TRX500FE1/FE2
FOURTRAX
FOREMAN
Part Number
This manual should be considered a permanent part of the ATV and
should remain with the ATV when it is resold.
This publication includes the latest production information available
before printing. Honda Motor Co., Ltd. reserves the right to make
changes at any time without notice and without incurring any
obligation.
No part of this publication may be reproduced without written
permission.
This vehicle pictured in this owner’s manual may not match your
actual vehicle.
© Honda Motor Co., Ltd. 2018
19 TRX420FA1 FA2 (U)-32HR3E400.book Page 1 Thursday, May 3, 2018 1:26 PM
Honda
TRX500FE1 4 × 4
TRX500FE2 4 × 4
with Power Steering
OWNER’S MANUAL
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Introduction
Introduction
Introduction
Congratulations on choosing your Honda ATV.
When you own a Honda, you’re part of a worldwide family of
satisfied customers — people who appreciate Honda’s reputation
for building quality into every product.
Your Honda was designed as a recreational ATV for off-road use by
one rider only.
Before riding, take time to get acquainted with your ATV and how it
works. To protect your investment, we urge you to take
responsibility for keeping your ATV well maintained. Scheduled
service is a must, of course. But it’s just as important to observe the
break-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 information, and helpful
tips. To make it easy to use, the manual contains a detailed list of
topics at the beginning of each section and an index at the back of
the book.
As you read this manual, you will find information that is preceded
by a symbol. This information is intended to help you avoid
damage to your Honda, other property, or the environment.
Whenever you ride, tread lightly. By staying on established trails and
riding only in approved areas, you help protect the environment and
keep off-road riding areas open for the future.
NOTICE
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Introduction
Introduction
If you have any questions, or if you ever need special service or
repairs, remember that your dealer knows your ATV best and is
dedicated to your complete satisfaction.
Happy riding!
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A Few Words About Safety
A Few Words About Safety
A Few Wo rds About Safety
Your safety, and the safety of others, is very important. And
operating this ATV safely is an 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 potential hazards that
could hurt you or others.
Of course, it is not practical or possible to warn you about all hazards
associated with operating or maintaining an ATV. You must use your
own good judgement.
You will find important safety information in a variety of forms,
including:
Safety Labels — on the ATV.
Safety Messages — preceded by a safety alert symbol
2
and one
of three signal words: DANGER, WARNING, or CAUTION.
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A Few Words About Safety
A Few Words About Safety
These signal words mean:
Safety Headings — such as Important Safety Reminders or
Important Safety Precautions.
Safety Section — such as ATV Safety.
Instructions — how to use this ATV correctly and safely.
This entire manual is filled with important safety information —
please read it carefully.
3
DANGER
You WILL be KILLED or
SERIOUSLY HURT if you don't
follow instructions.
3
WARNING
You CAN be KILLED or SERIOUSLY
HURT if you don’t follow
instructions.
3
CAUTION
You CAN be HURT if you don’t
follow instructions.
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Contents
Contents
Conten ts
These pages give an overview of the contents of your owner’s
manual.
The first page of each section lists the topics covered in that section.
ATV Safety ..................................................................................1
Important safety information you should know, plus a look at the
safety related labels on your ATV.
Instruments & Controls ..............................................................9
The location and function of indicators and controls on your ATV
and operating instructions for various controls and features.
Before Riding ............................................................................57
The importance of wearing a helmet and other protective gear,
how to make sure you and your ATV are ready to ride, and
important information about loading.
Basic Operation & Riding .........................................................73
How to start and stop the engine, shift gears, and brake. Also,
riding precautions.
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Contents
Contents
Servicing Your Honda ............................................................107
Why your ATV needs regular maintenance, what you need to
know before servicing your Honda, an owner maintenance
schedule, and instructions for specific maintenance and
adjustment items.
Tips ..........................................................................................199
How to store and transport your ATV and how to be an
environmentally responsible rider.
Taking Care of the Unexpected.............................................209
What to do if you have a flat tyre, your engine won’t start, etc.
Technical Information ............................................................233
ID numbers, technical specifications, and other technical facts.
Index........................................................................................242
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19 TRX500FE1 FE2 (U)-32HR4B400.book Page 9 Thursday, May 3, 2018 11:44 AM
ATV Safety
1
ATV Safety
ATV Sa fety
This section presents some of the most important information and
recommendations to help you ride your ATV safely. Please take a few
moments to read these pages. This section also includes information
about the location of safety labels on your ATV.
Important Safety Information........................................................ 2
Safety Labels ................................................................................ 5
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ATV Safety
2
Important Safety Information
Your ATV can provide many years of service and pleasure if you take
responsibility for your own safety and understand the challenges you
can meet while riding.
There is much that you can do to protect yourself when you ride.
You’ll find many helpful recommendations throughout this manual.
The following are a few that we consider to be most important.
Follow the Age Recommendation
The minimum recommended age for this ATV model is 16. Children
under age 16 should never operate this vehicle.
Always Wear a Helmet
It’s a proven fact: helmets significantly reduce the number and
severity of head injuries. So always wear an approved motorcycle
helmet. We also recommend that you wear eye protection, sturdy
boots, gloves, and other protective gear (page 58).
Never Carry a Passenger
Your ATV is designed for one person only. There are no handholds,
footrests, or seat for a second person, so never carry a passenger. A
passenger could interfere with your ability to move around to
maintain your balance and control of the ATV.
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ATV Safety
3
Important Safety Information
Ride Off-road Only
Your ATV is designed and manufactured for off-road use only. The
tyres are not made for pavement, and the ATV does not have turn
signals and other features required for use on public roads. If you
need to cross a paved or public road, get off and walk your ATV
across.
Take Time to Learn & Practice
Even if you have ridden other ATVs, take time to become familiar
with how this ATV works and handles. Practice in a safe area until
you build your skills and get accustomed to the ATV’s size and
weight.
Be Alert for Off-road Hazards
The terrain can present a variety of challenges when you ride off-
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.
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ATV Safety
4
Important Safety Information
Ride within Your Limits
Pushing limits is another major cause of ATV crashes. Never ride
beyond your personal abilities or faster than conditions warrant.
Remember that alcohol, drugs, fatigue, and inattention can
significantly reduce your ability to make good judgements and ride
safely.
Don’t Drink and Ride
Alcohol and riding don’t mix. Even one drink can reduce your ability
to respond to changing conditions, and your reaction time gets
worse with every additional drink. So don’t drink and ride, and don’t
let your friends drink and ride either.
Keep Your Honda in Safe Condition
It’s important to keep your ATV properly maintained and in safe
riding condition. Having a breakdown can be difficult, especially if
you are stranded off-road far from your base. To help avoid
problems, inspect your ATV before every ride and perform all
recommended maintenance.
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ATV Safety
5
Safety Labels
Your ATV comes with several labels containing important safety
information. Anyone who rides the vehicle should read and
understand this information before riding.
The labels should be considered permanent parts of the vehicle. If a
label comes off or becomes hard to read, contact your dealer for
replacements.
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ATV Safety
6
Safety Labels
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
without proper training or instruction
at speeds too fast for your skills or the conditions
on public roads - a collision can occur with
another vehicle
with a passenger - passengers affect balance
and steering and increase risk of losing control
ALWAYS:
use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns
avoid paved surfaces - pavement may seriously
affect handling and control
LOCATE AND READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
NEVER operate:
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
WITH DRUGS
OR ALCOHOL
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ATV Safety
7
Safety Labels
Improper tire pressure or overloading can
cause loss of control.
Loss of control can result in severe injury
or death.
Cold tire pressure :
Maximum weight capacity : 551lbs.(250kg)
Front : 4.4psi (30kPa)
Rear : 4.4psi (30kPa)
Overloading this ATV or carrying cargo
improperly can change handling, stability
and braking performance and can lead to an
accident.
Never exceed the maximum front cargo limit
of : 88 lbs (40 kg).
Refer to instructions in the Owner’s
Manual.
WARNING
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ATV Safety
8
Safety Labels
Overloading this ATV or carrying cargo
improperly can change handling, stability
and braking performance and can lead to an
accident.
Never exceed the maximum rear cargo limit
(combined weight on the rear rack and in
the storage area) of : 176 lbs (80 kg).
Refer to instructions in the Owner’s
Manual.
WARNING
Towing an improperly loaded
trailer can cause loss of control.
Read towing instructions
in owner's manual
Tow weight limit : 850lbs. (385kg)
: 30lbs. ( 14kg)
Tongue weight
Driving in Front Differential Lock Mode changes the
way your vehicle handles and turns. Use this mode only
at low speed. See owner’s manual for more information.
DRIVELINE INFORMATION
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Instruments & Controls
9
Instruments & Controls
(cont’d)
In st rumen ts & C ontrols
This section shows the location of all indicators and controls you
would normally use before or while riding your ATV.
The items 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.
Operation Component Locations ................................................ 11
Indicators & Displays................................................................... 14
Multi-function Display.............................................................. 20
Speed and Mileage Unit Changing........................................... 22
4WD Indicator ......................................................................... 22
Gear Position Indicator............................................................. 23
Fuel Gauge .............................................................................. 24
Digital Clock ............................................................................ 26
Odometer................................................................................ 27
Tripmeter................................................................................. 27
Coolant Temperature Gauge ................................................... 28
Hour meter.............................................................................. 30
Maintenance Tripmeter/Maintenance Hour meter.................... 31
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Instruments & Controls
10
Instruments & Controls
Controls & Features.................................................................... 34
Ignition Switch......................................................................... 34
4WD Switch ............................................................................ 35
Front Differential Lock and Speed Limiter Over-Ride (Differential
Lock Switch and Start/Over Ride Button)................................. 36
Start/Over Ride Button ............................................................. 39
Engine Stop Switch.................................................................. 40
Headlight Switch ..................................................................... 41
Headlight Dimmer Switch ........................................................ 41
Horn Button ............................................................................ 41
Recoil Starter ........................................................................... 42
Throttle Lever .......................................................................... 43
Gearshift Switch ...................................................................... 44
Front Brake Lever..................................................................... 45
Rear Brake Lever/Parking Brake Lever ....................................... 45
Rear Brake Pedal...................................................................... 45
Parking Brake/Reverse Lever (P/R Lever) .................................... 46
Flag Pole Bracket ..................................................................... 48
Trailer Hitch ............................................................................. 49
Accessory Socket ..................................................................... 50
Utility Box ................................................................................ 52
Utility Pocket ........................................................................... 53
Storage Compartment ............................................................. 54
EPS (Electric Power Steering) (TRX500FE2 only) ........................ 55
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Instruments & Controls
11
Operation Component Locations
start/over ride button
ignition switch
headlight switch
differential lock
switch
headlight dimmer switch
throttle lever
rear brake lever/
parking brake lever
P/R lever
gearshift
switches
horn button
front brake lever
4WD switch
engine stop switch
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Instruments & Controls
12
Operation Component Locations
rear cargo rack
recoil starter
rear brake pedalflag pole bracket
front cargo rack
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Instruments & Controls
13
Operation Component Locations
utility box
accessory socket
trailer hitch
storage
compartment
utility pocket
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Instruments & Controls
14
Indicators & Displays
The indicators and displays on your ATV keep you 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.
(1)
(5)
(1) neutral indicator
(3)
(8) (7) (6)
(4)(2)
(2) reverse indicator
(3) differential lock
indicator
(4) PGM-FI indicator
(8) mode select button
(5) high coolant
temperature indicator
(7) multi-function display
(6) PS (Electric Power Steering)
indicator (TRX500FE2 only)
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Instruments & Controls
15
Indicators & Displays
Lamp Check
Initial lamp check:
The indicators come on for a few seconds and then go off when you
turn the ignition switch to ON (q).
TRX500FE2 only:
The PS (Electric Power Steering) indicator comes back on and
remains on until the engine is started after initial lamp check.
The high coolant temperature indicator and PGM-FI indicator come
back on for a few seconds and then go off after initial lamp check.
These indicators are identified in the table on page 17 with the
words: Lamp Check.
When applicable, the reverse or neutral indicators comes back on
and remain on until you shift out of reverse or neutral after initial
lamp check.
When applicable, the differential lock indicator comes back on and
remains on until you shift out of the front differential lock mode
after initial lamp check.
If one of these indicators does not come on when it should, have
your dealer check for problems.
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Instruments & Controls
16
Indicators & Displays
Display Check
When the ignition switch is turned on, the multi-function display (1)
will temporarily show all the modes and digital segments and initial
message. So you can make sure the liquid crystal display is
functioning properly.
The displays are identified in the table on page 18 with the words:
Display Check.
If any part of these displays does not come on when it should, have
your dealer check for problems.
Meter Input Signal Failure
If the neutral indicator, reverse indicator, differential lock indicator,
PGM-FI indicator, high coolant temperature indicator stay on and
the gear position indicator “–” and coolant temperature gauge
“C – – – – – H” blink, have your dealer check for problems.
(1)
(1) multi-function display
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Instruments & Controls
17
Indicators & Displays
1
Neutral indicator
Lights when the transmission is in
neutral. Lamp Check.
2
Reverse
indicator
Lights when the transmission is in
reverse. Lamp Check.
3
Differential lock
indicator
Lights when the front differential lock
mode is engaged. Should also light for
a few seconds and go off when the
ignition switch is turned on, and then
come back on and remain on until the
differential lock switch or the ignition
switch is turned off. If the indicator
blinks with the 4WD indicator, there is
any abnormality in the front final gear
system. See page 38.
Lamp Check
.
4PGM-FI
indicator
Lights when there is any abnormality
in the PGM-FI (Programmed Fuel
Injection) system. Should also light
for a few seconds and then go off
when the ignition switch is turned on.
If the indicator comes on at any other
time, reduce speed and take your
vehicle to your dealer as soon as
possible.
Lamp Check
.
5 High coolant
temperature
indicator
Lights when coolant temperature is
high enough to adversely affect the
service life of the engine.
If the high coolant temperature
indicator comes on while you are
riding, immediately bring the vehicle
to a stop, turn the engine off and let
it cool. See page 221.
Lamp Check
.
6
PS (Electric Power
Steering) indicator
(TRX500FE2 only)
Lights when there is an abnormality
in the EPS (Electric Power Steering)
system. See page 55.
Lamp Check
.
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Instruments & Controls
18
Indicators & Displays
7
Multi-function
display
The display includes the following
functions. Display Check
4WD indicator Shows when the 4WD drive mode
is engaged. If the indicator blinks
with the differential lock
indicator when there is any
abnormality in the front final
gear system. See page 38.
Gear position
indicator
Shows the gear position
(page 23).
Maintenance
minder
indicator
Shows when specified
maintenance interval is reached
(page 32).
Speedometer Shows riding speed.
Fuel gauge Shows approximate fuel supply
available (page 24).
Digital clock Shows the time (hours and
minutes) (page 26).
Odometer Shows accumulated mileage
(page 27).
Tripmeter Shows mileage per trip (page 27).
Coolant
temperature
gauge
Shows approximate coolant
temperature (page 28).
Hour meter Shows hours and tenths of hours
of engine operation (page 30).
Maintenance
tripmeter
Inform when the mileage or
operating hours on your ATV
approaches and passes the
interval specified on the
maintenance schedule (page 31).
Maintenance
hour meter
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Instruments & Controls
19
Indicators & Displays
8
Mode select
button
Selects display in the lower parts
of multi-function display. Adjusts
the digital clock (page 26).
Changes the speed and mileage
units (page 22). Resets the
tripmeter to zero (0) (page 27).
This button also used to reset the
maintenance tripmeter and
maintenance hour meter
(page 33).
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Instruments & Controls
20
Indicators & Displays
The multi-function display (1) includes the following functions:
The lower part of the multi-function display (5) shows the fuel
gauge, digital clock, odometer, tripmeter, coolant temperature
gauge, hour meter, maintenance tripmeter or maintenance hour
meter. To change the lower part of the multi-function display, push
the mode select button (7).
Multi-function Display
4WD indicator
Gear position indicator
Speedometer
Maintenance minder indicator
Fuel gauge
Digital clock
Odometer
Tripmeter
Coolant temperature gauge
Hour meter
Maintenance tripmeter
Maintenance hour meter
(1) multi-function display
(2)
(4)
(3)(1)
(3) speedometer (6) 4WD indicator
(7) mode select button(4) maintenance minder indicator
(5) lower part of the
multi-function display
(5)(6)(7)
(2) gear position indicator
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Instruments & Controls
21
Indicators & Displays
Each time you press the mode select button, mode will change as
shown in the illustration.
If there is a fuel warning with your ATV, the display will automatically
change to the fuel gauge. If you try to change the display back to
ordinary display, it will automatically return to the fuel gauge.
If there is a coolant temperature warning with your ATV, the display
will automatically change to the coolant temperature gauge. If you
try to change the display back to ordinary display, it will
automatically return to the coolant temperature gauge.
Fuel gauge (page 24)
Digital clock (page 26)
Odometer (page 27)
Tripmeter (page 27)
Coolant temperature
gauge (page 28)
When ATV
is moving
When ATV is
not moving
Hour meter (page 30)
Maintenance tripmeter
(page 31)
Maintenance hour
meter (page 31)
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Instruments & Controls
22
Indicators & Displays
The speedometer, odometer, tripmeter, and maintenance tripmeter
show in either “MPH” and “MILE” or “KM/H” and “KM”.
To change the speed and mileage units, press and hold the mode
select button (1) for more than 5 seconds in the odometer mode
(page 21) with the ATV stopped.
The 4WD indicator (1) shows when the 4WD mode engages
(page 35).
Speed and Mileage Unit Changing
4WD Indicator
(1) mode select button
(1)
(1) 4WD indicator
(1)
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Instruments & Controls
23
Indicators & Displays
The gear position indicator (1) shows the gear position when the
ignition switch is in the ON (q) position.
The indicator displays: N for neutral, R for reverse, and 1 – 5 for the
five forward gears.
“–” will be displayed on the gear position indicator when the
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 the ignition
switch to the OFF (w) position, and then turn it back to the ON (q)
position again.
If the gear position indicator shows “–”, rock the vehicle back and
forth and make sure the gear position indicator is displayed properly
and then if the gear position indicator still shows “–” or blinks, see
your dealer.
If the “–” on the gear position indicator is blinking, see your dealer.
Gear Position Indicator
(1)
(1) gear position indicator
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Instruments & Controls
24
Indicators & Displays
The fuel gauge (1) shows the approximate fuel supply available with
the fuel mark (2). The fuel tank capacity is:
14.7 ℓ (3.88 US gal, 3.23 Imp gal)
Regardless of what mode the display is in, when the fuel level
reaches 1st segment (3), the display will automatically switch to the
fuel gauge display. You should refuel as soon as possible.
The amount of fuel remaining when the fuel gauge reaches the 1st
segment is approximately:
6.9 ℓ (1.82 US gal, 1.52 Imp gal)
Fuel Gauge
(2)
(1) fuel gauge
(1)
(2) fuel mark
(3) 1st segment
(3)
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Instruments & Controls
25
Indicators & Displays
When the fuel gauge show “E _ _ _ _ _ F” (4) and “LO FUEL” (5)
blink 3 times alternately and fuel mark blinks, you should refuel as
soon as possible.
The amount of fuel reserve is approximately:
4.9 ℓ (1.29 US gal, 1.08 Imp gal)
Fuel gauge failure:
If the fuel gauge E – – – – – F (6) is blinking, the fuel gauge function
has failed. See your dealer.
(5)
(5) “LO FUEL”
(4)
(4) “E _ _ _ _ _ F”
(6)
(6) “E – – – – – F”
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Instruments & Controls
26
Indicators & Displays
The digital clock (1) shows time with the clock mark (2) when the
ignition switch is ON (q).
To adjust the time, proceed as follows:
1.
Turn the ignition switch ON (q) and select the digital clock mode.
2.
Press and hold the mode select button (3) until the display start
blinking.
3.
To advance the display 1 minute at a time, press and release the
mode select button for 0.5 seconds.
Press and hold the mode select button, the display will begin
advancing fast. Press and hold the button for:
• 0.5 – 5.5 seconds: advance one minute at a time.
• 5.5 – 10.5 seconds: advance five minutes at a time.
• 10.5 seconds or more: advance ten minutes at a time.
4.
Release the mode select button when the display reaches the
desired time.
5.
To end the adjustment, press and release the mode select button
for less than 0.5 seconds or turn the ignition switch to OFF (w).
Digital Clock
(3)
(1) digital clock
(2) clock mark
(3) mode select button
(1) (2)
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Instruments & Controls
27
Indicators & Displays
The odometer (1) registers total distance traveled in mileage while the
ignition switch is ON (q) with the “ODO” mark (2). The odometer
locks at 999,999 when the readout exceeds 999,999.
The tripmeter (1) shows mileage per trip since you last reset the
tripmeter while the ignition switch is ON (q) with the “TRIP” mark
(2). The tripmeter returns to 0.0 when the readout exceeds 999.9. To
reset the tripmeter to zero, press the mode select button (3) and
hold it in for at least 2 seconds in the tripmeter mode.
Odometer
Tripmeter
(1)(2)
(1) odometer (2) “ODO” mark
(3)
(1)
(1) tripmeter (3) mode select button
(2) “TRIP” mark
(2)
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Instruments & Controls
28
Indicators & Displays
The coolant temperature gauge (1) shows coolant temperature with
the coolant temperature mark (2) while the ignition switch is ON (q).
The normal operating temperature range is within the section
between the 1st segment (3) and 4th segment (4).
When coolant temperature is low, the coolant temperature gauge
will display “Lo” (5).
