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61HP004

61CM002

31HP0740

2009 TRX500FE/FPE/FM/FPM

Service Manual

Common Service Manual

2009 TRX500FM/FPM Owner’s

Manual

$60.00

$48.00

$16.00

Publication Item No.

Description

Price Each

218

Authorized Manuals

Consumer Information

The Service Manual used by your authorized Honda dealer is
available from Helm, Inc. (USA only, Canada: See your Honda dealer
to order authorized manuals.)

Also available but not necessary to service your model is the Honda
Common Service Manual which explains theory of operation and
basic service information for various systems common to all Honda
motorcycles, motor scooters and ATVs.

These Honda manuals are written for the professional technician, but
most mechanically capable owners should find them easy to use if
they have the proper tools and observe proper safety standards.
Special Honda tools are necessary for some procedures.

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Содержание FOURTRAX FOREMAN 4X4 TRX500FM 2009

Страница 1: ...o US EPA Noise Emission regulations but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways i...

Страница 2: ...his manual We also recommend that you read this owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual contains a detailed...

Страница 3: ...ive harm If you have any questions or if you ever need special service or repairs remember that your Honda dealer knows your ATV best and is dedicated to your complete satisfaction You may also want t...

Страница 4: ...important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potent...

Страница 5: ...u don t follow instructions 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...

Страница 6: ...safety information 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 control...

Страница 7: ...ntenance schedule and instructions for specific maintenance and adjustment items How to store and transport your ATV and how to be an environmentally responsible rider What to do if you have a flat ti...

Страница 8: ......

Страница 9: ...ost important information and recommendations to help you ride your ATV safely Please take a few moments to read these pages This section also includes information about the location of safety labels...

Страница 10: ...important The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle Refer to the age warnings provided in this manual and on the ATV Your ATV is desi...

Страница 11: ...road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards Even if you have ridden other...

Страница 12: ...ake good judgments 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 S...

Страница 13: ...the vehicle If a label comes off or becomes hard to read contact your Honda dealer for replacements Your ATV comes with a hang tag and several labels containing important safety information Anyone wh...

Страница 14: ...6 Safety Labels ATV Safety...

Страница 15: ...7 Safety Labels ATV Safety TRX500FM TRX500FPM...

Страница 16: ...For Canada 8 Safety Labels ATV Safety...

Страница 17: ...s listed 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...

Страница 18: ...Box Accessory Socket Trailer Hitch Flag Pole Bracket Parking Brake Rear Brake Pedal Rear Brake Lever Front Brake Lever Reverse Selector Knob Throttle Lever Recoil Starter Starting Primer Knob Headligh...

Страница 19: ...ght switch throttle lever headlight dimmer switch start button choke knob engine stop switch rear brake lever 2WD 4WD select switch parking brake lock lever ignition switch parking brake lever 11 Inst...

Страница 20: ...rear cargo rack recoil starter rear brake pedal seat lock lever starting primer knob front cargo rack 12 Instruments Controls Operation Component Locations...

Страница 21: ...fuel valve trailer hitch accessory socket utility box storage compartment flag pole bracket shift lever 13 Instruments Controls Operation Component Locations...

Страница 22: ...t button 10 adjust button 11 PS Electric Power Steering indicator TRX500FPM only TRX500FM TRX500FPM 14 Indicators Displays Instruments Controls The indicators and displays on your ATV keep you informe...

Страница 23: ...d in the table on page with the words If any part of these displays does not come on when it should have your Honda dealer check for problems When the ignition switch is turned ON the multi function d...

Страница 24: ...ive mode is in the 4WD mode The 4WD indicator blinks if there is a possible problem with the 2WD 4WD select system See your Honda dealer as soon as possible High oil temperature indicator Neutral indi...

Страница 25: ...leage page Adjust button Used to set the digital clock page Hour select button Advances the hour displayed by the digital clock page Hourmeter Tripmeter Shows mileage per trip page Shows hours and ten...

Страница 26: ...0FPM 18 Multi function Display Indicators Displays Instruments Controls The multi function display includes the following functions The digital clock will reset if the battery is disconnected The digi...

Страница 27: ...nsmission is not shifted into gear properly Before riding check that the gear position is properly displayed on the gear position indicator The gear position indicator shows the gear position when the...

Страница 28: ...the oil change interval specified on the maintenance schedule If the oil is changed before the oil change indicator appears be sure to reset the oil change indicator after changing the oil The indicat...

Страница 29: ...has two functions odometer and tripmeter The tripmeter has two sub modes tripmeter A and tripmeter B The odometer registers total distance traveled in miles while the ignition switch is ON The tripme...

