealer for this...

Page 218: ...temporarily If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses that were instal...

Page 219: ...nspect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor da...

Page 220: ...arrying a duplicate either get your spare or have one made If you don t know your key number call the dealer where you purchased your Honda ATV They may have it listed in their records If they don t t...

Page 221: ...dead as long as the engine is running If the engine is not running it may be started using the recoil starter Jump starting is not recommended especially if you use an automobile battery The greater a...

Page 222: ...what tools and supplies you have with you If any component of the brake system is damaged you may be able to ride carefully back to your base using the other brake components for slowing or stopping...

Page 223: ...contains dimensions capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification Specifications Break in Guidelines Petrol Conta...

Page 224: ...e serial number and key number may be required when ordering replacement parts Record the numbers here for your reference The VIN is stamped on the front of the frame VIN The engine number is stamped...

Page 225: ...cle Identification Technical Information The colour label is attached on the left front of the frame The colour code is helpful when ordering replacement parts Record the colour and code here for your...

Page 226: ...r an equivalent 15 0 3 96 US gal 3 30 Imp gal 4 6 1 22 US gal 1 01 Imp gal 3 3 3 5 US qt 2 9 Imp qt 2 9 3 1 US qt 2 6 Imp qt 3 0 3 2 US qt 2 6 Imp qt including reserve after disassembly after draining...

Page 227: ...BKR5E 11 NGK K16PR U11 DENSO 1 400 100 min rpm 0 23 mm 0 009 in 0 15 mm 0 006 in 1 00 1 10 mm 0 039 0 043 in or NO ADJUSTMENT idle speed spark plug standard compression ratio bore stroke displacement...

Page 228: ...8 30 kPa 4 4 psi primary reduction secondary reduction final reduction 1st 2nd 3rd 4th 5th reverse final drive transmission ratio caster trail tyre size front tyre size rear tyre pressure front rear c...

Page 229: ...tor PS Electric Power Steering indicator 4WD indicator PGM FI indicator high coolant temperature indicator reverse indicator neutral indicator brake tail light headlight assist headlight PS Electric P...

Page 230: ...final gear case oil drain bolt Uncertainty of measurement Vibration on handlegrip ISO 5349 2001 EN 709 Uncertainty of measurement Vibration on seat EN 1032 ISO 5008 Uncertainty of measurement Noise le...

Page 231: ...our ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 25 km 15 miles During this period avoid full throttle starts rapid acceleration...

Page 232: ...aining more than 5 methanol even if it has cosolvents and corrosion inhibitors Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the warranty Honda...

Page 233: ...225 Technical Information 12 03 16 11 51 03 32HR0610_234...

Page 234: ...parel protective 50 appearance care 181 bank angle sensor ignition cut off system 74 battery 176 brake light switch adjustment 164 brakes cables 163 draining water from 165 fluid 155 front brake lever...

Page 235: ...appearance 181 cargo loading and operational guidelines 61 weight limit 60 cleaning appearance care 181 climbing hills 86 clips 113 clutch system 145 colour label 217 compartment owner s manual 111 to...

Page 236: ...isplay multi function 26 driveshaft boots 175 drivetrain boots 174 175 electric power steering PS 47 engine flooded 74 guard 172 number 216 oil 117 pinging 114 starting 72 stop switch 34 stopping 75 w...

Page 237: ...3 final gear case oil 126 flag pole bracket 41 flat tyre 201 flooded engine 74 front boot guards 173 front driveshaft boots 175 front driveshaft guards 173 fuel fill cap 115 gauge 31 recommendation 11...

Page 238: ...ton 35 hourmeter 25 26 30 identification vehicle 216 ignition switch 32 indicators gear position indicator 25 26 27 high coolant temperature indicator 22 24 204 neutral indicator 22 24 oil change indi...

Page 239: ...mp check 22 lever 2WD 4WD select 33 limit weight 60 load limits 60 loading guidelines 61 lubrication differential oil 129 engine oil 117 gear case oil 126 maintenance component locations 107 importanc...

Page 240: ...26 neutral indicator 22 24 numbers serial 216 obstacles riding over 93 odometer 25 26 29 odometer tripmeter hourmeter select button 22 25 28 29 30 oil differential 129 engine 117 gear case 126 operati...

Page 241: ...inspection 55 problems unexpected 195 propeller shaft boots yoke joint boot 174 protective apparel 50 PS Electric Power Steering TRX500FPM only 47 rear final gear case oil 126 recoil starter 36 remov...

Page 242: ...ty equipment 69 important precautions 101 labels 5 13 riding precautions 67 schedule maintenance 102 seat removal 112 select lever 2WD 4WD 33 serial numbers 216 shifting gears 77 skid plate 172 skiddi...

Page 243: ...111 suspension adjustment 152 spring pre load 153 switch engine stop 34 headlight 35 headlight dimmer 35 ignition 32 throttle cable 144 lever 37 143 144 tool kit 110 trailer hitch 42 trailer towing o...

Page 244: ...ht limit 60 wheel removal 202 valve clearance 150 vehicle identification no VIN 216 utility box 45 trouble unexpected 195 troubleshooting starting 198 turning on hills or slopes 91 on level ground 83...

Page 245: ...a of South Carolina Mfg Inc 1111 Honda way Timmonsville South Carolina 29161 U S A Authorised Representative for EU Market Manufacturer 237 Manufacturer and Authorised Representative for EU Market Man...

Page 246: ...12 03 16 11 52 03 32HR0610_247...

Page 247: ...12 03 16 11 52 25 32HR0610_248...

Page 248: ...12 03 16 11 52 48 32HR0610_249...

Page 249: ...12 03 16 11 53 10 32HR0610_250...

Page 250: ...12 03 16 11 53 28 32HR0610_251...

Page 251: ...12 03 16 11 53 30 32HR0610_252...

Page 252: ...12 03 16 11 53 32 32HR0610_253...

Page 253: ...12 03 16 11 53 33 32HR0610_254...

Page 254: ...12 03 16 11 53 35 32HR0610_255...

Page 255: ...12 03 16 11 53 36 32HR0610_256...

Page 256: ...12 03 16 11 53 38 32HR0610_257...

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