Coolant Temperature Gauge
(1) coolant temperature gauge
(2) coolant temperature mark
(3) 1st segment
(4) 4th segment
(5) “Lo”
(2)
(1) (3) (4) (5)
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Indicators & Displays
When the coolant is over specified temperature, the 5th segment (6)
appears and the high coolant temperature indicator (7) lights.
If this occurs, stop the engine and check the reserve tank coolant
level.
Read pages 221 – 222 and do not ride the ATV until the problem has
been corrected.
NOTICE
Continuing to ride with an overheated engine can cause serious
engine damage.
If the “C – – – – – H” (8) blinks, the meter input signal fails. See your
dealer.
(7) high coolant temperature indicator(6) 5th segment
(6) (7)
(8)
(8) “C – – – – – H”
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Indicators & Displays
The hour meter (1) shows accumulated hours while the ignition
switch is ON (q) with the hour meter mark (2). The hour meter
provides accurate service period information for initial and regular
maintenance. The hour meter locks at 99,999.9 when the readout
exceeds 99,999.9.
Hour meter
(2)(1)
(1) hour meter (2) hour meter mark
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Indicators & Displays
The maintenance tripmeter (1) shows mileage to maintenance while
the ignition switch is ON (q) with the maintenance minder indicator
(2).
The maintenance hour meter (3) shows remaining time to
maintenance while the ignition switch is ON (q) with the
maintenance minder indicator.
The maintenance tripmeter decreases from 1,000 km (600 miles)
after reset. The maintenance hour meter decreases from 100 hour
after reset.
Initial setting of the maintenance tripmeter is 150 km (100 miles).
Initial setting of the maintenance hour meter is 20 hour.
Maintenance Tripmeter/Maintenance Hour meter
(1)
(1) maintenance tripmeter
(2) (3) (2)
(2) maintenance minder
indicator
(3) maintenance hour meter
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Indicators & Displays
Maintenance Minder Indicators:
When the maintenance tripmeter or maintenance hour meter
amounts to 0, the display of the maintenance minder indicator
changes. When selected the maintenance tripmeter or maintenance
hour meter, the maintenance minder indicator and lower part of the
multi-function display (4) start blinking. When selected other mode,
the maintenance minder indicator appears in the display.
Initial Maintenance
Appears at 150 km (100 miles) or 20 operating
hours, whichever comes first.
Regular Maintenance Interval 1
Appears 1,000 km (600 miles) or 100 operating
hours after the Initial Maintenance or Regular
Maintenance Interval 2 is performed and
maintenance minder is reset, whichever comes first
in the maintenance schedule.
Regular Maintenance Interval 2
Appears 1,000 km (600 miles) or 100 operating
hours after Regular Maintenance Interval 1 is
performed and maintenance minder is reset,
whichever comes first in the maintenance schedule.
(4) (4)
(4) lower part of the multi-function display
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Indicators & Displays
Reset the maintenance tripmeter/maintenance hour meter after
maintenances.
To reset the maintenance tripmeter/maintenance hour meter,
proceed as follows:
Press and hold the mode select button (5) and turn the ignition
switch (6) to ON (q). The maintenance minder indicator will appear,
then it will blinks twice, and the multi-function display will
temporarily show all the modes and digital segments. The indicator
message will disappear.
Reset operation will be cancelled, if the mode select button is
released before the indicator blinks twice.
If the maintenance is done before the setting interval, be sure to
reset the meters after the maintenance.
(5)
(6)
(2)
(2) maintenance minder
indicator
(5) mode select button
(6) ignition switch
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Controls & Features
The ignition switch (1) is used for starting and stopping the engine
(page 79). Insert the key and turn it to the right for the ON (q)
position.
The ignition switch is also used to reset the maintenance tripmeter/
maintenance hour meter (page 33).
Ignition Switch
Key Position Function
ON (q) Electrical circuits on.
OFF (w) No electrical circuits function.
CENTRE OF HANDLEBAR
OFF ON
(1)
q ON
w OFF
(1) ignition switch
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Controls & Features
Your ATV is equipped with a 4WD switch (1), which permits a choice
between the “2WD” and “4WD” drive modes. Select a drive mode
that’s suitable for your riding.
Keep both hands on the handlebar while machine is in motion and
come to a complete stop before using the 4WD switch.
The 4WD switch is located above the throttle lever. To select the
drive mode, with your ATV stopped, push the 4WD switch.
To check your present drive mode, look at the 4WD indicator (2).
2WD mode: the 4WD indicator disappears when the 2WD mode engages.
4WD mode: the 4WD indicator appears when the 4WD mode engages.
If the 4WD indicator does not appear when selecting the 4WD
mode, accelerate your ATV slowly until the 4WD indicator appears.
The 4WD indicator and differential lock indicator both flash together
when there is any abnormality in the front final gear system. See
Front Differential Lock and Speed Limiter Over-Ride (Differential Lock
Switch and Start/Over Ride Button), page 38.
4WD Switch
(1) 4WD switch (2) 4WD indicator
(2)
(1)
2WD mode
4WD mode
2WD mode
4WD mode
(1)
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36
Controls & Features
Your ATV is equipped with a front differential lock feature that
includes a speed limiter and speed limiter over-ride. This system is
designed to provide maximum use of available traction to help you
escape from situations where the vehicle might otherwise become
stuck, in the mud for example. When the front differential lock
mode is activated, the front differential gear is locked causing all
four wheels to rotate at the same speed. Because locking all four
wheels together changes the way the vehicle handles and increases
the amount of room necessary to turn, a speed limiter restricts the
speed to 32 km/h (20 mph). Pushing and holding the start/over ride
button in this mode allows you to momentarily over-ride the 32 km/
h (20 mph) speed limiter, up to 64 km/h (40 mph), to help you free
the vehicle in more severe conditions. You should only use this
feature where maximum traction is required and only in low speeds.
For normal riding, use 2WD and 4WD modes.
Front Differential Lock and Speed Limiter Over-Ride
(Differential Lock Switch and Start/Over Ride Button)
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Controls & Features
To select the front differential lock mode:
When the 4WD mode is engaged, reduce the speed of your ATV to
below 16 km/h (10 mph) and slide the differential lock switch (1)
over the 4WD switch. The differential lock indicator (2) will flash fast
and the front differential locking process begins. When the locking
is complete, the differential lock indicator stays on.
If the speed of your ATV is above 16 km/h (10 mph), the locking
process will be interrupted and the differential lock indicator will
slowly flash.
If the differential lock indicator does not stay on when the front
differential lock mode is selected, steer the handlebar either to the
left or right all the way while your ATV is stopped. If the differential
lock indicator is still flashing, move your ATV slowly while steering
the handlebar all the way to right or left.
(2)
4WD mode
(in the locking
process)
front differential lock mode
(2)
(2)
(1)
(1)
(completed
locking)
(1) differential lock switch (2) differential lock indicator
off
fast
flashing
solid light
slow
flashing
(2)
(speed above 16 km/h
(10 mph). Locking
process interrupted)
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Controls & Features
To activate the speed limiter over-ride mode:
Push the start/over ride button (3) when the front differential lock
mode is activated.
Front final gear system failure:
The differential lock indicator and 4WD indicator (4) will both flash
when there is any abnormality in the front final gear system. If this
occurs, the front final gear actuator will stop moving, and the front
final gear system will be fixed in the current position, either 2WD
mode, 4WD mode or front differential lock mode.
If both the differential lock indicator and 4WD indicator flash, reduce
speed and take your ATV to your dealer as soon as possible.
LEFT HANDLEBAR
(3) start/over ride button
(3)
(2) (4)
(2) differential lock indicator (4) 4WD indicator
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39
Controls & Features
The start/over ride button (1) is used for starting the engine and
activate the speed limiter over-ride mode.
Pushing the button in starts the engine. See Starting Procedure,
page 81.
When the engine is not running and the start/over ride button is
pushed, the starter motor will crank the engine. The starter motor
will not operate if the engine stop switch is in the OFF (r) position
when the start/over ride button is pushed.
To activate the speed limiter over-ride mode, see Front Differential
Lock and Speed Limiter Over-Ride (Differential Lock Switch and Start/
Over Ride Button), page 36.
Start/Over Ride Button
LEFT HANDLEBAR
(1) start/over ride button
START or SPEED LIMITER OVER-RIDE MODE
(1)
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40
Controls & Features
The engine stop switch (1) is used to stop the engine in an
emergency. To operate, slide the switch to the OFF (r) position. The
switch must be in the RUN (e) position to start the engine, and it
should normally remain in the RUN (e) position even when the
engine is OFF.
If your ATV is stopped with the ignition switch ON (q) and the engine
stop switch OFF (r), the battery will discharge. Turn the ignition
switch to OFF (w) to prevent battery discharge.
Engine Stop Switch
e r
LEFT HANDLEBAR
(1) engine stop switch
(1)
e RUN
r OFF
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41
Controls & Features
The headlight switch (1) is used to turn the headlights and assist
headlight ON (y) or OFF (t). The assist headlight turns on only when
the dimmer switch (2) is in the HI (u) position. To operate, turn the
switch to ON (y) or OFF (t).
The headlight dimmer switch (2) is used to change between the high
and low beams of the headlight and to activate the assist headlight.
To operate, turn the switch to HI (u) for high beam of the headlights
and activate the assist headlight, LO (i) for low beam of the
headlights and deactivate the assist headlight.
Press the horn button (3) to sound the horn.
Headlight Switch
y t
Headlight Dimmer Switch
u i
Horn Button
LEFT HANDLEBAR
(1) headlight switch
(1)
y ON
u HI
(2)
t OFF
(2) headlight dimmer switch
i LO
(3) horn button
(3)
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42
Controls & Features
The recoil starter (1) is used to start the engine when the battery is
low. See Using the Recoil Starter, page 84.
Recoil Starter
RIGHT SIDE
(1) recoil starter
(1)
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43
Controls & Features
The throttle controls engine rpm (speed). To increase engine rpm,
press the throttle lever (1) with your thumb. To reduce engine rpm,
release pressure on the throttle lever. The throttle will automatically
return to the closed position (engine idle) when you remove your
thumb.
Throttle Lever
RIGHT HANDLEBAR
(A)
(1)
(1) throttle lever (A) to open the throttle
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44
Controls & Features
These switches are used to select the next higher or lower gear in the
transmission. To operate, press the upshift switch (1) to engage the
next higher gear or press the downshift switch (2) to engage the
next lower gear.
See Shifting Gears, page 85.
Gearshift Switch
(2)
(1)
(1) upshift switch
(2) downshift switch
LEFT HANDLEBAR
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45
Controls & Features
The front brake lever is used to slow or stop your ATV. To operate,
pull the lever. For information on braking techniques, see page 90.
The rear brake lever/parking brake lever is used to slow or stop your
ATV. To operate, pull the lever. For information on braking
techniques, see page 90.
The rear brake pedal is used to slow or stop your ATV. To operate,
depress the pedal. For information on braking techniques, see
page 90.
Front Brake Lever
Rear Brake Lever/Parking Brake Lever
Rear Brake Pedal
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46
Controls & Features
The P/R lever (1) on the rear brake lever/parking brake lever (2) is
used to apply the parking brake or to shift the transmission into
reverse.
Parking Brake/Reverse Lever (P/R Lever)
(1) P/R lever
(2) rear brake lever/parking brake lever
(1)
(2)
LEFT HANDLEBAR
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47
Controls & Features
To apply the parking brake:
Bring the vehicle to a complete stop, then make sure the
transmission is in neutral.
Squeeze the rear brake lever/parking brake lever, then rotate the P/R
lever clockwise until it engages the slot on the rear brake lever/
parking brake lever bracket.
For more information on Parking, see page 105.
To release the parking brake:
Squeeze the rear brake lever/parking brake lever until the P/R lever is
released from the slot on the rear brake lever/parking brake lever
bracket.
The brakelight is activated by applying the parking brake. When
using the parking brake, be sure to turn the ignition switch to OFF
(w) to avoid discharging the battery.
To shift the transmission into reverse:
See Riding in Reverse (page 88).
(1) P/R lever
(2) rear brake lever/parking brake lever
(1)
(2)
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48
Controls & Features
Flag poles are optional equipment available from your dealer. To
mount a pole in the bracket (1), follow the instructions that come
with the flag pole kit.
Flag poles are required in some riding areas. Check local regulations
before riding.
Flag Pole Bracket
RIGHT REAR
(1)
(1) flag pole bracket
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49
Controls & Features
The trailer hitch (1) is located on the rear axle housing. To use the
hitch, you’ll need a proper size ball (2) as specified by the trailer
manufacturer.
To attach the ball and properly hook up a trailer, follow the trailer
manufacturer’s instructions. For load limits and operational
guidelines, see page 68.
Trailer Hitch
REAR
(2) (1)
(1) trailer hitch (2) ball
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50
Controls & Features
The accessory socket (1) is attached to the left side under the assist
headlight (2). You can use the accessory socket to power a trouble
light, spotlight, CB radio, or cell phone, etc.
NOTICE
Do not plug in any heat-generating accessory, such as an automobile
cigarette lighter, because it can damage the socket.
To use the accessory socket, turn the ignition switch to ON (q), start
the engine. Then turn the headlights OFF (t), and open the accessory
socket cap (3).
Accessory Socket
LEFT FRONT
(2)
(1) accessory socket
(1) (3)
(2) assist headlight
(3) accessory socket cap
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51
Controls & Features
Be sure the engine is on and the headlights are turned off before
using the accessory socket, otherwise you may drain the battery.
The accessory socket’s rated capacity is DC 12 V, 120 Watts (10 A)
or less. If you exceed this limit, you may blow a fuse. See If a Fuse
Blows, page 223.
When you are done using an accessory, unplug it, and cover the
socket with the cap.
Be careful not to flood this accessory socket when washing your
ATV.
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52
Controls & Features
The utility box (1) is located on the left side of the front fender. You
may store small, lightweight items in the box.
To open:
Pull up the front of the utility box cover (2).
To close:
Push down the front of the utility box cover until it locks in place.
Make sure that the stud (3) is locked securely in position by pulling
up lightly on the front of the utility box cover.
Utility Box
LEFT FRONT FENDER
(3)
(1) utility box
(2)
(1)
(2) utility box cover
(3) stud
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53
Controls & Features
The utility pocket (1) is located on the left side cover. You may store
small, lightweight items in the pocket.
NOTICE
Do not store valuable item in the utility pocket.
Utility Pocket
LEFT SIDE COVER
(1)
(1) utility pocket
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54
Controls & Features
The storage compartment (1) is located below the rear cargo rack
(2).
To open the compartment, unhook the rubber strap (3).
Be careful not to flood this area when washing your ATV.
Storage Compartment
REAR
(3)
(1) storage compartment
(2)
(1)
(2) rear cargo rack
(3) rubber strap
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55
Controls & Features
This ATV is equipped with an electronically controlled, electric-
power-assisted steering system.
While the engine is running, the EPS (Electric Power Steering) system
provides power from the electric motor, which helps you to turn the
ATV’s handlebar more easily.
The EPS system on this ATV utilizes an overheat protection feature to
prevent damage to system components. In certain extended,
repetitive high-load situations, the system will reduce or even disable
power steering assist. The steering will perform as a normal non-EPS
system during this brief period. After cooling down, it will then
return to normal EPS operation.
The PS indicator should light when the ignition switch is turned on
and remain on until the engine is started.
The PS indicator also lights when there is any abnormality in the EPS
system. If this occurs, the electric power assist for turning will not be
available, but the manual steering system will perform as usual.
If the PS indicator lights at any time while riding, reduce speed and
take your ATV to your dealer as soon as possible. Continuing to ride
with a EPS system problem can cause system damage.
Do not modify your Electric Power Steering system. In case of a
malfunction, take your ATV to your dealer.
EPS (Electric Power Steering) (TRX500FE2 only)
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Before Riding
57
Before Riding
Before Riding
Before each ride, you need to make sure you and your Honda are
both ready to ride. To help get you prepared, this section discusses
how to evaluate your riding readiness, what items you should check
on your ATV, and adjustments to make for your comfort,
convenience, or safety. This section also includes important
information about loading.
Are You Ready to Ride?.............................................................. 58
Protective Apparel ................................................................... 58
Rider Training .......................................................................... 60
Age Recommendation ............................................................. 61
No Passengers ......................................................................... 61
No Alcohol or Drugs ................................................................ 62
Is Your ATV Ready to Ride? ........................................................ 63
Pre-ride Inspection ................................................................... 63
Load Limits & Guidelines............................................................. 67
Loading ................................................................................... 67
Load Limits .............................................................................. 68
Loading Guidelines .................................................................. 69
Accessories & Modifications........................................................ 70
Accessories.............................................................................. 70
Modifications........................................................................... 71
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Before Riding
58
Are You Ready to Ride?
Before you ride your ATV for the first time, we urge you to:
• Read this owner’s manual and the labels on your ATV carefully.
• Make sure you understand all the safety messages.
• Know how to operate all the controls.
Before each ride, be sure:
• You feel well and are in good physical and mental condition.
• You are wearing an approved motorcycle helmet (with chin strap
tightened securely), eye protection, and other 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,
and a long-sleeved shirt or jacket whenever you ride.
Although complete protection is not possible, wearing proper gear
can reduce the chance of injury when you ride.
Following are suggestions to help you choose the proper gear.
Helmet and Eye Protection
Your helmet is your most important piece of riding gear because it
offers the best protection against head injuries. A helmet should fit
your head comfortably and securely.
Protective Apparel
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Before Riding
59
Are You Ready to Ride?
An open-face helmet offers some protection, but a full-face helmet
offers more. Always wear a face shield or goggles to protect your
eyes and help your vision.
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 legs.
• Off-road motorcycle gloves to help protect your hands.
• Riding trousers with knee and hip pads, a riding jersey with
padded elbows, and a chest/shoulder protector.
WARNING
3
WARNING
Operating this ATV without wearing an
approved motorcycle helmet, eye protection,
and protective clothing could increase your
chances of severe injury or death in the event
of an accident.
Always wear an approved motorcycle helmet
that fits properly and wear eye protection
(goggles or face shield), gloves, boots, long-
sleeved shirt or jacket and trousers.
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Before Riding
60
Are You Ready to Ride?
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 safe area to build
your skills. Do not ride in rough terrain until you get accustomed to
the ATV’s controls, and feel comfortable with its size and weight.
Rider Training
WARNING
3
WARNING
Operating this ATV without proper
instruction could increase your risk of an
accident which could lead to serious injury or
death.
Beginning and inexperienced operators
should complete the certified training course
offered by Honda. They should then regularly
practice the skills learned in the course and
the operating techniques described in the
owner’s manual.
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Before Riding
61
Are You Ready to Ride?
The minimum recommended age for this ATV model is 16. For
safety, never let children under 16 years old operate this vehicle.
This ATV is designed as an operator-only vehicle. The long seat is
designed to allow the rider to change body position, not for carrying
a passenger. Never let a passenger ride on the seat or on the front or
rear cargo racks.
Age Recommendation
WARNING
3
WARNING
A child using an ATV that is not
recommended for their age could lose vehicle
control while riding, resulting in severe injury
or death.
A child under 16 should never operate an ATV
with engine size greater than 90cc.
No Passengers
WARNING
3
WARNING
Carrying a passenger on this ATV greatly
reduces your ability to balance and control
this ATV and could cause a crash and you or
your passenger could be injured or killed.
Never carry a passenger on this ATV.
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Before Riding
62
Are You Ready to Ride?
Alcohol, drugs and ATVs don’t mix. Even a small amount of alcohol
can impair your ability to operate an ATV safely. Likewise, drugs —
even if prescribed by a physician — can be dangerous while
operating an ATV. Consult your doctor to be sure it is safe to operate
a vehicle after taking medication.
No Alcohol or Drugs
WARNING
3
WARNING
Operating this ATV after consuming alcohol
or drugs can seriously affect your judgement,
cause you to react more slowly, affect your
balance and perception, and result in serious
injury or death.
Never consume alcohol or drugs before or
while operating this ATV.
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Before Riding
63
(cont’d)
Is Your ATV Ready to Ride?
Before each ride, it’s important to inspect your ATV and make sure
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 been involved in a collision, do not ride
the vehicle until it has been inspected by your dealer. There may be
damage or other problems you cannot see.
Check the following items before you get on the ATV:
WARNING
3
WARNING
Improperly maintaining this ATV or failing to
correct a problem before riding can cause a
crash in which you can be seriously hurt or
killed.
Always perform a pre-ride inspection before
every ride and correct any problems.
Pre-ride Inspection
Engine Oil Check the level and add oil if needed
(page 132).
Check for leaks.
Radiator Coolant Check the coolant level and add coolant if
needed (page 143).
Check for leaks.
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64
Is Your ATV Ready to Ride?
Fuel Check the level and add fuel (page 127) if
needed. Also make sure the fuel fill cap is
securely fastened.
Check for leaks.
Tyres Use a gauge to check the air pressure. Adjust if
needed. Also look for signs of damage or
excessive wear (page 180).
Drivetrain Boots Check for damage (pages 188, 189).
Guards Check for damage or looseness (pages 186,
187).
Nuts & Bolts Check the wheels to see that the axle nuts are
tightened. Use a wrench to make sure all
accessible nuts, bolts, and fasteners are tight.
Underbody &
Exhaust System
Check for, and remove, any dirt, vegetation or
other debris that could be a fire hazard or
interfere with the proper operation of the
vehicle.
Air Cleaner
Housing Drain
Tube
Check for deposits in the drain tube. If
necessary, clean the tube (page 156) and check
the air cleaner housing.
Leaks, Loose Parts Walk around your ATV and look for anything
that appears unusual, such as a leak or loose
cable.
Cable Check the cable housings for wear. Check the
fittings for looseness. Replace or tighten as
needed.
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65
Is Your ATV Ready to Ride?