Страница 30: ...5 RESET button 22 Indicators Displays Instruments Controls To reset the tripmeter to zero press and hold the RESET button for more than 2 seconds with the display in the tripmeter A or tripmeter B mod...

Страница 31: ...TRX500FPM 23 Hourmeter Indicators Displays Instruments Controls The hourmeter shows accumulated hours while the ignition is ON The hourmeter provides accurate service period information for initial a...

Страница 32: ...in advancing Release the button when the display reaches the desired hour To advance the minute display one unit at a time press and release the minute select button To advance the minute display auto...

Страница 33: ...1 adjust button 2 hour select button 3 minute select button 2 2 1 1 3 3 TRX500FM TRX500FPM 25 Indicators Displays Instruments Controls...

Страница 34: ...ate 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 amount of fuel remaining when the flashing starts is...

Страница 35: ...age Remember to check that the fuel valve is in the ON position each time you refuel If the fuel valve is left in the RES position you may run out of fuel with no reserve Reserve Fuel RES for extra fu...

Страница 36: ...1 B B A fully ON B fully OFF CENTER OF HANDLEBAR 1 choke knob A A 28 Choke Knob Controls Features Instruments Controls The choke knob may be used when starting the engine See page 1 67...

Страница 37: ...TER OF HANDLEBAR 1 ignition switch 1 ON OFF ON OFF Function Key Position 29 Ignition Switch Controls Features Instruments Controls The ignition switch is used for starting and stopping the engine page...

Страница 38: ...D 4WD select switch is located above the throttle lever To select the drive mode slide the 2WD 4WD select switch to the desired position To check your present drive mode look at the 4WD indicator 2WD...

Страница 39: ...starter motor will not operate if the engine stop switch is in the OFF position when the start button is pushed The engine stop switch is used to stop the engine in an emergency To operate slide the s...

Страница 40: ...ols The headlight dimmer switch is used to change between the high and low beams of the headlight To operate turn the switch to HI for high beam LO for low beam The headlight dimmer switch will not ch...

Страница 41: ...atures Instruments Controls Starting Procedure Using the Recoil Starter The starting primer knob is located on the carburetor float bowl The knob may be used when starting the engine in extremely cold...

Страница 42: ...ures Instruments 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 throttl...

Страница 43: ...Riding in Reverse 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...

Страница 44: ...ATV To operate pull the lever For information on braking techniques see page The rear brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see...

Страница 45: ...ing the parking 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 u...

Страница 46: ...tures Instruments Controls Flag poles are optional equipment available from your Honda dealer To mount a pole in the bracket follow the instructions that come with the flag pole kit Flag poles are req...

Страница 47: ...railer hitch is 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 t...

Страница 48: ...ch as an automobile 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...

Страница 49: ...e accessory socket 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 usi...

Страница 50: ...he 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 releases...

Страница 51: ...3 rubber strap 2 43 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 n...

Страница 52: ...sist The steering 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 i...

Страница 53: ...nd adjustments 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...

Страница 54: ...that you always wear an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved shirt or jacket whenever you ride Although complete protection is not possible wearing prop...

Страница 55: ...ng An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker on any helmet you buy USA only Always wear...

Страница 56: ...for the ATV Rider Developing your riding skills is an on going process Even if you have ridden other ATVs take time to become familiar with how this ATV works and handles Practice riding the ATV in a...

Страница 57: ...cause a crash and you or your passenger could be injured or killed Never carry a passenger on this ATV 49 Age Recommendation No Passengers Are You Ready to Ride Before Riding The minimum recommended a...

Страница 58: ...ume alcohol or drugs before or while operating this ATV 50 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 abili...

Страница 59: ...em you find is corrected A pre ride inspection is a must not only for safety but because having a breakdown or even a flat tire can be a major inconvenience If your ATV has overturned or been involved...

Страница 60: ...and remove any dirt vegetation or other debris that could be a fire hazard or interfere with the proper operation of the vehicle Check for deposits in the drain tube If necessary clean the tube page a...

Страница 61: ...e the front and rear brake levers and step on the rear brake pedal to check that the controls operate normally Check for proper freeplay pages Make sure there is no brake fluid leakage Check for prope...

Страница 62: ...erfere with your 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...

Страница 63: ...wing load limits apply 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 includes the weight...

Страница 64: ...tow another vehicle 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 ha...

Страница 65: ...designed and 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...

Страница 66: ...seriously impair your ATV s handling stability and braking making it unsafe to ride We also advise you not to make any modifications or remove any equipment such as the USDA qualified spark arrester...

Страница 67: ...ce life refer to Break in Guidelines page For information about carburetor adjustment for riding at high altitude see page cont d Safe Riding Precautions Off road Use Only Keep Hands and Feet on Contr...

Страница 68: ...c Operation Riding 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...

Страница 69: ...e 1 and the section 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 ac...

Страница 70: ...Feet on Controls 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 diffi...

Страница 71: ...cle the terrain visibility and other operating conditions and your experience 63 Control Speed Basic Operation Riding Safe Riding Precautions Riding at excessive speed increases the chance of an accid...

Страница 72: ...errain Always be alert to changing terrain conditions when operating the ATV 64 Use Care on Unfamiliar or Rough Terrain Safe Riding Precautions Basic Operation Riding Before riding in a new area alway...

Страница 73: ...on these kinds of 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 65 D...

Страница 74: ...operating the 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...

Страница 75: ...ime may cause the starter to overheat and damage the starter Release the start button for approximately 10 seconds before pressing it again With the throttle closed press the start button Immediately...

Страница 76: ...of the engine High Air Temperature 35 C 95 F or above Do not use the choke Low Air Temperature 10 C 50 F or below Follow the procedure for Do not race the engine during the warm up period Racing a co...

Страница 77: ...y OFF If the engine still won t start refer to page If the engine starts quickly close the throttle then if idling is unstable open it slightly If the engine does not start wait 10 seconds then follow...

Страница 78: ...dicator light is on then turn the ignition switch OFF To stop the engine in an emergency use the engine stop switch To operate slide the switch to the OFF position Emergency Engine Stop If your ATV is...

Страница 79: ...o operate the recoil starter Grasp the starter grip firmly then pull it out slowly approximately 4 in 100 mm Pull the grip up briskly and fully After the engine starts allow the starter grip to return...

Страница 80: ...shift lever shifts 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...

Страница 81: ...low rpm Avoid downshifting to help slow your ATV when engine rpm is high Downshifting when engine speed is near its allowable maximum may over rev the engine and possibly cause damage To prevent trans...

Страница 82: ...lector knob 2 rear brake lever parking brake lever 74 Riding in Reverse Basic Operation Riding If you need to ride in reverse make sure the area behind you is clear and only operate the ATV at low spe...

Страница 83: ...ATV may be equipped with a reverse speed limiter which helps the vehicle to maintain a safe speed while riding in reverse gear To shift out of reverse and into neutral raise the shift lever one strok...

Страница 84: ...ow or stop apply the brake lever and brake pedal smoothly while downshifting to match your speed For full braking effectiveness use both the pedal and lever simultaneously Using both braking systems w...

Страница 85: ...engine compression 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 th...

Страница 86: ...in this owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 78 Making Turns Riding Your ATV Basic Operation Riding Learn how to tur...

Страница 87: ...rating from a full stop To make a sharp turn at low speed It helps to shift your body slightly forward on the seat and lean inside as you steer the handlebar Shifting weight forward allows the rear wh...

Страница 88: ...Riding Riding Your ATV 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...

Страница 89: ...ing The ATV s ability 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 l...

Страница 90: ...start up any hill 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 sudd...

Страница 91: ...ft into neutral 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 b...

Страница 92: ...ot 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 ATV Stand with your body facing downhill...

Страница 93: ...scribed in this owner s manual 85 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...

Страница 94: ...ms extended and 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 w...

Страница 95: ...f the seat and lean 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 excess...

Страница 96: ...as described in this owner s manual 88 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...

Страница 97: ...y the brakes repeatedly 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...

Страница 98: ...le back and forth to allow shifting the transmission into neutral If rocks or other objects are available you can block the wheels as shown for additional security If the ATV begins to move either whi...

Страница 99: ...ic maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking good cont d For information about replacing fuses see page For...

Страница 100: ...Engine Oil Filter Differential Oil Air Cleaner Throttle Carburetor Choke Cable Knob Clutch System Reverse Lock System Engine Idle Speed Spark Plug Valves Spark Arrester Brakes Appearance Care Tires Dr...

Страница 101: ...educe air pollution 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...

Страница 102: ...rform many of these 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...

Страница 103: ...Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of a fire or explosion be careful when working around gasoline Use only non flamm...

Страница 104: ...dule can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual Other items involve more extensive procedures and may require special training...

Страница 105: ...e more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the o...