(cont’d)
If you are carrying cargo, also check the following:
Check these items after you get on the ATV:
Lights Make sure the headlights, brakelight and
taillight are working properly.
Loading Limits Make sure you do not exceed the load limits
(page 68).
Cargo Check that all cargo is secure.
Throttle Check the freeplay and adjust if needed. Press
the throttle to make sure it moves smoothly
without sticking, and snaps shut automatically
when it is released, in all steering positions
(page 157).
Brakes Squeeze 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 173, 175). Make sure there is no
brake fluid leakage.
Reverse Assist
Lever
Check the freeplay and adjust if needed
(page 160). Make sure the lever operates
smoothly without sticking.
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66
Is Your ATV Ready to Ride?
Remember, be sure to take care of any problem you find, or have
your dealer correct it before you ride.
Headlights and
Headlight Dimmer
Switch
Check for proper function (page 41).
Engine Stop Switch Check for proper function (page 40).
Steering 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.
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67
Load Limits & Guidelines
Your Honda was designed as a rider-only ATV. It was not designed
to carry a passenger. It can carry cargo on the cargo racks, however,
carrying cargo anywhere else or carrying a passenger could interfere
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 or making modifications that change this ATV’s
design and performance can also make it unsafe. Also, the weight of
any accessories will reduce the maximum load the ATV can carry.
More specific information on load limits, accessories, and
modifications follows.
How much weight you put on your ATV, and how you load it, are
important to your safety. If you decide to carry cargo, you should be
aware of the following information.
Loading
WARNING
3
WARNING
Overloading, improper loading, or carrying a
passenger can cause a crash and you can be
seriously hurt or killed.
Follow all load limits and other loading
guidelines in this manual.
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68
Load Limits & Guidelines
Following are the load limits for your ATV:
There are limits to how much weight can be carried on your ATV and
be pulled in a trailer.
The following 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.
Tongue weight can be measured with an ordinary bathroom scale.
Place the scale under the tongue, using either a tongue jack or other
support to keep the trailer level.
The weight of added accessories will reduce the maximum cargo
weight you can carry.
Load Limits
maximum weight capacity 250 kg (551 lb)
(includes the weight of the rider, all cargo, and accessories.)
front cargo rack weight limit
rear cargo rack weight limit
tow weight limit
= 40 kg (88 lb)
= 80 kg (176 lb)
= 385 kg (850 lb)
(Combined weight of the trailer and all cargo in the trailer)
tongue weight = 14 kg (30 lb) recommended
(Weight on the trailer tongue)
tongue and rear cargo weight = 80 kg (176 lb) maximum
(Combined weight on the trailer tongue and on the rear cargo rack)
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69
Load Limits & Guidelines
Carrying cargo or pulling a trailer will affect how your ATV handles
and greatly reduce its ability in accelerating, braking and making
turns and other maneuvers.
Be sure to observe the weight limits and follow these guidelines:
• Check that the tyres are properly inflated.
• Do not place cargo anywhere on the ATV other than on the front
and rear racks. Otherwise, operating stability may be adversely
affected.
• Never ride with a passenger on the front or rear cargo racks. The
ATV is not designed to carry a passenger.
• Use the trailer hitch to 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 handlebar
movement.
• Do not allow cargo to extend beyond the edges of either the
front or rear racks.
• Make sure all cargo is secured before riding.
• Balance cargo weight evenly on both sides.
• Never exceed the maximum weight limit.
• When towing a trailer, take care to maintain balance and
stability. Distribute cargo between the front and rear of the trailer
to obtain the recommended tongue weight.
• Allow extra room for starting, stopping and turning whenever
you carry cargo or pull a trailer.
• Avoid riding on steep slopes when carrying cargo or pulling a
trailer.
• Never cross a slope when towing a trailer.
Loading Guidelines
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70
Accessories & Modifications
Modifying your ATV or using non-Honda accessories can make your
ATV unsafe.
Before you consider making any modifications or adding an
accessory, be sure to read the following information.
We strongly recommend that you use only Honda Genuine
Accessories that have been specifically 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 dealer for assistance and always follow these
guidelines:
• Make sure the accessory does not obscure any lights, reduce
ground clearance, limit suspension travel or steering travel, or
interfere with operating any controls.
• Make sure the accessory does not interfere with your ability to
shift body position on the seat or operate hand and foot controls.
• Do not add any electrical equipment that will exceed the vehicle’s
electrical system capacity (page 238). A blown fuse can cause a
loss of lights or engine power (page 223).
WARNING
3
WARNING
Improper accessories or modifications can
cause a crash in which you can be seriously
hurt or killed.
Follow all instructions in this owner’s manual
regarding accessories and modifications.
Accessories
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71
Accessories & Modifications
We strongly advise you not to remove any original equipment or
modify 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 lights, exhaust system, emission control
system, or other equipment can also make your ATV illegal.
Modifications
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72
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Basic Operation & Riding
73
Basic Operation & Riding
(cont’d)
Basic O peration & R iding
This section gives basic riding instructions, including how to start and
stop your engine, and how to use the throttle and brakes. It also
provides important information on riding with cargo.
To protect your new engine and enjoy optimum performance and
service life, refer to Break-in Guidelines (page 240).
Safe Riding Precautions .............................................................. 75
Off-road Use Only.................................................................... 75
Keep Hands and Feet on Controls............................................ 76
Control Speed ......................................................................... 77
Use Care on Unfamiliar or Rough Terrain ................................. 77
Do Not Perform Stunts............................................................. 78
Starting & Stopping the Engine................................................... 79
Preparation.............................................................................. 80
Starting Procedure ................................................................... 81
Flooded Engine........................................................................ 82
Bank Angle Sensor Ignition Cut-off System .............................. 82
Stalled Engine.......................................................................... 83
How to Stop the Engine........................................................... 83
Using the Recoil Starter............................................................ 84
Shifting Gears............................................................................. 85
Riding in Reverse ........................................................................ 88
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Basic Operation & Riding
Braking....................................................................................... 90
Riding Your ATV......................................................................... 92
Making Turns .......................................................................... 92
Skidding or Sliding................................................................... 94
Riding Up Hills ......................................................................... 95
Riding Down Hills .................................................................... 99
Crossing or Turning on Hills or Slopes.................................... 100
Riding Over Obstacles ............................................................ 102
Riding Through Water ........................................................... 103
Parking..................................................................................... 105
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75
Safe Riding Precautions
Before riding your ATV for the first time, please review the ATV
Safety section beginning on page 1, and the Before Riding section
beginning on page 57.
Even if you have ridden other ATVs, take time to become familiar
with how this ATV works and handles. Practice in a safe area until
you build your skills and get accustomed to the ATV’s size and
weight.
Your ATV and its tyres are designed and manufactured for off-road
use only, not for pavement. Riding on pavement can affect handling
and control. You should not ride your ATV on pavement.
When riding off-road, also remember to always obey local off-road
riding laws and regulations. Obtain permission to ride on private
property. Avoid posted areas and obey “no trespassing” signs.
Off-road Use Only
WARNING
3
WARNING
Operating this ATV on paved surfaces may
seriously affect handling and control of the
ATV, and may cause the vehicle to go out of
control.
Never operate the ATV on any paved surfaces,
including sidewalks, driveways, parking lots
and streets.
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76
Safe Riding Precautions
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 and avoiding you, which could lead to a collision. In many states
it is illegal to operate ATVs on public streets, roads and highways.
Always keep both hands on the handlebars and both feet on the footpegs
when riding your ATV. This is important to maintain your balance and to
control the vehicle. Removing even one hand from the handlebars or one
foot from the footpegs can reduce your ability to control the ATV or could
cause you to lose your balance and fall off the ATV.
WARNING
3
WARNING
Operating this ATV on public streets, roads or
highways could cause you to collide with
another vehicle.
Never operate this ATV on any public street,
road or highway, even a dirt or gravel one.
Keep Hands and Feet on Controls
WARNING
3
WARNING
Removing hands from handlebars or feet
from footpegs during operation can reduce
your ability to control the ATV or could cause
you to lose your balance and fall off of the
ATV.
Always keep both hands on the handlebars
and both feet on the footpegs of your ATV
during operation.
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77
Safe Riding Precautions
Riding at excessive speed increases the chance of a crash. In
choosing a proper speed, you need to consider the capability of your
vehicle, the terrain, visibility and other operating conditions, plus
your own skills and experience.
Before riding in a new area, always check the terrain thoroughly.
Don’t ride fast on unfamiliar terrain or when visibility is limited. (It’s
sometimes difficult to see obstructions like hidden rocks, bumps, or
holes in time to react.)
Control Speed
WARNING
3
WARNING
Operating this ATV at excessive speeds
increases your chances of losing control of the
ATV, which can result in an accident.
Always go at a speed that is proper for your
vehicle, the terrain, visibility and other
operating conditions, and your experience.
Use Care on Unfamiliar or Rough Terrain
WARNING
3
WARNING
Failure to use extra care when operating this
ATV on unfamiliar terrain could result in the
ATV overturning or going out of control.
Go slowly and be extra careful when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions when
operating the ATV.
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78
Safe Riding Precautions
Never ride past the limit of visibility. Maintain a safe distance
between your ATV and other off-road vehicles. Always exercise
caution, and use extra care on rough, slippery and loose terrain.
You should always operate your ATV in a safe and reasonable
manner. When riding, always keep all four wheels on the ground.
WARNING
3
WARNING
Failure to use extra care when operating on
excessively rough, slippery or loose terrain
could cause loss of traction or vehicle control,
which could result in an accident, including an
overturn.
Do not operate on excessively rough, slippery
or loose terrain until you have learned and
practiced the skills necessary to control the
ATV on such terrain. Always be especially
cautious on these kinds of terrain.
Do Not Perform Stunts
WARNING
3
WARNING
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.
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79
Starting & Stopping the Engine
Always follow the proper starting procedure described below.
For your safety, avoid starting or 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.
WARNING
3
WARNING
Running the engine of your vehicle while in
an enclosed or even partially enclosed area
can cause a rapid build-up of toxic carbon
monoxide gas.
Breathing this colourless, odorless gas can
quickly cause unconsciousness and lead to
death.
Only run your vehicle's engine when it is
located in a well ventilated area outdoors.
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80
Starting & Stopping the Engine
1.
Before starting, make sure the vehicle is on a level surface and
lock the parking brake (page 47).
2.
Turn the ignition switch (1) to ON (q).
Confirm the following:
• The transmission is in neutral, the neutral indicator (2) is ON and
the gear position indicator shows “N”.
• The engine stop switch (3) is set to RUN (e).
Preparation
(1)
(2)
(3)
(1) ignition switch
(2) neutral indicator
(3) engine stop switch
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Starting & Stopping the Engine
This ATV is fuel-injected engine with an automatic choke.
Follow the procedure indicated below.
Any Air Temperature
• Press the start/over ride button with the throttle completely
closed.
The engine will not start if the throttle is fully open (because the
electronic control module cuts off the fuel supply).
Snapping the throttle or fast idling for more than 5 minutes may
cause exhaust pipe and muffler discolourations.
Starting Procedure
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82
Starting & Stopping the Engine
If the engine fails to start after repeated attempts, it may be flooded
with excess fuel. To clear a flooded engine:
1.
Leave the engine stop switch set to RUN (e).
2.
Open the throttle fully.
3.
Press the start/over ride button for 5 seconds (or operate the
recoil starter several times).
4.
Follow the normal starting procedure.
5.
If the engine starts, then open the throttle slightly if idling is
unstable.
If the engine does not start, wait 10 seconds, then follow steps
1 – 4 again.
If the engine still won’t start, refer to If Your Engine Quits or Won’t
Start, page 212.
Your vehicle’s banking (lean angle) sensor system is designed to
automatically stop the engine if the vehicle is overturned.
Before restarting the engine, you must turn the ignition switch to the
OFF (w) position and then back to ON (q). The engine will not restart
until you perform this procedure.
Flooded Engine
Bank Angle Sensor Ignition Cut-off System
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83
Starting & Stopping the Engine
You can restart the engine while the vehicle is stopped by squeezing
the front brake lever and pressing the start/over ride button.
Do not press the throttle lever while starting in gear. The engine will
not start if the throttle is fully open (because the electronic control
module cuts off the fuel supply).
Once you 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 indicator light is on, then turn the ignition
switch OFF (w).
The engine stop switch should normally remain in the RUN (e)
position even when the engine is OFF.
If your ATV is stopped with the engine stop switch OFF (r) and the
ignition switch ON (q), the battery will discharge.
Emergency Engine Stop
To stop the engine in an emergency, use the engine stop switch. To
operate, slide the switch to either OFF (r) position.
Stalled Engine
How to Stop the Engine
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84
Starting & Stopping the Engine
The recoil starter is used to start the engine when the battery is low.
To operate the recoil starter:
1.
Turn the ignition switch to the ON (q) position.
2.
Check that the transmission is in neutral.
3.
Grasp the starter grip (1) firmly, then pull it out slowly
approximately 100 mm (4.0 in).
4.
Pull the grip up briskly and fully.
5.
After the engine starts, allow the starter grip to return slowly.
Pull the recoil starter grip straight out so that the cord does not
touch the side cover. Repeated contact with the side cover can
damage the starter cord.
If the starter grip does not return smoothly (because of dirt in the
assembly), see your dealer.
Using the Recoil Starter
(1)
RIGHT SIDE
(1) starter grip
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85
(cont’d)
Shifting Gears
Your ATV has five forward gears (1, 2, 3, 4, and 5).
Two gearshift switches are located next to the left handlebar grip:
Upshift (a) and downshift (s).
To upshift the transmission, press the upshift switch (1) once.
To downshift the transmission, press the downshift switch (2) once.
To select reverse, see Riding in Reverse, page 88.
After starting the engine and letting it warm up, follow these
procedures:
1.
With the transmission in neutral, release the parking brake, but
continue squeezing the rear brake lever/parking brake lever.
2.
With the throttle closed, press the upshift switch once to shift
into 1st (first) gear.
UPSHIFTING SEQUENCE
DOWNSHIFTING SEQUENCE
(1) upshift switch
(A)
(2) downshift switch
(1)
(A)
(2)
(A) press
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86
Shifting Gears
3.
Release the rear brake lever/parking brake lever and increase
engine speed by gradually opening the throttle.
4.
When speed increases, release the throttle and shift to 2nd gear
by pressing the upshift switch once.
5.
Repeat this sequence to progressively upshift to 3rd, 4th and 5th
(top) gear.
6.
To downshift, press the downshift switch once. Remember to
close the throttle each time you shift to the next lower gear.
The transmission cannot be upshifted from neutral to 1st gear when
the engine speed is above 3,000 rpm or the ground speed is above
3 km/h (2 mph).
The transmission cannot be downshifted from 1st gear to neutral
when the engine speed is above 3,000 rpm or the ground speed is
above 3 km/h (2 mph).
If the electric shift system malfunctions, the transmission cannot be
shifted by pressing the gearshift switches. See your dealer. (In an
emergency, a gear may be selected manually so you may move the
vehicle. See Emergency Gear Selection & Operation, page 216)
procedures.
Learning when to shift gears comes with experience. Keep the
following tips in mind:
• As a general rule, shift while moving in a straight line.
• Close the throttle completely before shifting. Improper shifting
may damage the engine, 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.
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87
Shifting Gears
• Downshift to a lower gear before you feel the engine laboring
(lugging) at low rpm.
• Avoid downshifting to help slow your ATV when engine rpm is
high. Downshifting when engine speed is near its allowable
maximum may over-rev the engine and possibly cause damage.
• To prevent transmission damage, do not coast or tow the ATV for
long distances with the engine off.
Recommended Shift Points
Ride in the highest gear that lets the engine run and accelerate
smoothly.
This will give you good fuel economy and effective emissions control.
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88
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.
1.
Bring the vehicle to a complete stop, then make sure the
transmission is in neutral.
2.
Be sure there are no obstacles or people in the way.
3.
Fully rotate the P/R lever (1) counterclockwise to engage the P/R
lever with the reverse assist lever (2).
4.
While continuing to hold the P/R lever, squeeze the rear brake
lever/parking brake lever (3), then press the downshift switch (4)
once to shift into “R” (reverse) gear.
5.
Make sure that the reverse indicator comes on and the gear
position indicator shows “R”.
WARNING
3
WARNING
Improperly operating in reverse could cause
you to hit an obstacle or person behind you,
resulting in serious injury.
Make sure there are no obstacles or people
behind you before selecting reverse gear.
When it is safe to proceed, go slowly.
LEFT HANDLEBAR
(1)
(1) P/R lever
(3)
(3) rear brake lever/
parking brake lever
(2) reverse assist lever
(4) downshift switch
(4)
(5)
(5) upshift switch
(2)
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89
Riding in Reverse
NOTICE
Your ATV may be equipped with a reverse speed limiter, which helps
the vehicle to maintain a safe speed while riding in reverse gear.
6.
Release the rear brake lever/parking brake lever.
7.
Open the throttle gradually and ride slowly. Do not open the
throttle suddenly or make abrupt turns.
8.
To stop, close the throttle and gradually apply both the front and
rear brakes. Do not abruptly apply the rear brake by itself.
9.
To shift out of reverse and into neutral, press the upshift switch
(5) once to shift into “N” (neutral) gear. Make sure that the
reverse indicator goes off and the gear position indicator shows
“N”.
The transmission cannot be shifted from neutral back into reverse
when the engine speed is above 3,000 rpm or speed of your ATV is
above 3 km/h (2 mph).
WARNING
3
WARNING
Applying only the rear brake abruptly when
operating in reverse gear could cause the
front wheels to lift off the ground and the
ATV could overturn backwards.
Carefully apply both the front and rear brakes
when stopping in reverse gear.
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90
Braking
Your ATV is equipped with disc brakes on both front wheels which
are hydraulically activated by operating the front brake lever. A
single drum brake on the rear axle housing is mechanically activated
by depressing the brake pedal or operating the rear brake lever/
parking brake lever.
Although the front and rear brakes have separate controls, all four
wheels are interconnected when your ATV is in the 4WD mode. So
operating any brake control in the 4WD mode will cause braking at
both the front and rear wheels.
As a general rule, the front braking system provides about 70
percent of total stopping power.
For full braking effectiveness, use both the pedal and lever
simultaneously. Using both braking systems will stop your ATV faster
with greater stability.
To slow or stop, apply the brake lever and brake pedal smoothly,
while downshifting to match your speed.
Gradually increase braking as you feel the brakes slowing your
speed. The increase in engine compression from downshifting will
help slow your ATV.
Applying the brakes too hard may cause the wheels to lock and slide,
reducing control of your ATV. If this happens, release the brake
controls, steer straight ahead until you regain control, then reapply
the brakes more gently.
When possible, reduce your speed or complete braking before
entering a turn. Avoid braking or closing the throttle quickly while
turning. Either action may cause one or more wheels to slip and
reduce your control of your ATV.
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91
Braking
Your ability to brake in a turn and to brake hard in an emergency
situation are important riding skills.
When descending a long, steep grade, use 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 the brake pedal or your hands on
the brake levers may overheat the brakes, reducing effectiveness.
For information on how to apply the brakes in various riding
situations, see the following section, Riding Your ATV.
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Riding Your ATV
Learn how to turn your ATV properly. Practice the techniques
outlined in this section on level ground and at low speeds until you
are confident in making turns.
Remember that steering the handlebar in the front differential lock
mode will cause steering to be heavy and increase turning radius.
Making Turns
WARNING
3
WARNING
Turning improperly can make the ATV go out
of control, causing a collision or overturn.
• Always follow proper procedures for
turning as described in this owner’s manual.
• Practice turning at low speeds before
attempting to turn at faster speeds.
• Do not turn at excessive speeds.
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Riding Your ATV
To make a turn on level ground: Steer the handlebar and lean your
body toward the inside of the turn. Leaning helps balance the
vehicle, and it feels more comfortable. Leaning into a turn is an
important technique to master in riding an ATV.
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 wheels to turn easier, and it
also improves front-wheel steering.
To make a turn from a full stop:
Apply the throttle gradually when
you turn and start at the same time. Remember to shift your body
forward to make sharp low-speed turns and whenever you turn
while accelerating from a full stop.
Lean your body to the inside of a turn and forward.
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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 on ice, you may lose all
directional control. To avoid skidding on slippery terrain, keep your
speed low and ride with caution.
If your ATV skids sideways during a turn, steer in the direction of the
skid. Avoid hard braking or accelerating until you have regained
directional control.
Remember that steering the handlebar in the front differential lock
mode will cause steering to be heavy and increase turning radius.
Skidding or Sliding
WARNING
3
WARNING
Skidding or sliding improperly may cause you
to lose control of this ATV. You may also
regain traction unexpectedly, which may
cause the ATV to overturn.
Learn to safely control skidding by practicing
at low speeds and on level, smooth terrain.
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Basic Operation & Riding
95
Riding Your ATV
The ATV’s ability to safely climb hills largely depends on the rider’s
skill and judgement. Begin by practicing on smooth, gentle slopes.
As you gain experience, you’ll learn the hazards and your own
limitations. You may then proceed to ride on more difficult terrain.
However, you must be able to decide which hills or hazards might
cause the ATV to overturn. Avoid excessively steep hills.
When climbing hills, you must shift weight toward the front wheels
to help keep them on the ground. To do this, shift your body slightly
forward on the seat and lean forward. For greater weight shift, move
your body farther forward and lean forward.
Riding Up Hills
WARNING
3
WARNING
Operating on excessively steep hills can cause
the vehicle to overturn more easily than
operating on level surfaces or small hills.
Never operate the ATV on hills too steep for
the ATV or for your abilities.