Страница 106: ...FREQUENCY WHICHEVER COMES FIRST INITIAL INITIAL REGULAR 100 mi 150 km 20 operating hours or 1 month R Every 600 mi 1 000 km 100 operating hours or 12 months R HOURS MAINT INTERVAL MAINT 98 Maintenance...

Страница 107: ...C I I I I I 600 1000 100 I I I I I I I I C I I 100 150 20 I I I I I I I NOTE NOTE 3 NOTE 1 Refer to page 161 119 121 141 150 144 151 141 133 160 132 139 153 FREQUENCY ITEMS WHICHEVER COMES FIRST REGU...

Страница 108: ...your ATV is properly maintained Retain detailed receipts to verify the maintenance was performed If the ATV is sold these receipts should be transferred with the ATV to the new owner Make sure whoever...

Страница 109: ...front brake fluid reservoir fuel fill cap front brake lever throttle lever choke knob rear brake lever parking brake lever 101 Servicing Your Honda Maintenance Component Locations...

Страница 110: ...cleaner housing drain tube engine oil filter front brake caliper differential oil filler cap air cleaner differential oil drain bolt owner s manual throttle stop screw engine idle speed 102 Servicing...

Страница 111: ...ck gear case oil drain bolt battery spark plug tool kit air pressure gauge main fuse fuse box PS fuse TRX500FPM only gear case oil filler cap spark arrester engine oil drain bolt 103 Servicing Your Ho...

Страница 112: ...ool kit is stored under the seat page After using the tools be sure to use the rubber band to fasten the tool kit securely An optional larger tool kit may be available Check with your Honda dealer s p...

Страница 113: ...nda Be careful not to flood this area when washing your ATV Your ATV provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual on the underside of...

Страница 114: ...he seat until locks Installation Removal Pull the seat lock lever at the right side of the seat Slide the seat back and lift it Insert the front prongs into the hooks on the frame and press the studs...

Страница 115: ...ane gasoline can cause persistent pinging or spark knock a loud rapping noise which if severe can lead to engine damage Light pinging experienced while operating under a heavy load such as climbing a...

Страница 116: ...fueling Procedure Fuel Servicing Your Honda Safety Precautions Fuel tank capacity including reserve Reserve capacity Refer to on page The tank should be refilled as soon as possible after switching to...

Страница 117: ...bottom of the filler neck Avoid over filling the tank There should be no fuel in the filler neck If the fuel valve was set to RES turn the fuel valve ON If you replace the fuel fill cap use only a Hon...

Страница 118: ...life Even the best oil wears out Changing oil helps get rid of dirt and deposits in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oi...

Страница 119: ...lter Servicing Your Honda Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label Your ATV does not need oil additives Use the re...

Страница 120: ...chart may be used when the average 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...

Страница 121: ...TV check the engine oil level Refer to on page Check the engine oil level each day before operating your ATV and add if needed cont d Unsnap and remove the left engine sub cover Start the engine in a...

Страница 122: ...emove the oil filler cap dipstick and check the oil level The oil level should be between the upper level mark and the lower level mark on the oil filler cap dipstick Install the left engine sub cover...

Страница 123: ...l filter specified for your model or a filter of equal quality This procedure requires mechanical skill and professional tools such as a torque wrench and oil filter wrench as well as a means for disp...

Страница 124: ...1 RIGHT SIDE 2 1 right engine sub cover 2 screw 116 Engine Oil Filter Servicing Your Honda Install a New Engine Oil Filter Remove the right engine sub cover by removing the screw 1 1 2...

Страница 125: ...ved manner page Check that the oil filter cover O rings are in good condition and then install a new oil filter Use only the Honda Genuine oil filter or a filter of equivalent quality specified for yo...

Страница 126: ...ion If necessary replace the sealing washer Reinstall the oil drain plug and tighten it to the specified torque Fill the crankcase with the recommended grade oil approximately Reinstall the oil filler...

Страница 127: ...oil Honda shaft drive oil or equivalent 119 Changing Oil Oil Recommendation Gear Case Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the gear case at normal operatin...

Страница 128: ...ain pan under the oil drain plug Remove the oil filler cap and the drain plug After the oil has completely drained reinstall the drain plug and tighten it to the specified torque Pour the drained oil...

Страница 129: ...l Honda shaft drive oil or equivalent 121 Oil Recommendation Changing Oil Differential Oil Servicing Your Honda Safety Precautions Refer to on page Change the oil with the differential at normal opera...

Страница 130: ...ned reinstall the drain plug and tighten it to the specified torque Park the ATV on level ground Place an oil drain pan under the oil drain plug Remove the oil filler cap and the drain plug Pour the d...