WARNING
3
WARNING
Climbing hills improperly could cause loss of
control or cause the ATV to overturn.
Always follow proper procedures for climbing
hills as described in this owner’s manual.
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Basic Operation & Riding
96
Riding Your ATV
• Always check the terrain carefully before you start up any hill.
• Never climb hills with excessively slippery or loose surfaces.
• 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.
The ATV could flip over backward.
• Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.
Shift weight forward when climbing hills.
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Basic Operation & Riding
97
Riding Your ATV
Stalling the ATV and/or Rolling Backwards:
If you incorrectly estimate climbing capability or terrain conditions,
the ATV may not have enough power or traction to continue uphill.
If this happens, the ATV can stall and/or roll backwards.
What to do if the ATV stalls or rolls backwards when climbing a hill:
If you are about to lose all forward speed:
1.
Using the front and rear brakes together, bring the ATV to a stop
with the vehicle pointed straight uphill.
2.
Get off the ATV while you continue holding the brakes.
3.
Shift into neutral, set the parking brake and turn the engine off.
4.
Then assess the situation.
If the ATV starts rolling backwards before you begin braking:
1.
Keep your weight uphill.
2.
Carefully apply the front brakes first, then carefully apply the rear
brake. Do not apply the either brake only or abruptly if you are
rolling backwards, or the vehicle may overturn.
If the ATV continues sliding backwards:
After you’ve applied the brakes, get off and away from the vehicle.
Remember that operating any brake control in the 4WD mode will
cause braking at both the front and rear wheels.
WARNING
3
WARNING
Stalling, rolling backwards or improperly
dismounting while climbing a hill could result
in the ATV overturning.
Always follow proper procedures for climbing
a hill as described in this owner’s manual.
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Basic Operation & Riding
98
Riding Your ATV
What to do after the ATV has stalled or rolled backwards:
If the hill is too steep or too slippery, or if you have any doubt
whether you can safely walk the ATV back down the hill, leave the
vehicle where it is and get help. If possible, block the wheels so the
vehicle 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 ATV.
1.
Stand with your body facing downhill, beside the vehicle so you
can reach the rear brake lever/parking brake lever with your right
hand.
2.
Be sure your legs are clear of the wheels.
Check your footing.
3.
Slowly and carefully back the ATV down the hill using the rear
brake lever/parking brake lever to control speed.
4.
If you lose control of the ATV, for your safety, get away from the
vehicle.
Be sure your legs are
clear of the wheels.
Body position for
backing down a hill.
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Basic Operation & Riding
99
Riding Your ATV
It’s usually advisable to descend hills with the ATV pointed straight
downhill. Avoid angles that would cause the vehicle to lean sharply
to one side.
As you approach a downhill, stop and survey the terrain below.
Never ride past the limit of your visibility. Never go down a hill at
high speed.
Riding Down Hills
WARNING
3
WARNING
Going down a hill improperly could cause loss
of control or cause the ATV to overturn.
Always follow proper procedures for going
down hills as described in this owner’s
manual.
On downhills, shift your weight back.
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Basic Operation & Riding
100
Riding Your ATV
When you’ve selected a safe downhill path, shift into a lower gear,
shift your weight back with your arms 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 when riding down hills.
Remember that operating any brake control in the 4WD mode will
cause braking at both the front and rear wheels.
Remember, braking effectiveness is reduced on any hill with a loose
surface.
Riding on hills or slopes is different from riding on level terrain. Be
careful when riding on any hill. Make sure that you practice on
gentle, smooth slopes before attempting to ride on steeper or more
difficult terrain.
Remember that steering the handlebar in the front differential lock
mode will cause steering to be heavy and increase turning radius.
Crossing or Turning on Hills or Slopes
WARNING
3
WARNING
Improperly crossing hills or turning on hills
could cause loss of control or cause the ATV to
overturn.
Always follow proper procedures for crossing
or turning on slopes as described in this
owner’s manual. Avoid crossing steep hills if
possible.
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101
Riding Your ATV
Crossing Hills or Slopes
• To maintain balance and stability when riding across a slope, you
need to shift weight toward the uphill side of the vehicle. To do
this, move your body off the centre of 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 excessively steep, slippery or rough.
Making Turns on Slopes
• Compared to riding on level ground, you may need to shift more
weight and lean more when making turns on slopes.
• Do not make turns on any slopes until you have first mastered the
techniques for making turns on level terrain.
Shift weight uphill when crossing slopes.
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102
Riding Your ATV
Before operating in a new area, check for obstacles. Watch out for
bumps, rain ruts, potholes and other obstacles in the terrain. When
you approach any obstacle, reduce your speed and be prepared to
stop.
Never try to ride over large obstacles, such as large rocks or fallen
logs.
Riding Over Obstacles
WARNING
3
WARNING
Improperly operating over obstacles could
cause loss of control or a collision and could
cause the ATV to overturn.
When you go over obstacles, always follow
proper procedures as described in this
owner’s manual.
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Basic Operation & Riding
103
Riding Your ATV
Your ATV is designed to travel through water up to approximately
254 mm (10.0 in) deep. Before crossing a stream, make sure the
water is not too deep or flowing too fast.
NOTICE
Water entering the muffler may damage the oxygen sensor and
result in emissions control system malfunction. Have your ATV dealer
inspect the oxygen sensor immediately after water enters the
muffler.
Riding Through Water
WARNING
3
WARNING
The ATV tyres have some ability to float.
Operating this ATV through deep or fast-
flowing water may cause a loss of traction
and loss of control, which could lead to an
accident.
Never operate this ATV in fast-flowing water
or in water deeper than that specified in this
owner’s manual.
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Basic Operation & Riding
104
Riding Your ATV
1.
Choose a path where both banks have gradual slopes.
2.
Proceed through the water at a slow, steady speed.
3.
Watch out for submerged obstacles and slippery rocks.
4.
Avoid getting the spark plug or air cleaner wet, as this would
cause the engine to stop.
5.
After leaving the water, always test both the front and rear
brakes.
• Riding through water can make the brakes less effective than
normal, and may reduce stopping ability.
• If necessary, apply the brakes repeatedly until they dry out and
operate normally.
• If the brakes don’t regain effectiveness, stop your ATV and
follow the procedures on page 179.
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Basic Operation & Riding
105
Parking
1.
Look for level parking area. Make sure the ground surface is firm.
2.
After bringing your ATV to a stop, hold the brakes while you shift
into neutral.
3.
Set the parking brake (page 46).
4.
Turn the ignition switch OFF (w).
If it is necessary to start the engine when your ATV in gear and is
stopped on a grade, rock the vehicle back and forth to allow shifting
the transmission into neutral.
The brakelight is activated by applying the parking brake. When
using the parking brake, be sure to turn the ignition switch to OFF
(w) to avoid discharging the battery.
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Basic Operation & Riding
106
Parking
Parking on a Steep Incline or a Loose or Slippery Surface
If you must park your ATV on a steep incline or loose or slippery
surface, use the following procedure:
1.
While holding the brakes, set the parking brake.
2.
Turn the ignition switch to OFF (w ) and release the brakes.
3.
If the ATV begins to move, either while sitting on it or after you
dismount, find a better parking location.
4.
If rocks or other objects are available, you can block the wheels
as shown for additional security.
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Servicing Your Honda
107
Servicing Your Honda
(cont’d)
Servicing Y our Honda
To help keep your ATV in good shape, this section includes a
Maintenance Schedule for required service and step-by-step
instructions for specific maintenance tasks. 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 223.
Before You Service Your Honda
The Importance of Maintenance............................................... 109
Maintenance Safety.................................................................. 110
Important Safety Precautions ................................................. 111
Maintenance Schedule ............................................................. 112
Maintenance Record................................................................. 116
Service Preparations
Maintenance Component Locations ......................................... 117
Tool Kit .................................................................................... 120
Owner’s Manual Storage .......................................................... 121
Seat Removal............................................................................ 122
Rear Fender Cover Removal ...................................................... 123
Tank Cover Assembly Removal ................................................. 124
Clip Removal ............................................................................ 125
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Servicing Your Honda
108
Servicing Your Honda
Service Procedures
Fluids & Filters
Fuel.......................................................................................... 126
Engine Oil & Filter..................................................................... 129
Rear Final Gear Oil.................................................................... 138
Front Final Gear Oil................................................................... 141
Coolant.................................................................................... 143
Air Cleaner............................................................................... 151
Engine
Throttle .................................................................................... 157
Clutch System .......................................................................... 159
Reverse Lock System................................................................. 160
Spark Plug ................................................................................ 161
Valves....................................................................................... 164
Spark Arrester .......................................................................... 165
Chassis
Suspension ............................................................................... 166
Brakes ...................................................................................... 169
Tyres ........................................................................................ 180
Guards ..................................................................................... 186
Drivetrain Boots........................................................................ 188
Electrical
Battery ..................................................................................... 190
Appearance Care...................................................................... 195
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109
Before You Service Your Honda
The Importance of Maintenance
A well-maintained ATV is essential for safe, economical, and trouble-
free riding. It will also help reduce 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 ATV, this section of the manual
provides a Maintenance Schedule. The service intervals in this
schedule are based on average riding conditions.
Frequent servicing of the air cleaner is especially important to help
you avoid a possible costly engine repair.
If your ATV overturns or is involved in a crash, be sure your dealer
inspects all major parts, even if you are able to make some repairs.
WARNING
3
WARNING
Improperly maintaining this ATV or failing to
correct a problem before you ride can cause a
crash in which you can be seriously hurt or
killed.
Always follow the inspection and
maintenance recommendations and
schedules in this owner’s manual.
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Servicing Your Honda
110
Maintenance Safety
This section includes instructions on how to perform some important
maintenance tasks. If you have basic mechanical skills, you can
perform 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 handled only by a Honda technician or other qualified mechanic.
Instructions are included in this manual only to assist in emergency
service.
Some of the most important safety precautions follow. However, we
cannot warn you of every conceivable hazard that can arise in
performing maintenance. Only you can decide whether or not you
should perform a given task.
WARNING
3
WARNING
Failure to properly follow maintenance
instructions and precautions can cause you to
be seriously hurt or killed.
Always follow the procedures and
precautions in this owner’s manual.
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111
Maintenance Safety
• Make sure the engine is off before you begin any maintenance or
repairs. This will help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure
there is adequate ventilation whenever you operate the engine.
Burns from hot ATV parts. Let the engine and exhaust system
cool before touching.
Injury from moving parts. 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 careful when
working around petrol. Use only non-flammable solvent, not
petrol, to clean parts. Keep cigarettes, sparks, and flames away
from all fuel-related parts.
Remember that your Honda dealer knows your ATV best and is fully
equipped to maintain and repair it. To ensure the best quality and
reliability, use only new Honda Genuine Parts or other equivalents
for repair and replacement.
Important Safety Precautions
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Servicing Your Honda
112
Maintenance Schedule
The required Maintenance Schedule that follows specifies how often
you should have your ATV serviced, and what things need attention.
It is essential to have your ATV serviced as scheduled to maintain
safe, dependable performance and proper emission control.
The service intervals in this Maintenance Schedule are based on
average riding conditions. Some items will need more frequent
service if you ride in unusually wet or dusty areas or at full throttle.
Consult your dealer for recommendations applicable to your
individual needs and use.
Some items in the Maintenance Schedule 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, tools, and equipment.
We recommend that you have your dealer perform these tasks
unless you have advanced mechanical skills and the required tools
and equipment. Procedures for such items in this schedule are
provided in an official Honda Shop Manual available for purchase.
If you do not feel capable of performing a given task or need
assistance, remember that your Honda dealer knows your ATV best
and is fully equipped to maintain and repair it. If you decide to do
your own maintenance, use only Honda Genuine Parts or their
equivalents for repair or replacement to ensure the best quality and
reliability.
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113
Maintenance Schedule
Perform the pre-ride inspection (page 63) and owner maintenance
on this section at each scheduled maintenance period.
Each item on the maintenance schedule requires some mechanical
knowledge. Certain items (particularly those marked
*
and
**
) may
require more technical information and tools. Consult your dealer.
Summary of Maintenance Schedule Notes & Procedures:
NOTES:
1.
Service more frequently when riding in dusty areas, sand or
snow.
2.
Service more frequently after riding in very wet or muddy
conditions.
3.
Replace every 2 years. Replacement requires mechanical skill.
* Should be serviced by your dealer, unless you have the proper
tools and service data, and are mechanically qualified. Refer to
the official Honda Shop Manual.
** In the interest of safety, we recommend these items be serviced
only by your dealer.
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Servicing Your Honda
114
Maintenance Schedule
Maintenance Procedures:
I: inspect and clean, adjust, lubricate, or replace, if necessary
C: clean
A: adjust
L: lubricate
R: replace
* Should be serviced by your dealer, unless you have the proper tools and service data, and are
mechanically qualified. Refer to the official Honda Shop Manual.
FREQUENCY WHICHEVER
COMES FIRST
INITIAL
MAINT.
REGULAR
MAINT. INTERVAL
Refer to
page
ITEMS
km 150 1000 2000
mi 100 600 1200
MONTH 1 6 12
NOTE HOURS 20 100 200
* FUEL LINE I —
* THROTTLE OPERATION I 157
AIR CLEANER
NOTE 1
C C 151 – 155
AIR CLEANER HOUSING
DRAIN TUBE
NOTE 2
II156
SPARK PLUG I I 161
* VALVE CLEARANCE I I I 164
ENGINE OIL INITIAL=
150 km (100 mi), 20
operating hours or 1
month: R
129 – 137
ENGINE OIL FILTER REGULAR=
Every 1,000 km (600 mi),
100 operating hours or 12
months: R
136
* ENGINE IDLE SPEED I I I —
RADIATOR COOLANT
NOTE 3
II143
* COOLING SYSTEM
NOTE 2
II —
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 114 Thursday, May 3, 2018 11:44 AM
Servicing Your Honda
115
Maintenance Schedule
* Should be serviced by your dealer, unless you have the proper tools and service data, and are
mechanically qualified. Refer to the official Honda Shop Manual.
** In the interest of safety, we recommend these items be serviced only by your dealer.
FREQUENCY WHICHEVER
COMES FIRST
INITIAL
MAINT.
REGULAR
MAINT. INTERVAL
Refer to
page
ITEMS
km 150 1000 2000
mi 100 600 1200
MONTH 1 6 12
NOTE HOURS 20 100 200
DRIVETRAIN BOOTS I I 188
FRONT/REAR FINAL GEAR
OIL
(R: EVERY
2 YEARS)
I 138, 141
* BRAKE FLUID
NOTE 3
I I 169 – 171
* BRAKE SHOES WEAR
NOTE 1, 2
I177
* BRAKE PADS WEAR
NOTE 1, 2
I172
* BRAKELIGHT SWITCH I I I 178
BRAKE SYSTEM I I I 169 – 179
* REVERSE LOCK SYSTEM I I I 160
GUARDS I I 186
* CLUTCH SYSTEM I I I 159
* SUSPENSION I I 166
* SPARK ARRESTER C C 165
* NUTS, BOLTS, FASTENERS I I —
** WHEELS/TYRES I I I 180
** TIE-ROD AND JOINT
BOOTS
III —
** STEERING SHAFT HOLDER
BEARINGS
I—
** STEERING SYSTEM I —
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 115 Thursday, May 3, 2018 11:44 AM
Servicing Your Honda
116
Maintenance Record
Keeping an accurate maintenance record will help ensure that 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
performs 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 charged for by your dealer. Use the space under
Notes to record anything you want to remind yourself about or
mention to your dealer.
km (miles) or
months or hours
ODO or
HOUR
Date Performed
By:
Notes
150 (100) or
1 or 20
1,000 (600) or
6 or 100
2,000 (1,200) or
12 or 200
3,000 (1,800) or
18 or 300
4,000 (2,400) or
24 or 400
5,000 (3,000) or
30 or 500
6,000 (3,600) or
36 or 600
7,000 (4,200) or
42 or 700
8,000 (4,800) or
48 or 800
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Servicing Your Honda
117
Servic e Preparati ons
Maintenance Component
Locations
P/R lever
front brake fluid reservoirreverse assist lever
front brake lever
rear brake lever/
parking brake lever
throttle lever
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Servicing Your Honda
118
Maintenance Component
Locations
battery
fuse box
main fuse 1
main fuse 2
EPS fuse (TRX500FE2 only)
front suspension spring
pre-load adjuster
coolant reserve tank
seat latch
rear brakelight
switch
air cleaner
fuel fill cap
front brake
caliper
air cleaner housing
drain tube
front final gear oil fill cap
front final gear oil drain bolt
rear brake pedal
engine
oil filter
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Servicing Your Honda
119
Maintenance Component
Locations
spark plug
engine oil fill cap/
dipstick
owner’s manual
air pressure gauge
40 A spare fuse
tool kit
gear change tool
clutch adjuster
spark
arrester
engine oil drain bolt
rear suspension spring
pre-load adjuster
rear final gear oil fill cap
rear final gear oil drain bolt
rear brake panel
coolant
reserve tank
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Servicing Your Honda
120
Tool Kit
The tool kit (1) and gear change tool (2) are stored under the rear
fender cover (page 124).
After using the tools, be sure to use the rubber band (3) to fasten the
tool kit and gear change tool securely.
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 and gear change tool 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
UNDER REAR FENDER COVER
(1)
(2)
(3)
(1) tool kit
(2) gear change tool
(3) rubber band
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121
Owner’s Manual Storage
Your ATV provides storage for the owner’s manual so you’ll have it
with you for easy reference. Store your owner’s manual (1) in the
plastic document bag (2) underside of the rear fender cover (3).
The owner’s manual, air pressure gauge (4) and 40 A spare fuse (5)
should be stored in the plastic document bag and fastened with the
rubber band (6).
To remove the rear fender cover, see page 123.
Be careful not to flood this area when washing your ATV or riding
through water.
REAR FENDER COVER UNDERSIDE
(2)
(5)
(1)(4)
(1) owner’s manual
(2) plastic document bag
(4) air pressure gauge
(5) 40 A spare fuse
(3) rear fender cover
(3)
(6)
(6) rubber band
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 121 Thursday, May 3, 2018 11:44 AM
Servicing Your Honda
122
Seat Removal
Refer to Safety Precautions on page 111.
The seat must be removed for the engine oil filter, air cleaner, spark
plug, battery and fuse maintenance and to remove the rear fender
cover and tank cover assembly, to access the owner’s manual, air
pressure gauge, gear change tool, 40 A spare fuse and tool kit.
Removal
1.
Pull the seat latch (1) at the rear of the seat.
2.
Slide the seat (2) back and lift it.
Installation
1.
Insert the front prongs (3) into the backside of the tank cover (4)
and hooks (5) on the frame, and press the studs (6) into the
grommets (7).
2.
Press down on the seat until locks.
(3)
(1) seat latch
(2) seat
(3) front prongs
(5) hooks
(6) studs
(7) grommets
(6) (2)
(1)
(5)
(4)
(4) tank cover
(7)
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Servicing Your Honda
123
Rear Fender Cover Removal
Refer to Safety Precautions on page 111.
The rear fender cover must be removed for the battery and fuse
maintenance and to access the owner’s manual, air pressure gauge,
gear change tool, 40 A spare fuse and tool kit.
Removal
1.
Remove the seat (page 122).
2.
Unhook the rubber strap (1).
3.
Firmly pull the studs (2) from the grommets (3).
4.
Slide the rear fender cover (4) forward to disengage the tabs (5).
5.
Remove the rear fender cover.
Installation
Install the rear fender cover in the reverse order of removal.
(1) rubber strap
(3)(5)
(1)
(5) (4) (2)
(2) studs
(3) grommets
(4) rear fender cover
(5) tabs
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124
Tank Cover Assembly Removal
Refer to Safety Precautions on page 111.
The tank cover assembly must be removed for the engine oil filter
and spark plug maintenance.
Removal
1.
Remove the seat (page 122).
2.
Carefully remove the right studs (1) and left studs from the
grommets.
3.
Remove the tank cover assembly (2) by releasing the right tabs (3)
and left tabs from the slits.
Installation
Install the tank cover assembly in the reverse order of removal.
(1)
(1) right studs
(2)
(1)
(3)
(3)
(2) tank cover assembly
(3) right tabs
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Servicing Your Honda
125
Clip Removal
Removal
1.
Pull up the centre pin to release the lock.
2.
Pull out the clip of the hole.
Installation
1.
Insert the clip into the hole.
2.
Press down the centre pin securely to lock the clip.
1. 2.
1. 2.
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126
Servic e Procedur esFluids & Filters
Fuel
Refer to Safety Precautions on page 111.
Use only unleaded fuel in your Honda. If you ride your Honda in a
country where leaded fuel might be available, take precautions to
use only unleaded fuel.
Your engine is designed to use any unleaded petrol that has a pump
octane number (R + M)/2 of 86 or higher, or a research octane
number of 91 or higher. Petrol pumps at service stations normally
display the pump octane number. For information on the use of
Petrol Containing Alcohol, see page 241.
Use of lower octane petrol can cause persistent “pinging” or “spark
knock” (a loud rapping noise) which, if severe, can lead to engine
damage. Light pinging experienced while operating under a heavy
load, such as climbing a hill, is no cause for concern.
If pinging or spark knock occurs at a steady engine speed under
normal load, change brands of petrol. If pinging or spark knock
persists, consult your dealer.
Never use stale or contaminated petrol or an oil/petrol mixture.
Avoid getting dirt, dust, or water in the fuel tank.
Fuel Recommendation
type unleaded
research octane number 91 (or higher)
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127
Fuel
Fuel tank capacity, including reserve:
14.7 ℓ (3.88 US gal, 3.23 Imp gal)
Reserve capacity:
4.9 ℓ (1.29 US gal, 1.08 Imp gal)
When there is only one segment left in the fuel gauge (page 24), fuel
will be low and you should refuel as soon as possible.