Страница 131: ...will allow dirt 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 Honda dealer can help you determine the...

Страница 132: ...DER SEAT 2 1 1 retainer clips 2 air cleaner housing cover 124 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 1...

Страница 133: ...cleaner if it is damaged Gently wash the air cleaner and sub air cleaner in clean non flammable high flash point solvent such as kerosene not gasoline After cleaning gently squeeze out the remaining s...

Страница 134: ...venly 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 Install th...

Страница 135: ...1 dust cover 1 2 2 breather joint UNDER SEAT 127 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...

Страница 136: ...be serviced in 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...

Страница 137: ...Safety Precautions Refer to on page Check freeplay at the throttle lever Freeplay Inspection After adjustment check for smooth operation of the throttle lever from fully closed to fully open in all st...

Страница 138: ...from fully open to fully closed in all steering positions If there is a problem see your Honda dealer Inspect the condition of the throttle cables from the throttle lever down to the carburetor If the...

Страница 139: ...1 131 Servicing Your Honda Carburetor Choke Cable Knob Safety Precautions Refer to on page Check the condition of the choke cable Check the operation of the choke knob If the cable is damaged or kinke...

Страница 140: ...turn clockwise then tighten the lock nut to hold the adjuster in this position After adjustment start the engine and test ride your ATV to be sure the clutch is operating properly Install the removed...

Страница 141: ...Other Checks Check the reverse assist lever and cable for loose connections or other damage If the cable is worn or kinked have it replaced by your Honda dealer Refer to on page Check the reverse ass...

Страница 142: ...problems in your engine s fuel delivery system Adjusting the idle will not compensate for a fault elsewhere Adjust idle speed by turning the throttle stop screw Idle speed in neutral Park your ATV on...

Страница 143: ...ine damage Safety Precautions Use only the recommended type of spark plug in the recommended heat range Refer to on page cont d Loosen the screw and remove the clip Remove the seat page Using a spark...

Страница 144: ...cleaner if available or a wire brush Inspect the spark plug electrodes for wear The center electrode should have a flat tip and sharp edges and the side electrode should not be eroded If the electrode...

Страница 145: ...nt cross threading Tighten the spark plug If the old plug is good 1 8 turn after it seats If installing a new plug tighten it twice to prevent loosening First tighten the plug NGK turn after it seats...

Страница 146: ...ent and have the proper tools instructions on adjusting valve clearances are given in the official Honda Service Manual Otherwise the valves should be adjusted by your Honda dealer Excessive clearance...

Страница 147: ...ency cont d Regular servicing prevents carbon build up which can diminish engine performance and also complies with USDA regulations for regular maintenance to assure proper function The spark arreste...

Страница 148: ...rbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary Check the gasket Replace if...

Страница 149: ...Disc Front Brake If the right brake lever 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 th...

Страница 150: ...uld be above the LOWER level mark If the level is at or below the LOWER level mark check the brake pads for wear page Worn brake pads should be replaced If the pads are not worn have your brake system...

Страница 151: ...tact with your eyes wash them out with clean water and immediately call a doctor If it comes in contact with your skin wash with clean water and if necessary call a doctor Make sure there are no fluid...

Страница 152: ...g 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 an...

Страница 153: ...T SIDE 145 Rear Brake 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...

Страница 154: ...urn the brake pedal 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 t...

Страница 155: ...lever 147 Rear Brake 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 bra...

Страница 156: ...ith the front wheels pointed straight ahead Turn the brake lever 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...

Страница 157: ...kes Servicing Your Honda Check that the rear brake lever and brake pedal assemblies are positioned properly and the securing bolts are tight Make sure that the brake cables brake arm spring and fasten...

Страница 158: ...check brake wear without disassembly Application of the brake control causes the arrow on the brake arm to move toward a reference mark on the brake panel Apply the brake control and check the moveme...

Страница 159: ...r to on page Rear Brake Only Check the operation of the rear brakelight switch at the right side behind the engine from time to time The brakelight should turn on at 0 6 in 15 mm of pedal stroke See p...

Страница 160: ...ng Your Honda Safety Precautions Refer 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...

Страница 161: ...es must be the proper type and size in good condition with adequate tread and correctly inflated This ATV is equipped with low pressure tubeless tires Although the tires are designed specifically for...

Страница 162: ...dling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tires make your ATV ride harshl...

Страница 163: ...155 Tires Servicing Your Honda Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your ATV has only been ridden for a few miles the readings...