Refer to Safety Precautions on page 111.
Fuel Capacity
Refuelling Procedure
(2)
(1)
(1) fuel fill cap (2) lower edge of filler neck
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128
Fuel
1.
To open the fuel fill cap (1), turn it counterclockwise.
2.
Add fuel until the level reaches the lower edge of the filler neck
(2).
Avoid over filling the tank. There should be no fuel in the filler
neck.
3.
After refuelling, turn the fuel fill cap clockwise securely.
If you replace the fuel fill cap, use only a Honda Genuine
replacement part.
WARNING
3
WARNING
Petrol is highly flammable and explosive. You
can be burned or seriously injured when
handling fuel.
• Stop the engine and keep heat, sparks and
flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
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Servicing Your Honda
129
Engine Oil & Filter
Engine oil quality is a major factor that affects both the performance
and the service life of the engine.
Using the proper oil (page 130) and filter, and regularly checking,
adding, and changing oil will help extend your engine’s life. Even the
best oil wears out. Changing oil helps get rid of dirt and deposits in
the engine. Operating the engine with old or dirty oil can damage
your engine. Running the engine with insufficient oil can cause
serious damage to the engine and transmission.
Change the engine oil as specified in the maintenance schedule on
page 114. When running in very dusty conditions, oil changes
should be performed more frequently than specified in the
maintenance schedule.
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130
Engine Oil & Filter
*
Suggested oils are equal in performance to SJ oils that are not
labeled as energy conserving or resource 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 may
adversely affect clutch operation.
• Do not use API SH or higher oils displaying a circular API “energy
conserving” or “resource conserving” service label on the
container. They may affect lubrication and clutch performance.
• Do not use non-detergent, vegetable, or castor based racing oils.
Oil Recommendation
API classification
*
SG or higher except oils labeled as
energy conserving or resource
conserving on the circular API
service label
viscosity (weight) SAE 10W-30
JASO T 903
standard
MA
NOT
RECOMMENDED
RECOMMENDED
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131
Engine Oil & Filter
Other viscosities shown in the following 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.
There are two classes: MA and MB.
Oil conforming to the standard is labeled on the oil container. For
example, the following label shows the MA classification.
(1)
(2)
(1) oil code
(2) oil classification
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132
Engine Oil & Filter
Refer to Safety Precautions on page 111.
Check the engine oil level each day before operating your ATV and
add if needed.
The oil fill cap/dipstick is located at the front left crankcase cover.
Before riding your ATV, check the engine oil level.
1.
Park your ATV on a firm, level surface.
2.
Start the engine in a well-ventilated area and let it idle for 3 – 5
minutes. If the air temperature is below 10°C (50°F), let the
engine idle for an additional 5 minutes (a total of 10 minutes).
3.
Stop the engine and wait 2 – 3 minutes.
4.
Remove the oil check/fill door (1) by disengaging the studs (2)
from the grommets and releasing the tabs (3) from the slits.
Checking & Adding Oil
(1)
LEFT SIDE
(1) oil check/fill door
(2) (3)
(2) studs
(3) tabs
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133
Engine Oil & Filter
5.
Remove the oil fill cap/dipstick (4) from the front crankcase cover
and wipe it clean.
6.
Insert the oil fill cap/dipstick without screwing it in, then remove
the oil fill cap/dipstick and check the oil level. The oil level should
be between the upper level mark (5) and the lower level mark (6)
on the oil fill cap/dipstick.
7.
If the oil level is near or below the lower level mark, then add the
specified oil into the fill cap hole, up to the upper level mark on
the oil fill cap/dipstick. Do not overfill.
8.
Reinstall the oil fill cap/dipstick.
9.
Install the oil check/fill door.
NOTICE
Running the engine with an improper oil level can cause serious
engine damage.
LEFT SIDE
(4)
(6)
(5)
(4) oil fill cap/dipstick (5) upper level mark
(6) lower level mark
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134
Engine Oil & Filter
Refer to Safety Precautions on page 111.
Your ATV’s oil filter has very specific performance requirements. Use
a new Honda Genuine oil filter specified for your model or a filter of
equal quality.
NOTICE
Using the wrong oil filter may result in leaks or engine damage.
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 208). If you do not have the skills or the tools, see your
dealer.
Change the oil with the engine warm to assure complete and rapid
draining.
Drain the Engine Oil:
1.
With the ATV on level ground, remove the oil check/fill door
(page 132) and the oil fill cap/dipstick from the front crankcase
cover.
Changing Engine Oil & Filter
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135
Engine Oil & Filter
2.
Place an oil drain pan under the crankcase and remove the
engine oil drain bolt (1) and sealing washer (2).
(2)
(1)
(1) engine oil drain bolt (2) sealing washer
UNDER ENGINE
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136
Engine Oil & Filter
Install a New Engine Oil Filter:
Place shop towels under the oil filter cover because oil will flow out.
1.
Remove the seat (page 122) and tank cover assembly (page 124).
2.
Remove the oil filter cover (3) and O-rings (4) by removing the
bolts (5). Let the remaining oil drain out. Discard the oil filter (6)
in an approved manner (page 208).
3.
Apply engine oil to new O-rings and install them to the oil filter
cover and crankcase cover.
4.
Reposition the spring (7) to the crankcase cover and install a new
oil filter with the rubber seal (8) facing out, away from the
engine. You will see the “OUT-SIDE (TOWARDS FILTER COVER)”
mark (9) on the filter body, near the seal. Use only the Honda
Genuine oil filter or a filter of equivalent quality specified for your
model. Using the wrong Honda filter or a non-Honda filter which
is not of equivalent quality may cause engine damage.
NOTICE
Improper installation of the oil filter can cause serious engine
damage.
(5)
RIGHT SIDE
(3) oil filter cover
(4) O-rings
(5) bolts
(6) oil filter
(7) spring
(8) rubber seal
(9) “OUT-SIDE (TOWARDS
FILTER COVER)” mark
(3)
(4)
(7)
(6) (8)
(9)
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137
Engine Oil & Filter
5.
Reinstall the oil filter cover, making sure the bolts are tightened
to the specified torque:
10 N·m (1.0 kgf·m, 7 lbf·ft)
6.
Pour the drained oil into a suitable container and dispose of it in
an approved manner (page 208).
NOTICE
Improper disposal of drained fluids is harmful to the environment.
7.
Install the tank cover assembly and seat.
Add Engine Oil:
1.
Reinstall the oil drain bolt with the new sealing washer and
tighten it to the specified torque:
25 N·m (2.5 kgf·m, 18 lbf·ft)
2.
Fill the crankcase with the recommended grade oil
approximately:
3.0 ℓ (3.2 US qt, 2.6 Imp qt)
3.
Reinstall the oil fill cap/dipstick.
4.
Start the engine and let it idle for 3 – 5 minutes.
5.
Stop the engine, wait 2 – 3 minutes and check the oil level. Make
sure the oil is between the upper and lower level marks on the oil
fill cap/dipstick. If necessary, add more oil but do not overfill.
6.
Check that there are no oil leaks.
7.
Install the oil check/fill door.
If a torque wrench is not used for installation, see your dealer as
soon as possible to verify proper assembly.
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138
Rear Final Gear Oil
Refer to Safety Precautions on page 111.
Change the oil with the rear final gear at normal operating
temperature to assure complete and rapid draining.
Oil Recommendation
type hypoid gear oil
viscosity (weight) SAE 80W-90
Changing Oil
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139
Rear Final Gear Oil
(cont’d)
1.
Park your ATV on a firm, level surface.
2.
Place an oil drain pan under the oil drain bolt (1).
3.
Remove the oil fill cap (2), O-ring (3), drain bolt and sealing
washer (4).
4.
After the oil has completely drained, reinstall the drain bolt with
a new sealing washer and tighten it to the specified torque:
12 N·m (1.2 kgf·m, 9 lbf·ft)
(1) oil drain bolt
(3) (4)
(2) (1)
(2) oil fill cap
(3) O-ring
(4) sealing washer
REAR UNDERSIDE
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140
Rear Final Gear Oil
5.
Remove the oil level check bolt (5) and sealing washer (6).
6.
Pour the drained oil into a suitable container and dispose of it in
an approved manner (page 208).
NOTICE
Improper disposal of drained fluids is harmful to the environment.
7.
Slowly fill the rear final gear case with the recommended oil until
oil starts to flow out of the oil level check hole (7). Allow oil to
settle for 2 – 3 minutes before moving to next step to prevent
overfilling.
85 cm
3
(2.9 US oz, 3.0 Imp oz)
8.
Coat a new O-ring with grease and install it into the fill cap
groove and tighten it to the specified torque:
12 N·m (1.2 kgf·m, 9 lbf·ft)
9.
Install the oil level check bolt with a new sealing washer and
tighten it to the specified torque:
12 N·m (1.2 kgf·m, 9 lbf·ft)
REAR
(7)
(5) oil level check bolt (7) oil level check hole
(6) sealing washer
(5) (6)
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141
Front Final Gear Oil
Refer to Safety Precautions on page 111.
Change the oil with the front final gear at normal operating
temperature to assure complete and rapid draining.
Oil Recommendation
type hypoid gear oil
viscosity (weight) SAE 80W-90
Changing Oil
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142
Front Final Gear Oil
1.
Park your ATV on a firm, level surface.
2.
Place an oil drain pan under the oil drain bolt (1).
3.
Remove the oil fill cap (2), O-ring (3), drain bolt and sealing
washer (4).
4.
After the oil has completely drained, reinstall the drain bolt with
a new sealing washer and tighten it to the specified torque:
12 N·m (1.2 kgf·m, 9 lbf·ft)
5.
Pour the drained oil into a suitable container and dispose of it in
an approved manner (page 208).
NOTICE
Improper disposal of drained fluids is harmful to the environment.
6.
Fill the front final gear case with the recommended oil.
325 cm
3
(11.0 US oz, 11.4 Imp oz)
Make sure the oil level is at the lower edge of the oil fill inspection
hole (5).
7.
Coat a new O-ring with grease and install it into the fill cap
groove and tighten it to the specified torque:
12 N·m (1.2 kgf·m, 9 lbf·ft)
FRONT
(1) oil drain bolt (4) sealing washer
(2) oil fill cap
(5)
(3) O-ring
(5) oil fill inspection hole
(1)
(4)
(2)
(3)
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143
Coolant
Your ATV’s liquid cooling system dissipates engine heat through the
coolant jacket that surrounds the cylinder and cylinder head.
Maintaining the coolant will allow the cooling system to work
properly and prevent freezing, overheating, and corrosion.
Use only high quality ethylene glycol antifreeze containing corrosion
protection inhibitors specifically recommended for use in aluminium
engines. Check the antifreeze container label.
Use only distilled water as a part of the coolant solution. Water that
is high in mineral content or salt may be harmful to the aluminium
engine.
NOTICE
Using coolant with silicate inhibitors may cause premature wear of
water pump seals or blockage of radiator passages. Using tap water
may cause engine damage.
The factory provides a 50/50 solution of antifreeze and water in this
ATV. This coolant solution is recommended for most operating
temperatures and provides good corrosion protection.
Decreasing the concentration of antifreeze to less than 40% will not
provide proper corrosion protection.
Coolant Recommendation
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144
Coolant
Increasing the concentration of antifreeze is not recommended
because it decreases cooling system performance. Higher
concentrations of antifreeze (up to 60%) should only be used to
provide additional protection against freezing. Check the cooling
system frequently during freezing weather.
Refer to Safety Precautions on page 111.
Check the engine coolant level each day before operating your ATV
and add if needed.
1.
Make sure the vehicle is on level ground.
2.
With the engine at normal operating temperature, check the
coolant level in the reserve tank (1). It should be between the
UPPER (2) and LOWER (3) level marks.
If the reserve tank is empty, or if coolant loss is excessive, check
for leaks and see your dealer for repair.
Checking & Adding Coolant
LEFT FRONT
(2)
(1) reserve tank
(3)(1)
(2) UPPER level mark
(3) LOWER level mark
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145
Coolant
3.
Remove the radiator cap lid (4) by disengaging the stud (5) from
the grommet (6).
4.
Remove the reserve tank cap (7).
Always add coolant to the reserve tank. Do not attempt to add
coolant by removing the radiator cap.
5.
Add coolant to the reserve tank as required to bring the coolant
level to the UPPER level mark.
6.
After adding coolant, reinstall the reserve tank cap.
7.
Install the radiator cap lid.
FRONT
(4) radiator cap lid
(5)
(5) stud
(6) grommet
(7) reserve tank cap
(4) (7)
(6)
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146
Coolant
Refer to Safety Precautions on page 111.
Coolant should be replaced by your dealer, unless you have the
proper tools and service data, and are mechanically qualified. Refer
to the official Honda Shop Manual.
To properly dispose of drained coolant, refer to You & the
Environment, page 208.
NOTICE
Improper disposal of drained fluids is harmful to the environment.
Coolant Replacement
WARNING
3
WARNING
Removing the radiator cap while the engine is
hot can cause the coolant to spray out,
seriously scalding you.
Always let the engine and radiator cool down
before removing the radiator cap.
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147
Coolant
Refer to Safety Precautions on page 111.
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 than
20% of the radiator surface.
Clean the radiator core after riding the ATV in mud.
TRX500FE1:
The right, left and centre radiator grill covers must be removed to
clean the radiator core.
TRX500FE2:
The left and centre radiator grill covers must be removed to clean the
radiator core.
Radiator Core
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148
Coolant
To clean the radiator core and radiator grill plate:
1.
Remove the radiator cap lid (page 145).
2.
Remove the reserve tank (1) by removing the bolt (2) and clips (3)
(page 125).
3.
Release the hoses (4) from the guides.
4.
Hold the reserve tank being careful not to spill the coolant.
LEFT FRONT
(1) reserve tank
(1)
(2) bolt
(3) clips
(4) hoses
(2)
(3)
(3)
(4)
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149
Coolant
(cont’d)
5.
Remove the clips.
6.
Remove the left radiator grill cover (5) by releasing the tab A (6),
tab B (7), tab C (8), hook A (9) and hook B (10).
7.
TRX500FE1 only:
Remove the right radiator grill cover (11) by releasing the tab A,
tab B, tab C, hook A, hook B and hose (12), then remove the
centre radiator grill cover (13).
LEFT FRONT
(3) clips
(3)
(8)
(5)
(6)
(9)
(10)
(5) left radiator
grill cover
(6) tab A
(7) tab B
(8) tab C
(9) hook A
(10) hook B
(7)
RIGHT FRONT (TRX500FE1)
(11) right radiator grill cover
(12) hose
(13) centre radiator grill cover
(8) (10) (6) (7)
(13)
(12)
(9)
(11)(3)
(14)
(14) radiator core
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150
Coolant
8.
TRX500FE2 only:
Remove the centre radiator grill cover by releasing the tab A, tab
B, hook A and hook B.
9.
Wash the radiator core (14) and radiator grill covers.
NOTICE
Do not apply pressured water directly to the radiator core.
The pressured water can damage the radiator core.
10.
Install the removed parts in reverse order of removal.
FRONT (TRX500FE2)
(6) tab A
(7) tab B
(9) hook A
(10) hook B
(13) centre radiator grill cover
(14) radiator core
(9) (14) (13)
(10)
(7)
(6)
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151
Air Cleaner
Refer to Safety Precautions on page 111.
Proper air cleaner maintenance is very important for off-road
vehicles. A dirty, water-soaked, worn-out, or defective air cleaner
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 dealer can help you determine the correct service
interval for your riding conditions.
Your ATV’s air cleaner has very specific performance requirements.
Use a new Honda Genuine air cleaner specified for your model or an
air cleaner of equal quality.
NOTICE
Using the wrong air cleaner may result in premature engine wear.
Proper air cleaner maintenance can prevent premature engine wear
or damage, expensive repairs, low engine power, poor gas mileage,
and spark plug fouling.
NOTICE
Improper or lack of proper air cleaner maintenance can cause poor
performance and premature engine wear.
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152
Air Cleaner
1.
Remove the seat (page 122).
2.
Unlatch the retainer clips (1).
3.
Remove the air cleaner housing cover (2).
Cleaning
UNDER SEAT
(2)
(1)
(1) retainer clips (2) air cleaner housing cover
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153
Air Cleaner
(cont’d)
4.
Loosen the screw (3) and remove the air cleaner assembly (4)
from the air cleaner housing.
5.
Remove the clamp (5).
6.
Remove the air cleaner (6) from the air cleaner body (7).
7.
Gently wash the air cleaner in clean, non-flammable (high flash
point) solvent such as kerosene — not petrol. After cleaning,
gently squeeze out the remaining solvent. Avoid twisting or
wringing the air cleaner. This can tear the foam.
8.
Inspect for tears or cracks in the foam or seams of the air cleaner.
Replace the air cleaner if it is damaged.
9.
Allow the air cleaner to dry thoroughly before applying oil. A wet
air cleaner will not fully absorb the oil.
10.
Pour clean air filter oil over the entire surface of the air cleaner.
Use both hands to evenly spread the oil into the air cleaner.
Gently squeeze out any excess oil. (To keep your hands dry, place
the air cleaner in a clean plastic bag before spreading the oil into
the air cleaner.)
UNDER SEAT
(6)
(3)
(7)
(5)
(3) screw
(4) air cleaner assembly
(5) clamp
(6) air cleaner
(7) air cleaner body
(4)
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154
Air Cleaner
11.
Install the air cleaner on the air cleaner body.
12.
Install the clamp.
13.
Insert the air cleaner assembly into the air cleaner housing.
14.
Fasten the screw.
15.
Reassemble by reversing the disassembly sequence.
• Install the air cleaner housing cover with the FRONT mark (8)
facing forward and fit the cut out of the tab (9) at the end of
the air cleaner.
(8) FRONT mark
(9) tab
(9)
(9)(8)
UNDER SEAT
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155
Air Cleaner
Do not push the dust cover (1) too far into the breather joint (2). If
the dust cover is dirty, clean it.
Dust Cover
UNDER SEAT
(1) dust cover (2) breather joint
(2)
(1)
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156
Air Cleaner
The air cleaner housing drain tube should 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 vehicle.
1.
Remove the drain tube (1) by removing the clip (2) under the air
cleaner housing (3).
2.
Drain the deposits.
3.
Reinstall the drain tube, securing it with the clip.
Air Cleaner Housing Drain Tube
REAR
(3)
(1) drain tube (3) air cleaner housing
(2)(1)
(2) clip
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157
Engine
Throttle
Refer to Safety Precautions on page 111.
Inspection
Check freeplay at the throttle lever (1).
Freeplay:
3 – 8 mm (0.1 – 0.3 in)
Adjustment
1.
Slide the rubber sleeve (2) back to expose the throttle cable
adjuster (3).
2.
Loosen the lock nut (4).
3.
Turn the adjuster to obtain the correct freeplay.
4.
Tighten the lock nut and reinstall the sleeve.
5.
After adjustment, check for smooth operation of the throttle
lever from fully closed to fully open in all steering positions.
Throttle Freeplay
RIGHT HANDLEBAR
(4)
3 – 8 mm
(0.1 – 0.3 in)
(1)
(3)
(2)
(1) throttle lever
(2) rubber sleeve
(3) throttle cable adjuster
(4) lock nut
(A) decrease freeplay
(B) increase freeplay
(A)
(B)
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Throttle
Refer to Safety Precautions on page 111.
1.
Check that the throttle assembly is positioned properly and the
securing bolts are tight.
2.
Check for smooth operation of the throttle lever from fully open
to fully closed in all steering positions. If there is a problem, see
your dealer.
3.
Inspect the condition of the throttle cable from the throttle lever
down to the throttle body. If the cable is kinked or chafed, have
it replaced.
4.
Check the throttle cable for tension or stress in all steering
positions.
5.
Lubricate the throttle cable with a commercially available cable
lubricant to prevent premature wear and corrosion.
Throttle Inspection
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Clutch System
Your ATV’s shift-activated, wet, multiplate clutch is part of the
primary drive system. Proper adjustment allows a smooth, gradual
engagement when shifting gears.
Refer to Safety Precautions on page 111.
1.
Make sure the engine is cool.
2.
Make sure the ignition switch is OFF (w).
3.
Loosen the lock nut (1).
4.
Turn the clutch adjuster (2) counterclockwise until you feel slight
resistance.
5.
Turn the adjuster 1/4 turn clockwise, then tighten the lock nut to
hold the adjuster in this position.
6.
After adjustment, start the engine and test ride your ATV to be
sure the clutch is operating properly.
If you cannot get proper adjustment, or the clutch does not work
properly, the clutch friction discs may be worn. See your dealer or
refer to official Honda Shop Manual.
Clutch Adjustment
LEFT FRONT
(1)
(1) lock nut (2) clutch adjuster
(2)
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Reverse Lock System
Refer to Safety Precautions on page 111.
1.
Turn over the dust cover (1).
2.
Check the reverse assist lever (2) freeplay, measured at the
reverse assist lever end near the cable:
2 – 4 mm (0.1 – 0.2 in)
3.
To adjust, slide the rubber sleeve (3), loosen the lock nut (4) and
turn the adjusting nut (5) to obtain the correct freeplay.
After adjustment, tighten the lock nut securely.
4.
Return the dust cover and rubber sleeve.
Other Checks
Check the reverse assist lever and cable for loose connections or
other damage. If the cable is worn or kinked, have it replaced by
your dealer.
Reverse Lock System Adjustment
LEFT HANDLEBAR
(2)
2 – 4 mm
(0.1 – 0.2 in)
(1)
(5)
(4)
(1) dust cover
(2) reverse assist lever
(4) lock nut
(5) adjusting nut
(3) rubber sleeve
(3)
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(cont’d)
Spark Plug
Use only the recommended type of spark plug in the recommended
heat range.
NOTICE
Using spark plugs with an improper heat range can cause engine
damage.
Refer to Safety Precautions on page 111.
1.
Remove the seat (page 122) and tank cover assembly (page 124).
2.
Clean any dirt from around the spark plug base.
3.
Disconnect the spark plug cap (1). Take care to avoid damaging
the spark plug wire when disconnecting the cap.
4.
Using a spark plug wrench provided in the tool kit, remove the
spark plug.
Spark Plug Recommendation
standard spark plug BKR5E-11 (NGK) or
K16PR-U11 (DENSO)
Spark Plug Inspection & Replacement
(1)
(1) spark plug cap
LEFT SIDE
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Spark Plug
5.
Inspect the electrodes and centre porcelain for deposits,
corrosion, or carbon 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 centre electrode (2) should have a flat tip
and sharp edges, and the side electrode (3) should not be eroded.
If the electrodes and insulator tip appear unusually fouled or
burned, we suggest that you contact your dealer.
6.
Discard the spark plug if there is apparent wear or if the insulator
is cracked or chipped.
7.
Using a wire-type feeler gauge, check the spark plug gap (4). If
adjustment is necessary, bend the side electrode carefully.
The gap should be:
1.00 – 1.10 mm (0.039 – 0.043 in)
(4)
(2)
(2) centre electrode
(3) side electrode
(4) spark plug gap
(3)
1.00 – 1.10 mm
(0.039 – 0.043 in)
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Spark Plug
8.
With the plug washer attached, thread the spark plug in by hand
to prevent cross-threading.
9.
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:
a) First, tighten the plug:
b) Then loosen the plug.
c) Next, tighten the plug again:
1/8 turn after it seats.
NOTICE
An improperly tightened spark plug can damage the engine. If a
plug is too loose, the piston may be damaged. If a plug is too tight,
the threads may be damaged.
10.
Connect the spark plug cap. Take care to avoid pinching any
cables or wires.
11.
Install the remaining parts in the reverse order of removal.
NGK: 3/4 turn after it seats.
DENSO: 1/2 turn after it seats.
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Valves
Refer to Safety Precautions on page 111.
Valve clearance should be:
Excessive clearance will cause noise. Insufficient clearance will cause
loss of power and possibly damage the valves.
For those who are mechanically proficient and have the proper tools,
instructions on adjusting valve clearances are given in the official
Honda Shop Manual. Otherwise, the valves should be adjusted by
your dealer.
Valve Inspection
intake: 0.15 mm (0.006 in)
exhaust: 0.23 mm (0.009 in)
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Spark Arrester
Refer to Safety Precautions on page 111.
The exhaust system must be periodically purged of accumulated
carbon.
To purge the system:
1.
Select a well-ventilated area free of combustible materials and
make sure the exhaust pipe is cool.
2.
Remove the bolt (1).
3.
Start the engine and rev it up approximately twenty times while
momentarily creating exhaust system back pressure by blocking
the end of the muffler with a shop towel.
4.
Stop the engine and allow the exhaust pipe to cool.
5.
Reinstall the bolt securely.
(1)
(1) bolt
REAR
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Suspension
Your front and rear suspension systems use springs and hydraulic
damping devices that suspend your weight and most of the weight
of your ATV.
The oil damper systems hydraulically control the natural compression
and rebound of the suspension springs so that traction and comfort
are maintained as the wheels ride over rough terrain.
The spring pre-loads for your front and rear suspension systems
adjust the amount of force required to begin compression of the
spring.
Consider adjusting your suspensions 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 also influence your suspension needs.
Lower spring pre-load provides a softer ride and is usually preferred
for light loads and smooth terrain. Higher spring pre-load provides a
firmer ride and is recommended for heavy loads and rough terrain.
Using a pin spanner, which is available from your dealer, the
suspensions can be adjusted for rider weight and riding conditions
by changing the spring pre-load.
Do not attempt to disassemble, service, or dispose of the damper;
see your dealer. The instructions found in this owner’s manual are
limited to adjustments of the shock assembly only.
Suspension Adjustment
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Suspension
Refer to Safety Precautions on page 111.
The spring pre-load adjuster (1) has 5 positions for different load or
riding conditions.
Use the pin spanner (2) to adjust the shock spring pre-load.
Suspension Spring Pre-Load
FRONT REAR
(1) spring pre-load adjuster
(2) pin spanner
(1) (1)(2)
(2)
12345 12345
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Suspension
Position 1: for a light load and smooth terrain.
Position 2: standard position.
Positions 3 to 5: for when the ATV 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 sequence (1-2-3-4-5 or
5-4-3-2-1). Attempting to adjust directly from 1 to 5 or 5 to 1 may
damage the shock absorber.
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Cha ssis
Brakes
The hydraulic disc brakes (front) and single mechanical drum brake
(rear) on your ATV dissipate heat generated by the friction of the
brake pads on the discs (front) and the brake shoes on the drum
(rear) as the wheels are slowed.
Hydraulic Disc Front Brake
As the front brake pads wear, brake fluid level will drop. A leak in the
system will also cause the level to drop.
There are no adjustments to perform, but fluid level and pad wear
must be inspected periodically. The system must be inspected
frequently to ensure there are no fluid leaks.
If the right brake lever freeplay does not feel within the normal range
while riding, check the brake pads for wear (page 172).
Worn pads should be replaced. If the pads are not worn beyond the
recommended limit, there is probably air in the brake system. See
your dealer to have the air bled from the system.
Mechanical Drum Rear Brake
If the rear brake lever/parking brake lever or brake pedal freeplay
does not feel within the normal range while riding, check the brake
shoes for wear (page 177).
The recommended brake fluid is DOT 4 Brake Fluid, or any brake
fluid of equal quality and performance. Use fresh brake fluid from a
sealed container. Be sure to read the label before opening the sealed
container. An opened container may be contaminated or may have
absorbed moisture from the air.
Brake Fluid Recommendation
brake fluid DOT 4 Brake Fluid
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Brakes
Refer to Safety Precautions on page 111.
If your inspection indicates a low fluid level, have your dealer 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.
NOTICE
Brake fluid can damage plastic and painted surfaces. Handle with
care.
Wipe up spills immediately. Avoid brake fluid contact with skin or
eyes. If it comes in contact 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.
Fluid Level Inspection
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Brakes
With the ATV on a level surface, check the fluid level.
It should be above the LOWER level mark (1). If the level is at or
below the LOWER level mark, check the brake pads for wear
(page 172).
Worn brake pads should be replaced. If the pads are not worn, have
your brake system inspected for leaks.
• Make sure there are no fluid leaks.
• Check for deterioration or cracks in the hoses and fittings. If the
hoses are worn or cracked, have them replaced by your dealer.
Other Inspections
RIGHT HANDLEBAR
(1)
(1) LOWER level mark
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Brakes
Refer to Safety Precautions on page 111.
Brake pad wear will depend upon the severity of usage and riding
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.
Check the wear indicator (1). If the wear indicator aligns with the
edge of the reference mark (2), both pads must be replaced, see
your dealer for this replacement.
Always inspect both pads in both the right and left front brake
calipers.
Brake Pad Wear
RIGHT FRONT (Left side similar)
(1) wear indicator (2) edge of reference mark
(2)
(1)
(1)
(2)
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Brakes
Inspection
Measure the distance the rear brake pedal (1) moves before the
brake starts to take hold. Freeplay, measurement at the tip of the
end of the pedal, should be:
15 – 20 mm (0.6 – 0.8 in)
If necessary, adjust to the specified range.
Rear Brake Pedal Freeplay
(1)
RIGHT SIDE
(1) rear brake pedal
15 – 20 mm
(0.6 – 0.8 in)
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Brakes
Adjustment
1.
Turn the brake pedal adjusting nut (2), 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 (3).
2.
Adjust the freeplay of the rear brake pedal. Push the brake arm
(4), then check the clearance between the brake arm and the
brake arm pin.
(3)
RIGHT REAR
(2) brake pedal adjusting nut
(2)
(3) brake arm pin
(4)
(4) brake arm
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Brakes
Inspection
Measure the distance the rear brake lever/parking brake lever (1)
moves before the brake starts to take hold. Freeplay, measurement
at the tip of the end of the brake lever, should be:
15 – 20 mm (0.6 – 0.8 in)
If necessary, adjust to the specified range.
Rear Brake Lever Freeplay
(1)
LEFT HANDLEBAR
(1) rear brake lever/parking brake lever
15 – 20 mm
(0.6 – 0.8 in)
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Brakes
Adjustment
Adjust the freeplay of the rear brake lever/parking brake lever with
the front wheels pointed straight ahead.
1.
Turn the brake lever adjusting nut (2), 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 (3).
2.
Adjust the freeplay of the rear brake lever/parking brake lever.
Push the brake arm (4) then check the clearance between the
brake arm and the brake arm pin.
(3)
RIGHT REAR
(2) brake lever adjusting nut
(2)
(3) brake arm pin
(4)
(4) brake arm
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Brakes
• Check that the rear brake lever/parking brake lever and brake
pedal assemblies are positioned properly and the securing bolts
are tight.
• Make sure that the brake cables, brake arm, spring, P/R lever and
fasteners are in good condition.
Refer to Safety Precautions on page 111.
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 arrow on the brake arm to move
toward a reference mark on the brake panel.
1.
Apply the brake control and check the movement of the arrow
(1) on the brake arm (2).
2.
Replace the brake shoe if the arrow aligns with the reference
mark (3) on the brake panel upon full application of the brake. If
replacement is necessary, see your dealer.
Other Inspections
Brake Shoe Wear
RIGHT REAR
(3)
(1)
(2)
(2) brake arm
(3) reference mark(1) arrow
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Brakes
Refer to Safety Precautions on page 111.
Rear Brake Only:
Check the operation of the rear brakelight switch (1) at the right side
behind the engine from time to time. Adjustment is done by turning
the adjusting nut (2). Turn the nut in direction (A) if the switch
operates too late and in direction (B) if the switch operates too soon.
Brakelight Switch Adjustment
RIGHT SIDE
(1) (2)
(1) rear brakelight switch (2) adjusting nut
(A)
(B)
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Brakes
Refer to Safety Precautions on page 111.
1.
Make sure the engine is OFF and the parking brake is set.
2.
Remove the rear brake drain bolt (1) and sealing washer (2) from
the bottom of the rear brake panel.
If any water drains, the brake seals must be replaced by your
dealer as soon as possible.
3.
Install the rear brake drain bolt with a new sealing washer and
tighten it to the specified torque:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Draining Water from Brakes
RIGHT REAR
(1)
(1) rear brake drain bolt (2) sealing washer
(2)
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Tyres
To safely operate your ATV, your tyres must be the 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, they are not immune
to punctures. Always select your riding area with care.
The following pages give detailed information on how and when to
check your air pressure, how to inspect your tyres for wear and
damage, and our recommendations for tyre repair and replacement.
Refer to Safety Precautions on page 111.
Properly inflated tyres provide the best combination of handling,
tread life, and riding comfort. Generally, underinflated tyres wear
unevenly, adversely affect handling, and are more likely to fail from
being overheated. Overinflated tyres make your ATV ride harshly, are
more prone to damage from surface hazards, and wear unevenly.
Make sure the air valve caps are secure. If necessary, install new
caps.
WARNING
3
WARNING
Using tyres that are excessively worn or
improperly inflated can cause a crash in which
you can be seriously hurt or killed.
Follow all instructions in this owner’s manual
regarding tyre inflation and maintenance.
Air Pressure
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Tyres
Always check air pressure when your tyres are “cold.” If you check
air pressure when your tyres are “warm” – even if your ATV has only
been ridden for a few miles – the readings will be higher. If you let
air out of warm tyres to match the recommended cold tyre
pressures, the tyres will be underinflated. Be sure to check tyre
pressure at the riding site, since changes in altitude can affect air
pressure.
The recommended “cold” tyre pressures are:
FRONT REAR
RECOMMENDED
PRESSURE
30 kPa (4.4 psi) 30 kPa (4.4 psi)
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Tyres
A manually operated tyre pump should be used rather than the high
pressure system found in 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 frequently to prevent possible tyre
damage from overinflation.
Refer to Safety Precautions on page 111.
Whenever you check the tyre pressures, you should also look for:
• Bumps or bulges in the side of the tyre or the tread. Replace any
tyre that has a bump or bulge.
• Cuts, slits, or cracks in the tyres. Replace the tyre if you can see
fabric or cord.
• Nails or other foreign objects embedded in the side of the tyre or
tread.
• Excessive tread wear.
WARNING
3
WARNING
Operating this ATV with improper tyres, or
with uneven tyre pressure may cause loss of
control, and you could be seriously injured or
killed.
• Always use the size and type tyres specified
in this owner’s manual for this vehicle.
• Always maintain proper tyre pressure as
described in this owner’s manual.
Inspection
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Tyres
Also, if 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
To check the condition of a tyre tread, measure the groove depth (1)
in the centre of the tyre, or check the wear indicator (2).
For best performance, you should replace a tyre before the tread
depth at the centre reaches the following limits:
front 4 mm (0.16 in)
rear 4 mm (0.16 in)
FRONT
(3)
(2)
(1)
4 mm
(0.16 in)
REAR
(1) groove depth
(2) wear indicator
(3) wear indicator
location mark
Replace
NEW
Replace
NEW
4 mm
(0.16 in)
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Tyres
Refer to Safety Precautions on page 111.
A tyre that is repaired, either temporarily or permanently, will have
lower speed and performance limits than a new or undamaged tyre.
A temporary repair can sometimes be made in an emergency
situation. However, since a temporary repair may not hold, you must
ride very slowly, preferably without any cargo, and have the tyre
replaced or permanently repaired as soon as possible. (For more
information on temporary repairs, see If You Have a Flat Tyre,
page 218.)
A permanent repair, such as an internal plug patch, can be made if
a tyre has only a small puncture in the tread area. However you may
not be able to safely carry as much weight. If you choose to have a
tyre repaired, be sure the repair work is performed by a professional.
If you have a tyre professionally repaired at a non-Honda facility, we
recommend that you have the work checked by your dealer.
Tyre Repair
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Tyres
Refer to Safety Precautions on page 111.
The tyres that came on your ATV were 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 tyres, however if that is not possible, you
must replace the tyres in pairs (front or rear) with tyres of the same
size and type as the originals. Never replace just one tyre.
The recommended tyres for your ATV are:
When you replace a tyre, remember:
Have the tyre replaced by your dealer if possible.
If you have a tyre professionally replaced at a non-Honda facility, we
recommended that you have the work checked by your dealer.
Tyre Replacement
WARNING
3
WARNING
Installing improper tyres on your ATV can
affect handling and stability. This can cause a
crash in which you can be seriously hurt or
killed.
Always use the size and type of tyres
recommended in this owner’s manual.
front AT25 × 8-1211 MAXXIS M975
rear AT25 × 10-1211 MAXXIS M978
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Guards
Refer to Safety Precautions on page 111.
The engine guard (1) protects the frame, front final gear case and
engine crankcase.
The skid plate (2) protects the rear final gear case. Check the guard
and plate for cracks, damage or looseness at intervals shown in the
Maintenance Schedule.
Have the engine guard and skid plate replaced if they are cracked or
damaged. If the guard and plate bolts are loose, tighten them
securely.
Skid Plate & Engine Guard
(1) (2)
(1) engine guard (2) skid plate
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Guards
Refer to Safety Precautions on page 111.
Check the front boot guards (1) and front driveshaft guards (2) for
cracks, damage or looseness.
Tighten any loose fasteners. Replace the front boot guards and front
driveshaft guards as required.
Front Boot Guards & Front Driveshaft Guards
FRONT
(1) front boot guards (2) front driveshaft guards
(2) (1) (1) (2)
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Drivetrain Boots
Refer to Safety Precautions on page 111.
Check the propeller shaft boots (1) and yoke joint boot (2) for cuts,
damage or leaking grease. If necessary, have your dealer replace
them.
Propeller Shaft Boots & Yoke Joint Boot
(1) propeller shaft boots
(2) yoke joint boot
(2)(1)
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189
Drivetrain Boots
Refer to Safety Precautions on page 111.
Check the driveshaft boots (1) for cuts, damage or leaking grease. If
necessary, have your dealer replace them.
Front Driveshaft Boots
FRONT
(1) driveshaft boots
(1)
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Electr ical
Battery
Your ATV has a maintenance-free type battery. You do not have to
check the battery electrolyte level or add distilled water as you would
with a conventional-type battery.
NOTICE
Your battery is a maintenance-free type and can be permanently
damaged if the cap strip is removed.
Electrical accessories use current from the battery, even when the
ignition is OFF (w). 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 frequently
(see Battery Charging, page 194).
If you do not expect to ride your ATV for at least two weeks, we
recommend you remove the battery, or at least disconnect the
battery cables (negative cable first).
If you plan to store your ATV, see Battery Storage, page 191.
If your battery seems weak and/or is leaking electrolyte (causing slow
starting or other electrical problems), see your dealer.
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Battery
Refer to Safety Precautions on page 111.
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 battery, we recommend disconnecting the
battery cables (negative cable first).
You will get the best storage results from removing the battery and
slow charging it every 30 days (see Battery Charging, page 194).
Before you remove the battery, be sure to read all the information
that follows, as well as the information on the battery label.
Battery Storage
WARNING
3
WARNING
The battery gives off explosive hydrogen gas
during normal operation.
A spark or flame can cause the battery to
explode with enough force to kill or seriously
hurt you.
Wear protective clothing and a face shield, or
have a skilled mechanic do the battery
maintenance.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 191 Thursday, May 3, 2018 11:44 AM
Servicing Your Honda
192
Battery
The battery is located in a compartment under the rear fender cover.
Removal
1.
Make sure the ignition switch is OFF (w).
2.
Remove the seat (page 122).
3.
Remove the rear fender cover (page 123).
4.
Release the rings and remove the rubber band (1).
5.
Disconnect the negative (–) terminal lead (2) from the battery (3)
first, then disconnect the positive (+) terminal lead (4).
6.
Remove the battery taking care not to drop the terminal nuts (5).
(3)
(1) rubber band
(2) negative (–) terminal lead
(4) positive (+) terminal lead
(5) terminal nuts
UNDER REAR FENDER COVER
(2)
(4)
(1)
(3) battery
(5)
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Servicing Your Honda
193
Battery
7.
Charge the battery (see following section).
8.
Store your battery in an easy-to-reach location off the floor, in an
area protected from freezing temperature and direct sunlight.
9.
Clean the compartment after removing the battery for storage.
Dry the compartment.
10.
Slow charge the battery (see following section) once every 30
days.
Installation
1.
Check that the battery rubber (6) for damage. If necessary,
replace the battery rubber.
2.
Make sure the battery rubber is properly installed.
3.
Reinstall the battery in the reverse order of removal.
Be sure to connect the positive (+) terminal first, then the
negative (–) terminal.
4.
Make sure all bolts and other fasteners are secure.
5.
Install the removed parts in reverse order of removal.
Make sure the clock is set to the proper time (page 26) after the
battery is reconnected.
(6)
(6) battery rubber
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 193 Thursday, May 3, 2018 11:44 AM
Servicing Your Honda
194
Battery
Refer to Safety Precautions on page 111.
Be sure to read the information that came with your battery charger
and follow the instructions on the battery. Improper charging may
damage the battery.
We recommend using a charger (1) designed specifically for your
Honda, which can be purchased from your dealer. These units can
be left connected for long periods without risking damage to the
battery. However, do not intentionally leave the charger connected
longer than the time period recommended in the charger’s
instructions. Avoid using an automotive-type battery charger. An
automotive charger can overheat an ATV battery and cause
premature damage.
Battery Charging
(1)
(1) charger
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 194 Thursday, May 3, 2018 11:44 AM
Servicing Your Honda
195
Appearance Care
Frequent cleaning and polishing will keep your Honda looking newer
longer.
Frequent cleaning also identifies you as an owner who values his ATV.
A clean ATV is also easier to inspect and service.
Refer to Safety Precautions on page 111.
• To clean your ATV, you may use:
– water
– a mild, neutral detergent and water
– a mild spray and wipe cleaner/polisher
– a mild spray and rinse cleaner/degreaser and water
• Avoid products 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 to cool off.
• Park in a shady area. Washing your ATV in bright sunlight may
cause the finish to fade because water droplets intensify the sun’s
brightness.
• Spotting is also more likely because surface water can dry before
you have time to wipe it off.
• Clean your ATV regularly to protect surface finishes.
• We recommend the use of a low pressure garden hose to wash
your ATV. High pressure washers (like those at coin-operated car
washers) can damage certain parts of your ATV.
NOTICE
High pressure water (or air) can damage certain parts of your ATV.
Water entering the muffler may damage the oxygen sensor.
• After cleaning, inspect for damage, wear, and leaks (fuel, oil,
coolant and brake fluid).
General Recommendations
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 195 Thursday, May 3, 2018 11:44 AM
Servicing Your Honda
196
Appearance Care
Refer to Safety Precautions on page 111.
1.
Cover or plug the exhaust outlet prior to washing your ATV.
2.
Rinse your ATV thoroughly with cool water to remove loose dirt.
3.
Fill a bucket with cool water. Mix in a mild, neutral detergent,
such as dish washing liquid or a product made especially for
washing motorcycles or automobiles.
4.
Wash your ATV with a sponge or soft towel. As you wash, check
for heavy grime. If necessary, use a mild cleaner/degreaser to
remove the grime.
5.