Страница 164: ...e system found in service stations This will minimize the possibility of tire damage from overinflation If you use a high pressure system at a service station add air in small amounts and check the pr...

Страница 165: ...o if you hit a pothole or other hard object while riding stop as soon as you safely can and carefully inspect the tires for damage Tread Wear For best performance you should replace a tire before the...

Страница 166: ...temporary repairs see page A tire that is repaired either temporarily or permanently will have lower speed and performance limits than a new or undamaged tire If you have a tire professionally repaire...

Страница 167: ...e designed 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 tires however if that is not possible you m...

Страница 168: ...rotects the engine crankcase The skid plates protect the frame and rear final gear case Check the guard and plates for cracks damage or looseness at intervals shown in the Maintenance Schedule Have th...

Страница 169: ...er driveshaft boots 161 Driveshaft Boots Servicing Your Honda Safety Precautions Refer to on page Check the rubber driveshaft boots for damage or leaking grease If necessary have your Honda dealer rep...

Страница 170: ...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 that you charge the battery freque...

Страница 171: ...tery Charging 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...

Страница 172: ...r Honda The battery is located in a compartment under the seat Remove the battery Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Release the ri...

Страница 173: ...emperature and direct sunlight Clean the battery box after removing the battery for storage Dry the battery box and if paint is missing re paint the area Slow charge the battery see following section...

Страница 174: ...arging may damage the battery We recommend using a trickle charger for home charging These units can be left connected for long periods without risking damage to the battery However do not intentional...

Страница 175: ...cts that contain harsh 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...

Страница 176: ...fter 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 chamois or a soft towel Leaving water on the surfa...

Страница 177: ...ply a spray cleaner 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 Brak...

Страница 178: ...y for motorcycles or automobiles Apply the polish or wax according to the instructions on the container If a surface on your ATV is chipped or scratched your Honda dealer has touch up paint to match y...

Страница 179: ...and store your Honda and how to be an environmentally responsible ATV owner What to Take to the Riding Area What to Take on the Trail Transporting Your Honda Storing Your Honda Preparation for Storag...

Страница 180: ...USA only the Ministry of Natural Resources Canada only riding clubs and off road magazines are good sources of information Along with your ATV and riding gear you should take along some tools and supp...

Страница 181: ...expect to ride 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...

Страница 182: ...ecommend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking gasoline could be a h...

Страница 183: ...wn straps in the areas shown Suitable tie down straps are available from your Honda dealer Ordinary rope is not recommended because it can stretch under load Using tie down straps in any other areas c...

Страница 184: ...y problem before storing it That way needed repairs won t be forgotten and it will be easier to get your ATV running again For more information about storage refer to the available from your Honda dea...

Страница 185: ...to on page This procedure requires a means for draining and disposing of drained fuel page Change the engine oil and filter page Fill the fuel tank Make sure the fuel fill cap is properly installed c...

Страница 186: ...ry and charge it fully Store it in an area protected from freezing temperatures and direct sunlight Slow charge the battery page once a month Cover your ATV with a porous material Avoid using plastic...

Страница 187: ...as been stored for more than two months ask your Honda 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...

Страница 188: ...y increase noise 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 da...

Страница 189: ...s practical advice to help you deal with a wide range of problems Take time to read this section before you ride Also review the tips in page General Guidelines If Your Engine Quits or Won t Start If...

Страница 190: ...doesn t feel right If you continue riding you could cause more damage and endanger your own safety After stopping take time to assess the situation Carefully inspect your ATV to identify the problem...

Страница 191: ...time to assess the situation and your options before deciding what to do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have perma...

Страница 192: ...cases the cause 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...

Страница 193: ...ty See your Honda dealer SYMPTOM POSSIBLE CAUSE out of fuel flooded engine loose or unconnected spark plug cap loose battery cables weak battery WHAT TO DO Fill the fuel tank See page Install the spar...

Страница 194: ...high oil temperature indicator Refer to page See your Honda dealer See your Honda dealer If applicable switch to the recommended octane gasoline page or change your brand of gasoline If the problem pe...

Страница 195: ...a temporary repair As soon as possible have the tire permanently repaired by your Honda dealer Any tire that cannot be repaired should be replaced Whenever the ATV is to be operated far from service...

Страница 196: ...f the temporary repair fails you can crash and be seriously injured or killed If you must ride with a temporary tire repair ride slowly and carefully until the tire is permanently repaired or replaced...

Страница 197: ...el surface Removal Avoid getting grease oil or dirt on the disc or pad surfaces when removing and installing each wheel Any contamination can cause poor brake performance or rapid pad wear after reass...

Страница 198: ...the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque Position the wheel nuts so that the tapered sides face the wheel rim If a torque w...

Страница 199: ...l or extended operation under adverse conditions If the indicator comes on while you re riding don t ignore it Pull safely to a stop Stop the engine as soon as it s safe to do so and let it cool If th...

Страница 200: ...current flow short circuit 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...

Страница 201: ...of the Unexpected Main Fuse Access Remove the seat page To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuses To access the main fuse remove the fu...

Страница 202: ...f damage to the electrical system 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 rati...

Страница 203: ...ou replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses that were installed If you do not...

Страница 204: ...ly carefully inspect your ATV for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If the...

Страница 205: ...e If you lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer where you purchased your Honda ATV They may have it list...

Страница 206: ...it appears unable to hold a charge contact your Honda dealer Bump starting is also not recommended Jump starting is not recommended especially if you use an automobile battery The greater amperage of...

Страница 207: ...he damage is and what tools and supplies you have with you If any component of the brake system is damaged you may be able to ride carefully back to your base using the other brake components for slow...

Страница 208: ...200 Taking Care of the Unexpected...

Страница 209: ...ties and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification Specifications Break in Guidelines High Altitude Carburetor Adjustment Emi...

Страница 210: ...ation The VIN engine serial number and key number may be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN is stam...

Страница 211: ...icle Identification Technical Information The color label is attached on the front of the frame The color code is helpful when ordering replacement parts You may record the color and code in the Quick...

Страница 212: ...rving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 stroke oil USA Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil including reserve afte...

Страница 213: ...shaft 2 103 1 818 0 006 in 0 15 mm 0 006 in 0 15 mm or intake exhaust passenger capacity bore stroke maximum weight capacity displacement spark plug standard compression ratio spark plug gap valve cle...

Страница 214: ...trail tire size front tire size rear tire pressure front rear cold tire pressure front rear cold battery generator headlight assist headlight brake tail light neutral indicator reverse indicator high...

Страница 215: ...lbf ft 12 N m 1 2 kgf m 47 lbf ft 64 N m 6 5 kgf m main other PS Electric Power Steering fuse engine oil drain bolt engine oil filter cover bolts differential oil drain bolt rear final gear case oil...

Страница 216: ...on Help assure your ATV s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts ra...

Страница 217: ...ill also foul the spark plug and cause hard starting Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitud...

Страница 218: ...Information The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Environment Canada EC require that your ATV comply with applicable exhaust emissions standards duri...

Страница 219: ...hen subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons The e...

Страница 220: ...mptoms have the vehicle inspected and repaired by your Honda ATV dealer Symptoms Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burning backfirin...

Страница 221: ...E ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of...

Страница 222: ...ls that come near it Park your ATV away from high grasses dry leaves or other flammables A defective catalytic converter contributes to air pollution and can impair your engine s performance Follow th...

Страница 223: ...ed on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing e...

Страница 224: ...toms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of...

Страница 225: ...This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals Warranty Coverage Warranty Service Contacting Honda Your Honda Dealer The Honda R...

Страница 226: ...lable from Helm Inc USA only Canada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of...

Страница 227: ...e Each Sub Total Item Description Qty 219 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00...

Страница 228: ...e Telephone Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Check here if your billing address is different from the shipping address shown above VISA Discover...

Страница 229: ...s important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage will not be voided if you choose to perform your own maintenance However yo...

Страница 230: ...you the results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the rep...

Страница 231: ...o work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Mot...

Страница 232: ...products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the...

Страница 233: ...Club USA only Consumer Information www hrca honda com You may be eligible for a Honda Rider s Club of America HRCA membership with the purchase of your new Honda You can log on to the HRCA Clubhouse w...

Страница 234: ...the contents of each section of your owner s manual Important Safety Information Safety Labels Operation Component Locations Indicators Displays Multi function Display Gear Position Indicator Oil Cha...

Страница 235: ...r Knob Front Brake Lever Rear Brake Lever Rear Brake Pedal Parking Brake Flag Pole Bracket Trailer Hitch Accessory Socket Utility Box Storage Compartment Recoil Starter PS Electric Power Steering only...

Страница 236: ...are on Unfamiliar or Rough Terrain Do Not Perform Stunts Starting Stopping the Engine Preparation Starting Procedure Flooded Engine Riding Through Water Riding Over Obstacles Crossing or Turning on Hi...