After washing, rinse your ATV thoroughly with plenty of clean
water to remove any residue. Detergent residue can corrode alloy
parts.
6.
Dry your ATV with a chamois or a soft towel. Leaving water on
the surface to air dry can cause dulling and water spots. As you
dry, inspect for chips and scratches.
7.
Remove the cover or the plug from exhaust outlet. Then, start the
engine and let it idle for several minutes. The engine heat will
help dry moist areas.
8.
As a precaution, ride your ATV at a slow speed and apply the
brakes several times. This will help dry the brakes and restore
normal braking performance.
The headlights' inside lens may fog temporarily after washing or
while riding in the rain. This does not impact the headlight
function.
Any condensation inside the headlight should dissipate after a
few minutes of running the engine with the headlight(s) on.
However, if you see a large amount of water or ice accumulated
inside the lens(es), have your vehicle inspected by your dealer.
Washing Your ATV with a Mild Detergent
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Servicing Your Honda
197
Appearance Care
Refer to Safety Precautions on page 111.
Avoid using spray cleaner products on the tyres or suspension
components.
Suggestions for using spray cleaner(s) follow:
Spray Cleaning Your ATV
ATV condition Recommended Cleaning
Dust and fingerprint
smudges.
Apply a spray cleaner/polish
and wipe paint, chrome, glass,
and clear plastic.
Light road grimes. Spray any difficult-to-reach or
very dirty areas with a spray
cleaner/degreaser.
Rinse and dry.
Apply a spray cleaner/polish
and wipe with a non-abrasive
cloth.
Heavy grime. Oil leaks.
Brake dust.
Use a spray cleaner/degreaser.
If necessary, rub with a
sponge.
Rinse and dry.
Apply a spray cleaner/polish
and wipe with a non-abrasive
cloth.
Dull, corroded chrome
or aluminium.
Apply a high quality chrome/
aluminium polish and wipe
with a non-abrasive cloth.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 197 Thursday, May 3, 2018 11:44 AM
Servicing Your Honda
198
Appearance Care
Refer to Safety Precautions on page 111.
After washing your ATV, consider using a commercially available
spray cleaner/polish or quality liquid or paste wax to finish the job.
Use only a non-abrasive polish or wax made specifically for
motorcycles or automobiles. Apply the polish or wax according to
the instructions on the container.
Refer to Safety Precautions on page 111.
The exhaust pipe and muffler are stainless steel but may become
stained by mud or dust.
To remove mud or dust, use a wet sponge and a liquid kitchen
abrasive, then rinse well with clean water. Dry with chamois or a soft
towel.
If necessary, remove heat stains by using a commercially available
fine texture compound. Then rinse by the same manner as removing
mud or dust.
Finishing Touches
Exhaust Pipe and Muffler Maintenance
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 198 Thursday, May 3, 2018 11:44 AM
Tips
199
Tips
Tips
Here’s helpful advice on how to prepare for an off-road adventure,
how to transport and store your Honda, and how to be an
environmentally responsible ATV owner.
Preparing for a Ride.................................................................. 200
What to Take to the Riding Area............................................ 200
What to Take on the Trail ...................................................... 201
Transporting Your Honda ......................................................... 202
Storing Your Honda.................................................................. 204
Preparation for Storage.......................................................... 205
Removal from Storage ........................................................... 207
You & the Environment ............................................................ 208
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 199 Thursday, May 3, 2018 11:44 AM
Tips
200
Preparing for a Ride
A safe and enjoyable ride begins with good planning and
preparation. Always ride with at least one other person in case you
have trouble, and let someone know where you’re going and when
you expect to return.
Before riding in an unfamiliar area, find out in advance if you need
special permits, get maps so you can study the terrain, and talk to
other riders who know the area.
Along with your ATV and riding gear, you should take along some
tools and supplies in case you have a problem. For some of the
difficulties you might encounter, see Taking Care of the Unexpected,
which begins on page 209.
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 tool kit
• tyre repair supplies and tools, and tyres
• extra parts, control levers, cables, and spark plugs
• wire, duct tape, and rope
• extra petrol
For safety, all refuelling should be done at a gas station on the way
to the riding area or at your base camp.
What to Take to the Riding Area
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 200 Thursday, May 3, 2018 11:44 AM
Tips
201
Preparing for a Ride
What you take with you during a ride depends on the kind of terrain,
how long you 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
trail, be sure you can carry them safely and know how to use them.
Also, be sure to follow the loading guidelines and weight limit
(page 68).
What to Take on the Trail
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 201 Thursday, May 3, 2018 11:44 AM
Tips
202
Transporting Your Honda
Do not tow your ATV behind a car or other vehicle.
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 upright on its rear end. This can damage the
vehicle, and leaking petrol could be a hazard.
Follow these procedures:
1.
Set the parking brake.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 202 Thursday, May 3, 2018 11:44 AM
Tips
203
Transporting Your Honda
2.
Secure the vehicle with tie-down straps in 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.
3.
Rock the vehicle back and forth to make sure the tie-down straps
are tight and the vehicle is secure.
(3)
(2)
(1)
(1) front carry pipe
(2) rear cargo rack
(3) trailer hitch
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 203 Thursday, May 3, 2018 11:44 AM
Tips
204
Storing Your Honda
If you won’t be riding for an extended period, such as during the
winter, thoroughly inspect your ATV and 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
in top condition. These storage procedures will reduce the
deterioration that can occur during storage.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 204 Thursday, May 3, 2018 11:44 AM
Tips
205
Storing Your Honda
(cont’d)
Refer to Safety Precautions on page 111.
This procedure requires a means for draining and disposing of
drained fuel (page 208).
1.
Change the engine oil and filter (page 134).
2.
Make sure the cooling system is filled with a 50/50% antifreeze
solution (page 143).
3.
Fill the fuel tank. Make sure the fuel fill cap is properly installed.
4.
To prevent rusting in the cylinders, perform the following:
• Remove the spark plug cap from the spark plug (page 161).
• Remove the spark plug.
Do not connect the spark plug to the spark plug cap.
• Pour a tablespoon (15 – 20 cm
3
) of clean engine oil into the
cylinder and cover the spark plug hole with a piece of cloth.
• With the engine stop switch in the RUN (e) position, press the
start/over ride button several times to crank the engine and
distribute the oil.
• Reinstall the spark plug and spark plug cap.
Preparation for Storage
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 205 Thursday, May 3, 2018 11:44 AM
Tips
206
Storing Your Honda
5.
Remove the battery and charge it fully. Store it in an area
protected from freezing temperatures and direct sunlight. Slow
charge the battery (page 194) once a month.
6.
Wash and dry your ATV. Wax all painted surfaces.
7.
Inflate the tyres to their recommended pressures (page 181).
8.
Store your ATV in an unheated area, free of dampness, away
from sunlight, with a minimum of daily temperature variation.
9.
Place your ATV on blocks to lift all tyres off the floor.
10.
Cover your ATV with a porous material. Avoid using plastic or
similar non-breathing, coated materials that restrict air flow and
allow heat and moisture to accumulate.
WARNING
3
WARNING
The battery gives off explosive hydrogen gas
during normal operation.
A spark or flame can cause the battery to
explode with enough force to kill or seriously
hurt you.
Wear protective clothing and a face shield, or
have a skilled mechanic do the battery
maintenance.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 206 Thursday, May 3, 2018 11:44 AM
Tips
207
Storing Your Honda
Refer to Safety Precautions on page 111.
1.
Uncover and clean your ATV.
2.
If your ATV has been stored for more than four months —
change the engine oil (page 134).
3.
If your ATV has been stored for more than two months — ask
your dealer to drain and replace the fuel.
4.
Charge the battery (page 194) as required. Install the battery.
5.
Perform a pre-ride inspection (page 63), then test-ride your ATV
at low speeds.
Removal from Storage
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 207 Thursday, May 3, 2018 11:44 AM
Tips
208
You & the Environment
Owning and riding an ATV can be enjoyable, but you must do your
part to protect nature. When you show respect for the land, wildlife,
and other people, you also help preserve the sport of off-road riding.
Following are tips on how you can be an environmentally responsible
ATV owner.
• Tread Lightly. Stay on existing roads and trails, avoid surfaces
that are easily damaged, and ride only in areas approved for off-
road vehicles.
• Keep the Noise Down. Loud vehicles can be offensive. Ride as
quietly as possible, don’t remove your spark arrester, and don’t
modify the muffler or any other part of your air intake and
exhaust systems. Such modifications not only increase noise, they
also reduce engine performance and may be illegal.
• Choose Sensible Cleaners. Use a biodegradable detergent
when you wash your ATV. Avoid aerosol spray cleaners that
contain chlorofluorocarbons (CFCs) which damage the
atmosphere’s protective ozone layer. Don’t throw cleaning
solvents away; see the following guidelines for proper disposal.
• Recycle Wastes. It’s illegal and thoughtless to put used engine
oil in the trash, down a drain, or on the ground. Used oil, petrol,
and cleaning solvents contain poisons that can hurt refuse
workers and contaminate our drinking water, lakes, rivers, and
oceans. Before changing your oil, make sure you have the proper
containers. Put oil and other toxic wastes in separate sealed
containers and take them to a recycling centre. Call your local or
state office of public works or environmental services to find a
recycling centre in your area, and to get instructions on how to
dispose of non-recyclable wastes.
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Taking Care of the Unexpected
209
Taking Care of the Unexpected
Taking Ca re of the Une xpe cted
With all the challenges you can encounter off-road, there’s a chance
that sometime something may go wrong. This section gives practical
advice to help you deal with a wide range of problems. Take time to
read this section before you ride. Also review the tips in Preparing for
a Ride (page 200).
General Guidelines ................................................................... 210
If Your Engine Quits or Won’t Start .......................................... 212
If the Shift Switches Do Not Function........................................ 215
Emergency Gear Selection & Operation .................................... 216
If You Have a Flat Tyre.............................................................. 218
If the High Coolant Temperature Indicator Lights...................... 221
If a Fuse Blows.......................................................................... 223
If You Crash ............................................................................. 228
If You Lose Your Key ................................................................ 229
If the Battery Is Low (or Dead)................................................... 230
If a Component Fails................................................................. 231
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Taking Care of the Unexpected
210
Taking Care of the Unexpected
Keeping your ATV well-maintained is the best way to reduce the
possibility of having a problem while riding. However, problems can
arise even with well-maintained machines.
Remember to take along your owner’s manual, the tool kit that
came with your ATV, and any other items (such as tyre repair
supplies and additional tools) that might help you solve a problem on
your own.
If something goes wrong during a ride, the first thing to do is stop as
soon as you safely can. Do not continue riding if you have a flat tyre,
or you hear an unusual noise, or your ATV just 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, then consider your options before
you decide what to do.
If a problem is relatively minor and you have 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 to your base where you can
make a permanent repair or get help.
When a problem is more serious — or you don’t have the tools,
supplies, experience, or time to deal with it — you need to choose
the safest way to get yourself and your ATV back to base. For
example, if you are close enough, you (or you and another person)
might be able to push it back.
General Guidelines
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Taking Care of the Unexpected
211
Taking Care of the Unexpected
Should you ever have a problem while riding, please follow these
guidelines:
• Always put personal safety first.
• Take 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 permanent
repairs made as soon as possible.
• Do not continue riding if you are hurt or your ATV is not in safe
riding condition.
Additional recommendations for specific problems follow.
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Taking Care of the Unexpected
212
If Your Engine Quits or Won’t
Start
Proper operation and maintenance can prevent starting and engine
performance problems. In many 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’t correct the problem, see your dealer.
If your ATV won’t start, listen as you press the start/over ride button.
If you don’t hear the starter motor turning, refer to the Starter motor
doesn’t operate symptom. If you can hear the starter motor working
normally, refer to the Starter motor works, but the engine won’t
start symptom.
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Taking Care of the Unexpected
213
If Your Engine Quits or Won’t
Start
SYMPTOM: Starter motor doesn’t operate.
POSSIBLE CAUSE WHAT TO DO
ignition switch OFF Turn the ignition switch ON.
engine stop switch
OFF
Slide the engine stop switch to
RUN.
transmission not in
neutral
Shift into neutral or squeeze the
front brake lever.
blown fuse Replace with a new fuse of the
same rating (page 223).
battery lead loose Tighten the battery lead.
low (or dead)
battery
Charge the battery (page 194).
If charging doesn’t help, see your
dealer.
faulty starter
motor
If all possible causes are negative,
the starter motor may be faulty.
See your dealer.
SYMPTOM: Starter motor works, but the engine won’t
start.
POSSIBLE CAUSE WHAT TO DO
out of fuel Fill the fuel tank.
flooded engine See Flooded Engine (page 82).
loose or
unconnected spark
plug cap
Install the spark plug cap securely.
If the engine still won’t start, see
your dealer.
loose battery
cables
Tighten the battery terminal bolts.
weak battery Charge the battery (page 194). If
charging doesn’t help, see your
dealer.
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Taking Care of the Unexpected
214
If Your Engine Quits or Won’t
Start
SYMPTOM: Engine starts, but runs poorly.
POSSIBLE CAUSE WHAT TO DO
high coolant
temperature
Check the coolant temperature
gauge and high coolant
temperature indicator. Refer to If
the High Coolant Temperature
Indicator Lights, page 221.
runs erratically,
misfires
See your dealer.
blubbers (rich fuel
mixture)
See your dealer.
sooty exhaust (rich
fuel mixture)
See your dealer.
detonates or pings
under load
If applicable, switch to the
recommended octane petrol
(page 126) 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: Engine starts, but runs poorly or dies when
hot.
POSSIBLE CAUSE WHAT TO DO
poor or
inadequate fuel
flow due to
clogged fuel filter
See your dealer.
(ensure clean fuel supply)
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Taking Care of the Unexpected
215
If the Shift Switches Do Not
Function
If one or both shift switches do not function, see the following
instructions. If proper function cannot be restored, see your dealer.
When the engine is running:
1.
Stop the ATV.
2.
Turn the ignition switch to the OFF (w) position.
3.
After the engine stops, turn the ignition switch to the ON (q)
position.
4.
Press both shift switches and check that they are functioning.
5.
If both switches are functioning, shift into neutral and restart the
engine.
If one or both switches are not functioning, see Emergency Gear
Selection & Operation, page 216.
When the engine is stopped and the ignition switch is ON (
q
):
1.
Turn the ignition switch to the OFF (w) position.
2.
Turn the ignition switch to the ON (q) position.
3.
Press both shift switches and check that they are functioning.
4.
If both switches are functioning, shift into neutral and restart the
engine.
If one or both switches are not functioning, see Emergency Gear
Selection & Operation, page 216.
When the battery is low (or dead):
• See If the Battery Is Low (or Dead), page 230.
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Taking Care of the Unexpected
216
Emergency Gear Selection &
Operation
If the shift switches do not operate, use the following procedure to
manually select a gear so you may drive the vehicle to a location
where it can be loaded and transported to your dealer.
1.
Turn the ignition switch to the ON (q) position.
2.
Remove the seat (page 122).
3.
Remove the rear fender cover (page 123).
4.
Remove the gear change tool from under the rear fender cover
(page 120).
5.
Check the neutral indicator.
If the transmission is in neutral, go to step 6.
If the transmission is not in neutral, use the gear change tool to
shift to neutral so you will be able to start the engine, Refer to
How to Shift Gears Manually: (page 217).
6.
Apply the parking brake.
7.
Press the start/over ride button to start the engine.
8.
Select the gear you want. For running on level ground: 3rd or 4th
gear. For mountainous roads: 2nd or 3rd gear. Refer to How to
Shift Gears Manually: (page 217).
9.
Return the gear change tool to under the rear fender cover.
10.
Install the rear fender cover.
11.
Install the seat.
12.
Get on the ATV, release the parking brake, and drive it at a safe
speed to a place where it can be repaired or serviced.
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Taking Care of the Unexpected
217
Emergency Gear Selection &
Operation
How to Shift Gears Manually:
• With the ATV unoccupied, align the hexagonal hole of the gear
change tool (1) with the hexagonal end of the secondary spindle
which is located on the front crankcase next to the front propeller
shaft.
• To downshift, turn the gear change tool to counterclockwise (A).
To upshift, turn the gear change tool to clockwise (B).
• If the alignment of the hexagonal hole does not allow sufficient
movement in the desired shifting direction, remove the tool, flip tool
over, and realign the hexagonal hole with the secondary spindle.
• If the transmission does not shift, rock the vehicle back and forth
and try again. And then if not shift again, the surface of the gear
change tool invert and turn the gear change tool.
• Return the gear change tool to under the rear fender cover.
Do not attempt to shift gears manually using the gear change tool
while riding.
If the transmission is shifted manually when the electric shift system is
functioning, the system will shutdown automatically and the shift
switches will not operate. To reactivate the system, turn the ignition
switch to the OFF (w) position, then turn it back to the ON (q) position.
(A) downshift (counterclockwise)
(B) upshift (clockwise)
(B)
(A)
(1)
(1) gear change tool
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Taking Care of the Unexpected
218
If You Have a Flat Tyre
How you handle a flat tyre on the trail depends on how serious the
tyre damage is, and what tools and supplies you have with you.
If you have a slow leak or a minor puncture, use the plug method to
make a temporary repair. (The plug method is applied from the
outside of the tyre and is the same as that for conventional tubeless
tyres.)
A plug-type repair kit, available at most auto parts stores or service
stations, provides a plug, an installation tool, tyre cement, and an
instruction sheet. Follow the instructions provided with the repair kit
to make a temporary 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
available transportation, we recommend that you carry a tyre pump
and a repair kit with the vehicle.
If the leak is more serious, or a temporary repair doesn’t hold, the
tyre must be replaced. The tyre will also need to be replaced if it is
damaged (page 185). Replacing a tyre involves removing and re-
installing the wheel (page 219).
If you are unable to repair a flat tyre on the trail, you will need to
send for help. We strongly recommend that you do not try to ride
with a flat tyre. The ATV will be hard to handle, and if the tyre comes
off the rim, it may lock up the wheel and cause you to crash.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 218 Thursday, May 3, 2018 11:44 AM
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219
If You Have a Flat Tyre
Refer to Safety Precautions on page 111.
Removal
1.
Park your ATV on a firm, level surface.
2.
Loosen — but do not remove — the wheel nuts (1).
3.
Raise the front (or rear) wheels off the ground and place a
support block under the vehicle.
4.
Remove the wheel nuts.
5.
Remove the wheel.
• Avoid 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.
Emergency Wheel Removal/Installation
(1)
(1)
(2)
(1) wheel nuts (2) wheel rim
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 219 Thursday, May 3, 2018 11:44 AM
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220
If You Have a Flat Tyre
Installation
1.
Position the wheel.
2.
Position the wheel nuts so that the tapered sides face the wheel
rim (2).
3.
Hand-tighten the wheel nuts on the wheel, then lower the ATV
to the ground before tightening the nuts in a crisscross (rather
than circular) pattern to the specified torque:
64 N·m (6.5 kgf·m, 47 lbf·ft)
If a torque wrench was not used for installation, see your dealer as
soon as possible to verify proper assembly. Improper assembly may
lead to loss of braking capability.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 220 Thursday, May 3, 2018 11:44 AM
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221
(cont’d)
If the High Coolant Temperature
Indicator Lights
Normally, the high coolant temperature indicator will only light
momentarily when you turn the ignition to ON (q).
High coolant temperature may be caused by restriction of air flow to
the radiator (such as mud caked on the radiator), extended idling, an
oil leak, a coolant leak, a low oil level, a low coolant level, or
extended operation under adverse conditions.
If the all segment of the coolant temperature gauge and high
coolant temperature indicator are 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.
NOTICE
Continuing to ride with high coolant temperature or an overheated
engine can cause serious engine damage.
• A steaming engine indicates a coolant leak. Shut the engine off
and wait until the steaming stops. Look for a leak, but don’t
touch the engine or radiator system. Let everything cool off first.
• Check for any restriction of air flow to the radiator.
• If there’s no obvious problem, leave the engine on so the fan and
coolant circulating system can continue working. Monitor the
coolant temperature gauge and high coolant temperature
indicator. The indicator may turn off after a brief stop with no
load on the engine.
• Check the radiator fan.
If the fan is not working, turn the engine off. Open the fuse box
(page 224) and check the radiator fan fuse. If the fuse is blown,
replace it with the proper (same rating) spare fuse. Start the
engine. If the all segment of the coolant temperature gauge and
high coolant temperature indicator stays on, turn the engine off.
If the radiator fan is working, visually check the coolant level in
the reserve tank, located under the left front fender. It isn’t
necessary to touch the radiator system.
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222
If the High Coolant Temperature
Indicator Lights
• If the reserve tank is low or empty, don’t ride without adding
coolant (page 143). After adding coolant, turn the engine on and
check the coolant temperature gauge and 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 202).
If the temperature drops to normal, check the coolant level. If it
has gone down, add more coolant.
• Check for an oil leak.
• Check the oil level. If necessary, add the recommended oil
(page 130) to the upper level mark. If you must leave your ATV to
get oil, secure it as much as possible.
• Start the engine, and check that the coolant temperature gauge
and high coolant temperature indicator goes off.
If you are able to resume riding, continue to monitor the coolant
temperature gauge and high coolant temperature indicator
frequently.
If there is an oil leak — do not ride the ATV until the leak is repaired
by your dealer (page 202).
If there’s a mild coolant leak, you can ride for awhile, carefully
watching the coolant temperature gauge and indicator. Be prepared
to stop and add more coolant or water. If the leak is bad, transport
your ATV to your dealer (page 202).
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 222 Thursday, May 3, 2018 11:44 AM
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223
If a Fuse Blows
All of the electrical circuits on your ATV have fuses to protect them
from damage caused by excess 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 (1).