Страница 237: ...Important Safety Precautions Maintenance Schedule Tool Kit Owner s Manual Storage Seat Removal Fuel Engine Oil Filter Gear Case Oil Differential Oil Air Cleaner Throttle Carburetor Choke Cable Knob Cl...

Страница 238: ...rting Your Honda Storing Your Honda Preparation for Storage Removal from Storage You the Environment If Your Engine Quits or Won t Start General Guidelines If You Have a Flat Tire If the High Oil Temp...

Страница 239: ...ENCE Vehicle Identification Specifications Break in Guidelines High Altitude Carburetor Adjustment Emission Control Systems Catalytic Converter Oxygenated Fuels Authorized Manuals Warranty Coverage Wa...

Страница 240: ...27 filter 123 housing drain tube 128 air pressure gauge 104 tire 154 altitude high 209 American Honda contacting 223 apparel protective 46 appearance care 167 authorized manuals 218 battery 162 brakel...

Страница 241: ...just 14 17 25 hour select 14 17 25 minute select 14 17 25 odometer tripmeter select 14 16 20 21 RESET 14 16 20 22 capacity fuel 108 carburetor altitude adjustment 209 care appearance 167 cargo loading...

Страница 242: ...stick 114 display check 15 display multi function 18 driveshaft boots 161 compartment owner s manual 105 storage compartment 43 tool kit 104 component fails 199 consumer information 217 controls featu...

Страница 243: ...lat tire 187 flooded engine 69 electric power steering PS 44 emission control systems 210 engine flooded 69 guard 160 idle speed 134 number 202 oil 110 pinging 107 starting 66 stop switch 31 stopping...

Страница 244: ...209 oxygenated 215 recommendation 107 refueling 108 reserve fuel supply 108 tank capacity 108 valve 27 fuses 192 gap spark plug 136 205 gasohol 215 gasoline 107 gear case oil 119 gear shifting 72 hea...

Страница 245: ...Club 225 service manual 218 hourmeter 23 hour select button 14 17 24 identification vehicle 202 idle speed engine 134 ignition switch 29 indicators gear position indicator 19 neutral indicator 14 16...

Страница 246: ...101 importance 93 precautions 95 record 100 safety 94 schedule 96 key lost 197 number 197 kit tool 104 labels safety 5 lamp check 15 limit weight 55 load limits 55 loading guidelines 56 lubrication d...

Страница 247: ...8 neutral indicator 14 16 noise emission control system 213 numbers serial 202 obstacles riding over 88 odometer tripmeter 21 odometer tripmeter select button 14 16 20 21 oil differential 121 engine 1...

Страница 248: ...pection 51 problems unexpected 181 protective apparel 46 PS Electric Power Steering 44 rear final gear case oil 119 recoil starter 33 removal seat 106 RESET button 14 16 20 22 reverse assist cable 133...

Страница 249: ...riding precautions 61 schedule maintenance 96 seat removal 106 serial numbers 202 service customer 223 manuals 218 warranty 222 riding basic operations 59 clothing 46 over obstacles 88 precautions 61...

Страница 250: ...7 spark plug 135 specifications 204 speedometer 18 stalled engine 69 stalling on a hill 83 start button 31 starting engine 66 troubleshooting 184 stop switch engine 31 stopping engine 70 storage ATV 1...

Страница 251: ...4 flat 187 replacing 159 repairing 158 tread conditions 156 157 tool kit 104 trailer hitch 39 trailer towing operational guidelines 56 weight limits 55 training rider 48 transporting your ATV 174 trou...

Страница 252: ...el 27 valve clearance 138 vehicle identification no VIN 202 warning labels 5 warranty coverage 221 extended 221 service 222 washing your ATV 168 water draining from brakes 152 riding through 89 weight...

Страница 253: ...tant notes The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequen...

Страница 254: ...Quick Reference Quick Reference Engine No VIN Ignition Key No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr...

Страница 255: ...bolts underbody exhaust system air cleaner housing drain tube leaks loose parts cables lights throttle brakes reverse assist lever switches steering Engine Oil unleaded gasoline pump octane number 86...

Страница 256: ...A 15 A 2 10 A 2 3 6 psi 25 0 kPa 3 6 psi 25 0 kPa 4 4 psi 30 0 kPa 3 6 psi 25 0 kPa 40 A Front Rear Front Rear or standard Front Rear main other PS Electric Power Steering TRX500FM TRX500FPM TRX500FPM...

Страница 257: ...n switch 2WD 4WD select switch LO headlight dimmer switch HI headlight dimmer switch OFF headlight switch ON headlight switch OFF engine stop switch RUN engine stop switch START button SEE PAGE choke...

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