Check all the fuses before looking elsewhere for another possible
cause of the problem. Replace a blown fuse and check component
operation.
The main fuse and the circuit fuses are located under the rear fender
cover.
TRX500FE2 only:
The EPS (Electric Power Steering) fuse is located under the rear
fender cover.
Recommended Fuses
main fuse 1 40 A
main fuse 2 10 A
other fuses 30 A, 20 A × 3, 10 A
EPS (Electric
Power Steering)
fuse (TRX500FE2
only)
40 A
(1)
(1) blown fuse
(1)
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224
If a Fuse Blows
Main Fuses Access
1.
To prevent an accidental short circuit, turn the ignition switch to
OFF (w) before checking or replacing the fuses.
2.
Remove the seat (page 122).
3.
Remove the rear fender cover (page 123).
4.
To access the main fuse 1 (2), remove the fuse cover (3).
5.
To access the main fuse 2 (4), remove the fuse box cover (5).
6.
Pull the main fuses out.
If the main fuse 1 is blown, install the spare fuse (page 121).
If the main fuse 2 is blown, install the spare fuse (6).
7.
Install the fuse cover.
UNDER REAR FENDER COVER
(2) main fuse 1
(3) fuse cover
(4) main fuse 2
(5) fuse box cover
(6) spare fuse
(5) (3)
(2)
(6)
(4)
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 224 Thursday, May 3, 2018 11:44 AM
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225
If a Fuse Blows
Circuit Fuses Access
8.
To check or replace a circuit fuse (7), pull the old fuse out of its
retaining clips.
If the fuse is blown, replace it with a spare fuse (8) of the same
rating.
If you do not have a replacement fuse with the proper rating for the
circuit, install one with a lower rating.
NOTICE
Replacing a fuse with one that has a higher rating greatly increases
the chance of damage to the electrical system.
9.
Install the fuse box cover.
10.
Install the rear fender cover.
11.
Install the seat.
(8)
(7)
(7) circuit fuses (8) spare fuses
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 225 Thursday, May 3, 2018 11:44 AM
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226
If a Fuse Blows
EPS (Electric Power Steering) Fuse Access (TRX500FE2 only)
1.
Turn the ignition switch to OFF (w ) before checking the fuse.
2.
Remove the seat (page 122).
3.
Remove the rear fender cover (page 123).
4.
To access the EPS fuse (1), remove the fuse cover (2).
If the EPS fuse is blown, install the spare fuse (page 121).
5.
Install the fuse cover.
6.
Install the rear fender cover.
7.
Install the seat.
UNDER REAR FENDER COVER
(1) EPS fuse (2) fuse cover
(1) (2)
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 226 Thursday, May 3, 2018 11:44 AM
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227
If a Fuse Blows
If you do not have a spare fuse and you cannot ride the ATV without
fixing the problem, take a fuse of the same rating or a lower rating
from one of the other circuits that you can do without temporarily.
If you replace a blown fuse with a spare fuse that has a lower rating,
replace the fuse with the correct rating as soon as you can. Also
remember to replace any spare fuses that were installed.
If the replacement fuse of the same rating burns out in a short time,
there is probably a serious electrical problem on your ATV. Leave the
blown fuse in that circuit and have your ATV checked by your dealer.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 227 Thursday, May 3, 2018 11:44 AM
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228
If You Crash
Personal safety is your first priority after a crash. If you or anyone else
has been injured, take time to assess the severity of the injuries and
whether it is safe to continue riding. If you cannot ride safely, send
someone for help. Do not ride if you will risk further injury.
If you decide you are capable of riding safely, 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 there is minor damage, or you are unsure about possible damage
but decide to try riding the ATV back to your base, ride slowly and
cautiously.
Sometimes, crash damage is hidden or not immediately apparent.
When you get home, thoroughly check your ATV and correct any
problems you find. Also, be sure to have your dealer check the frame
and suspension after any serious crash.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 228 Thursday, May 3, 2018 11:44 AM
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229
If You Lose Your Key
Be sure to record your key number (1) at following space. You’ll
need this number to have a duplicate key made.
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
listed in their records. If they don’t, transport your ATV to them or
the nearest dealer. The dealer will probably have to remove the
ignition switch assembly to find the key number so they can make a
key for you.
KEY NO. __________________________________________________
(1)
(1) key number
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230
If the Battery Is Low (or Dead)
The electric shift system will operate even if the battery is low (or
dead), as long as the engine is running. If the engine is not running,
it may be started using the recoil starter.
1.
Turn the ignition switch to the ON (q) position.
2.
Check if the transmission is in neutral by moving the vehicle back
and forth.
3.
If the transmission is in neutral, the vehicle will move easily. Go to
step 6. If the transmission is not in neutral, the vehicle will not
move.
4.
Remove the gear change tool from under of the rear fender cover
(page 123).
5.
Use the gear change tool to shift to neutral so you will be able to
start the engine. Refer to How to Shift Gears Manually:
(page 217).
6.
Apply the parking brake.
7.
Turn the ignition switch to the OFF (w) position, then turn it back
to the ON (q) position.
8.
Use the recoil starter (page 84) to start the engine.
Jump starting is not recommended, especially if you use an
automobile battery. The greater amperage of an automobile battery
when the car engine is running can damage your ATV’s electrical
system.
Bump starting is also not recommended.
If you can’t charge the battery or it appears unable to hold a charge,
contact your dealer.
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231
If a Component Fails
The brake levers or pedal, control cables, and other components can
be damaged as you ride in dense brush or over rocky terrain. Making
a trailside repair depends on how serious the 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 slowing or stopping.
• If you damage a throttle cable or other critical component, your
ATV may be unsafe to ride. Carefully assess the damage and
make any repairs that you can. But if there is any doubt, it’s best
to be conservative and safe.
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232
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 232 Thursday, May 3, 2018 11:44 AM
Technical Information
233
Technical Information
Te chni ca l Infor ma tion
This section contains dimensions, capacities, and other technical
data, plus information on government requirements and how to
break-in your ATV.
Vehicle Identification ................................................................ 234
Specifications ........................................................................... 236
Break-in Guidelines................................................................... 240
Petrol Containing Alcohol......................................................... 241
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 233 Thursday, May 3, 2018 11:44 AM
Technical Information
234
Vehicle Identification
The VIN and engine serial number may be required when ordering
replacement parts. Record the numbers here for your reference.
The VIN (1) is stamped on the front of the frame.
Remove the radiator cap lid (page 145).
VIN ______________________________________________________
The engine number (2) is stamped on the upper side of the rear
crankcase.
ENGINE No. _______________________________________________
Serial Numbers
FRONT
(1)
(1) VIN
REAR
(2) engine number
(2)
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 234 Thursday, May 3, 2018 11:44 AM
Technical Information
235
Vehicle Identification
The colour label (1) is attached on the left side of the frame.
The colour code is helpful when ordering replacement parts. Record
the colour and code here for your reference.
COLOUR__________________________________________________
CODE ____________________________________________________
Colour Label & Code
LEFT SIDE
(1)
(1) colour label
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 235 Thursday, May 3, 2018 11:44 AM
Technical Information
236
Specifications
Dimensions
overall length 2,103 mm (82.8 in)
overall width 1,205 mm (47.4 in)
overall height 1,219 mm (48.0 in)
wheelbase 1,268 mm (49.9 in)
ground clearance 190 mm (7.5 in)
Fuel & Lubricants
fuel
recommendation
unleaded petrol, research octane
number of 91 or higher
fuel tank
capacity
14.7 ℓ (3.88 US gal, 3.23 Imp gal)
including reserve
fuel tank reserve 4.9 ℓ (1.29 US gal, 1.08 Imp gal)
engine oil
capacity
after disassembly:
3.3 ℓ (3.5 US qt, 2.9 Imp qt)
after draining:
2.9 ℓ (3.1 US qt, 2.6 Imp qt)
after draining & oil filter change:
3.0 ℓ (3.2 US qt, 2.6 Imp qt)
engine oil
recommendation
API Service Classification SG or
higher except oils labeled as energy
conserving or resource conserving on
the circular API service label, SAE
10W-30, JASO T 903 standard MA,
Honda 4-stroke oil or an equivalent
cooling system
recommendation
High quality ethylene glycol
antifreeze containing corrosion
protection inhibitors specifically
recommended for use in aluminium
engines
cooling system
capacity
1.6 ℓ (1.7 US qt)
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 236 Thursday, May 3, 2018 11:44 AM
Technical Information
237
Specifications
Capacities
passenger
capacity
operator only
maximum
weight capacity
250 kg (551 lb)
rider, all cargo and accessories
Engine Specifications
displacement 475 cm
3
(29.0 cu-in)
bore & stroke 92.0 × 71.5 mm (3.62 × 2.81 in)
compression ratio 9.5 : 1
spark plug
(standard)
BKR5E-11 (NGK) or
K16PR-U11 (DENSO)
spark plug gap 1.00 – 1.10 mm (0.039 – 0.043 in)
valve clearance
(cold)
intake: 0.15 mm (0.006 in)
exhaust: 0.23 mm (0.009 in)
idle speed 1,400 ± 100 min
–1
(rpm)
Power Transmission
primary reduction 2.103
secondary reduction 1.875
final
reduction
front 3.230
rear 3.153
gear ratio 1st 4.230
2nd 2.388
3rd 1.608
4th 1.178
5th 0.848
reverse 5.743
final drive shaft
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 237 Thursday, May 3, 2018 11:44 AM
Technical Information
238
Specifications
Chassis & Suspension
caster 2°
trail 6 mm (0.2 in)
tyre size, front AT25 × 8-1211 MAXXIS M975
tyre size, rear AT25 × 10-1211 MAXXIS M978
tyre pressure,
front & rear
(cold)
front:
30 kPa (4.4 psi)
rear:
30 kPa (4.4 psi)
Electrical
battery GYZ16H
12 V – 16 Ah (10HR)
generator 0.481 kW/5,000 min
–1
(rpm)
Lights
headlight 12 V 35/35 W × 2
assist headlight 12 V 45 W
brake/tail light LED
neutral indicator LED
reverse indicator LED
high coolant
temperature indicator
LED
PGM-FI indicator LED
differential lock
indicator
LED
PS (Electric Power
Steering) indicator
(TRX500FE2 only)
LED
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 238 Thursday, May 3, 2018 11:44 AM
Technical Information
239
Specifications
Fuses
main 1 40 A
main 2 10 A
other 30 A, 20 A × 3, 10 A
EPS (Electric Power
Steering)
(TRX500FE2 only)
40 A
Torque Specification
engine oil drain
bolt
25 N·m (2.5 kgf·m, 18 lbf·ft)
engine oil filter
cover bolts
10 N·m (1.0 kgf·m, 7 lbf·ft)
rear final gear oil
drain bolt
12 N·m (1.2 kgf·m, 9 lbf·ft)
rear final gear oil
fill cap
12 N·m (1.2 kgf·m, 9 lbf·ft)
rear final gear oil
level check bolt
12 N·m (1.2 kgf·m, 9 lbf·ft)
front final gear
oil drain bolt
12 N·m (1.2 kgf·m, 9 lbf·ft)
front final gear
oil fill cap
12 N·m (1.2 kgf·m, 9 lbf·ft)
rear brake drain
bolt
12 N·m (1.2 kgf·m, 9 lbf·ft)
wheel nuts 64 N·m (6.5 kgf·m, 47 lbf·ft)
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 239 Thursday, May 3, 2018 11:44 AM
Technical Information
240
Break-in Guidelines
Help assure your 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, and
constant rpm operation.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 240 Thursday, May 3, 2018 11:44 AM
Technical Information
241
Petrol Containing Alcohol
If you decide to use a petrol containing alcohol (gasohol), be sure its
octane rating is at least as high as that recommended above.
There are two types of gasohol: One contains ethanol, and the other
contains methanol. Do not use gasohol that contains more than
10% ethanol. Do not use gasohol that contains methanol (methyl or
wood alcohol) unless it also contains cosolvents and corrosion
inhibitors for methanol. Never use petrol containing 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 cannot
endorse the use of fuels containing methanol since evidence of their
suitability is not yet complete.
Before buying fuel from an unfamiliar station, try to find out if the
fuel contains alcohol. If it does, confirm the type and percentage of
alcohol used. If you notice any undesirable operating symptoms
while using a petrol that contains alcohol, or one that you think
contains alcohol, switch to a petrol that you know does not contain
alcohol.
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 241 Thursday, May 3, 2018 11:44 AM
Index
Index
242
Index
A
accessories .................................................................................70
accessory socket .........................................................................50
age recommendation .................................................................61
air cleaner,
dust cover .............................................................................155
filter ......................................................................................151
housing drain tube ................................................................156
air pressure,
gauge ....................................................................................121
tyre .......................................................................................180
apparel, protective ......................................................................58
appearance care .......................................................................195
B
bank angle sensor ignition cut-off system ...................................82
battery .....................................................................................190
brakelight switch adjustment ....................................................178
brakes,
cables ....................................................................................177
draining water from ..............................................................179
fluid ......................................................................................169
front brake lever ......................................................................45
pad wear ...............................................................................172
rear brake lever freeplay ........................................................175
rear brake lever/parking brake lever .........................................45
rear brake pedal ......................................................................45
rear brake pedal freeplay .......................................................173
shoe wear .............................................................................177
braking .......................................................................................90
break-in guidelines ...................................................................240
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 242 Thursday, May 3, 2018 11:44 AM
Index
243
Index
button,
horn ........................................................................................41
mode select .................................................................14, 19, 20
start/over ride ..........................................................................39
C
capacity, fuel ............................................................................127
care, appearance ......................................................................195
cargo,
loading and operational guidelines ..........................................69
weight limit .............................................................................68
cleaning, appearance care ........................................................195
climbing hills ..............................................................................95
clip ...........................................................................................125
clutch system ............................................................................159
colour label ..............................................................................235
compartment,
owner’s manual .....................................................................121
tool kit ..................................................................................120
component fails ........................................................................231
controls & features .....................................................................34
coolant temperature gauge ........................................................28
crash, if you ..............................................................................228
crossing or turning on hills or slopes .........................................100
D
differential lock switch ................................................................36
digital clock ................................................................................26
dimmer switch, headlight ...........................................................41
dipstick .....................................................................................133
display check ..............................................................................16
display, multi-function ................................................................20
drivetrain boots ........................................................................188
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 243 Thursday, May 3, 2018 11:44 AM
Index
244
Index
E
electric power steering (EPS) .......................................................55
engine,
flooded ...................................................................................82
guard ....................................................................................186
number .................................................................................234
oil ..........................................................................................129
pinging ..................................................................................126
starting ....................................................................................79
stop switch ..............................................................................40
stopping ..................................................................................83
won’t start ............................................................................212
environment .............................................................................208
exhaust system,
cleaning ..................................................................................64
purging .................................................................................165
F
final gear oil,
front ......................................................................................141
rear .......................................................................................138
flag pole bracket ........................................................................48
flat tyre ....................................................................................218
flooded engine ...........................................................................82
front boot guards .....................................................................187
front differential lock ..................................................................36
front driveshaft boots ...............................................................189
front driveshaft guards .............................................................189
front final gear oil .....................................................................141
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 244 Thursday, May 3, 2018 11:44 AM
Index
245
Index
(cont’d)
fuel,
fill cap ................................................................................... 127
recommendation ...................................................................126
refuelling ...............................................................................127
reserve fuel supply .................................................................127
tank capacity .........................................................................127
fuses ........................................................................................223
G
gap, spark plug ........................................................................162
gasohol ....................................................................................241
gear shifting ...............................................................................85
gearshift switch ..........................................................................44
guards ......................................................................................186
H
headlight dimmer switch ............................................................41
headlight switch .........................................................................41
high coolant temperature indicator ...............................14, 17, 221
hills,
crossing or turning on slopes .................................................100
riding down hills ......................................................................99
riding up hills ...........................................................................95
stopping on hills ......................................................................97
horn button ................................................................................41
hour meter .................................................................................30
I
identification, vehicle ................................................................234
ignition switch ............................................................................34
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 245 Thursday, May 3, 2018 11:44 AM
Index
246
Index
indicators,
4WD indicator .............................................................18, 20, 35
differential lock indicator .............................................14, 17, 37
gear position indicator .......................................................18, 23
high coolant temperature indicator ............................14, 17, 221
maintenance minder indicator ...........................................18, 31
neutral indicator ................................................................14, 17
PGM-FI indicator ................................................................14, 17
PS (Electric Power Steering) indicator (TRX500FE2 only) .....14, 17
reverse indicator ................................................................14, 17
inspection, pre-ride .....................................................................63
K
key,
lost ........................................................................................229
number .................................................................................229
kit, tool ....................................................................................120
L
labels, safety .................................................................................5
lamp check .................................................................................15
limit, weight ...............................................................................68
load limits ...................................................................................68
loading guidelines ......................................................................69
lubrication,
engine oil ..............................................................................129
front final gear oil ..................................................................141
rear final gear oil ...................................................................138
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 246 Thursday, May 3, 2018 11:44 AM
Index
247
Index
(cont’d)
M
maintenance,
component locations .............................................................117
hour meter ..............................................................................30
importance ............................................................................109
minder indicator ................................................................20, 31
precautions ...........................................................................111
record ...................................................................................116
safety ....................................................................................110
schedule ................................................................................112
tripmeter .................................................................................31
maximum weight limit ................................................................68
modifications ..............................................................................71
multi-function display .................................................................20
N
neutral indicator .........................................................................17
numbers, serial .........................................................................234
O
obstacles, riding over ................................................................102
odometer ...................................................................................27
oil,
engine ...................................................................................129
front final gear ......................................................................141
rear final gear ........................................................................138
operation component locations ..................................................11
owner’s manual storage ...........................................................121
P
parking .....................................................................................105
parking brake/reverse lever (P/R lever) .........................................46
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 247 Thursday, May 3, 2018 11:44 AM
Index
248
Index
passenger, no carrying ................................................................61
pavement, no riding on ..............................................................75
petrol .......................................................................................126
petrol containing alcohol ..........................................................241
pinging, engine ........................................................................126
plug, spark ...............................................................................161
pre-ride inspection ......................................................................63
problems, unexpected ..............................................................209
propeller shaft boots & yoke joint boot .....................................188
protective apparel .......................................................................58
EPS (Electric Power Steering) (TRX500FE2 only) ...........................55
R
rear fender cover removal .........................................................123
rear final gear oil ......................................................................138
recoil starter ...............................................................................42
removal,
rear fender cover ...................................................................123
seat .......................................................................................122
tank cover assembly ..............................................................124
reverse,
assist cable ............................................................................160
assist lever .............................................................................160
gear, shifting into ....................................................................88
indicator ..................................................................................17
riding in ...................................................................................88
rider training ..............................................................................60
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 248 Thursday, May 3, 2018 11:44 AM
Index
249
Index
(cont’d)
riding,
basic operations ......................................................................73
clothing ...................................................................................58
over obstacles ........................................................................102
precautions .............................................................................75
preparing for .........................................................................200
safety ........................................................................................2
safety precautions ...................................................................75
through water .......................................................................103
S
safety,
important precautions ...........................................................111
labels .........................................................................................5
riding precautions ....................................................................75
schedule, maintenance .............................................................112
seat removal .............................................................................122
serial numbers ..........................................................................234
shifting gears ..............................................................................85
skid plates ................................................................................186
skidding or sliding ......................................................................94
spark arrester ...........................................................................165
spark knock ..............................................................................126
spark plug ................................................................................161
specifications ............................................................................236
speed limiter over-ride ................................................................36
speedometer ..............................................................................18
stalled engine .............................................................................83
stalling on a hill ..........................................................................97
start/over ride button ..................................................................39
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 249 Thursday, May 3, 2018 11:44 AM
Index
250
Index
starting,
engine .....................................................................................79
troubleshooting .....................................................................212
stop switch, engine ....................................................................40
stopping engine .........................................................................83
storage,
ATV .......................................................................................204
owner’s manual .....................................................................121
suspension,
adjustment ............................................................................166
spring pre-load ......................................................................167
switch,
4WD .......................................................................................35
differential lock .......................................................................36
downshift ..........................................................................44, 85
engine stop .............................................................................40
headlight .................................................................................41
headlight dimmer ....................................................................41
ignition ....................................................................................34
upshift ...............................................................................44, 85
T
tank cover assembly removal ....................................................124
throttle,
cable .....................................................................................157
lever ................................................................................43, 157
tool kit .....................................................................................120
trailer hitch .................................................................................49
trailer towing,
operational guidelines .............................................................69
weight limits ............................................................................68
training, rider .............................................................................60
transporting your ATV ..............................................................202
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 250 Thursday, May 3, 2018 11:44 AM
Index
251
Index
tripmeter ....................................................................................27
trouble, unexpected .................................................................209
troubleshooting, starting ..........................................................212
turning,
on hills or slopes ....................................................................100
on level ground .......................................................................92
tyres,
air pressure ............................................................................180
flat ........................................................................................218
repairing ................................................................................184
replacing ...............................................................................185
tread conditions ....................................................................182
U
utility box ...................................................................................52
utility pocket ..............................................................................53
V
valve clearance .........................................................................164
vehicle identification no. (VIN) ..................................................234
W
warning labels ..............................................................................5
washing your ATV ....................................................................196
water,
draining from brakes .............................................................179
riding through .......................................................................103
weight limit ................................................................................68
wheel removal ..........................................................................219
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 251 Thursday, May 3, 2018 11:44 AM
19 TRX500FE1 FE2 (U)-32HR4B400.book Page 257 Thursday, May 3, 2018 11:44 AM
00X32-HR4-B400
32HR4B40 WPCXXXX.2018.XX.19
PRINTED IN USA
U
