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Honda FourTrax Foreman Rubicon TRX500FA5 2019, Owner'S Manual

The Honda FourTrax Foreman Rubicon TRX500FA5 2019 is a powerful and reliable all-terrain vehicle built for adventure seekers. Experience superior handling, rugged durability, and unmatched performance. To make the most of your Rubicon, don't forget to download the Owner's Manual for free at 88.208.23.73:8080 and master every feature of your ride.

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Consumer Information

260

Warranty Service

Please remember that recommended maintenance interval servicing 
is not included in your warranty coverage. Additionally, your 
warranty does not apply to the normal wear of items (such as brakes, 
tires, etc.).

If you believe you have a problem with your ATV, call the service 
department of your dealer. Make an appointment for an inspection 
and diagnosis. Remember, as the owner of the ATV, you will be 
asked to authorize that inspection. Your dealer will give you the 
results of the inspection. If the problem is covered under warranty, 
your dealer will perform the warranty repairs for you.

If you have questions about warranty coverage or the nature of the 
repair, it is best to talk to the Service Manager of your dealer.

Sometimes, in spite of the best intentions of all concerned, a 
misunderstanding may occur. If you aren’t satisfied with your 
dealer’s handling of the situation, we suggest you discuss your 
problem with the appropriate member of the dealership’s 
management team. If the problem has already been reviewed with 
the Service Manager, Parts Manager, Sales Manager, etc., contact 
the Owner of the dealership or their designated representative.

19 TRX500FA5 FA6-FA7 31HR6640.book  Page 260  Friday, May 4, 2018  10:57 AM

Summary of Contents for FourTrax Foreman Rubicon TRX500FA5 2019

Page 1: ...luxe FOURTRAX FOREMAN RUBICON FOURTRAX FOREMAN RUBICON Read this manual carefully it contains important safety information Minimum recommended operator age 16 Models sold in and used in California The removal or modification of evaporative emission related parts on this OHRV is illegal Violators may be subject to civil and or criminal penalties as provided under California and federal law Part Num...

Page 2: ...ions are based on the TRX500FA6 model 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 ...

Page 3: ...ion regulations and operation on public streets roads or highways is illegal The vehicle is equipped with a USDA qualified spark arrester Obey local laws and regulations It conforms to US EPA and Environment Climate Change Canada emission regulations for ATVs 2019 Honda TRX500FA5 4 4 TRX500FA6 4 4 with Power Steering TRX500FA7 4 4 Deluxe FOREMAN RUBICON AT OWNER S MANUAL 19 TRX500FA5 FA6 FA7 31HR6...

Page 4: ...e 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 ...

Page 5: ... dedicated to your complete satisfaction Please report any change of address or ownership to your dealer so we will be able to contact you concerning important product information You may also want to visit our website at USA www powersports honda com Canada www honda ca Happy riding 19 TRX500FA5 FA6 FA7 31HR6640 book Page 4 Friday May 4 2018 10 57 AM ...

Page 6: ...is 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 judgment 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...

Page 7: ... to use this ATV correctly and safely This entire manual is filled with important safety information please read it carefully 3DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions 3WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions 3CAUTION You CAN be HURT if you don t follow instructions 19 TRX500FA5 FA6 FA7 31HR6640 book Page 6 Friday May 4 2018 ...

Page 8: ...ments Controls 9 The location and function of indicators and controls on your ATV and operating instructions for various controls and features Before Riding 59 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 75 How to start and stop the engine shift gears and brake Also r...

Page 9: ...e an environmentally responsible rider Taking Care of the Unexpected 215 What to do if you have a flat tire your engine won t start etc Technical Information 241 ID numbers technical specifications and other technical facts Consumer Information 257 Information on warranties emission controls how to get Honda service manuals Index 264 Quick Reference Handy facts about fuel engine oil tire sizes and...

Page 10: ...19 TRX500FA5 FA6 FA7 31HR6640 book Page 9 Friday May 4 2018 10 57 AM ...

Page 11: ...d 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 1 Friday May 4 2018 10 57 AM ...

Page 12: ...ge 16 should never operate this vehicle Refer to the age warnings provided in this manual and on the ATV Always Wear a Helmet It s a proven fact helmets significantly 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 60 Never Carry a Passenger Your ATV is des...

Page 13: ...you build your skills and get accustomed to the ATV s size and weight Because many crashes involve inexperienced or untrained riders we urge all riders to take a ATV operator course approved by the ATV Safety Institute ASI See page 62 Contact an authorized ATV dealer or call 1 800 887 2887 USA only to find out about the training courses nearest you Be Alert for Off road Hazards The terrain can pre...

Page 14: ... 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 f...

Page 15: ...ormation 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 5 Friday May 4 2018 10 57 AM ...

Page 16: ...ng 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 PASSEN...

Page 17: ...he maximum front cargo limit of 99 lbs 45 kg Refer to instructions in the Owner s Manual WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Maximum weight capacity 573lbs 260kg Front 4 4psi 30kPa Rear 4 4psi 30kPa 19 TRX500FA5 FA6 FA7 31HR6640 book Page 7 Friday May 4 2018 10 57 AM ...

Page 18: ...cur 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 HEL...

Page 19: ...onents 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 LOW Indicator 23 Gear Position Indicator 24 Fuel Gauge 25 Digital Clock 27 Odometer 28 Tripmeter 28 Coolant Temperature Gauge 29 Hour meter 31 Maintenance Tripmeter Maintenance Hour...

Page 20: ...Headlight Switch 43 Headlight Dimmer Switch 43 Recoil Starter Canada only 44 Throttle Lever 45 Drive Mode Select Switch 46 Gearshift Switch 47 Front Brake Lever 48 Rear Brake Lever Parking Brake Lever 48 Rear Brake Pedal 48 Parking Brake Reverse Lever P R Lever 49 Flag Pole Bracket 51 Trailer Hitch 52 Accessory Socket 53 Utility Box 55 Storage Compartment 56 EPS Electric Power Steering TRX500FA6 F...

Page 21: ...arking brake lever engine stop switch range select lever ignition switch throttle lever front brake lever 4WD switch headlight dimmer switch gearshift switches drive mode select switch differential lock switch start override button 19 TRX500FA5 FA6 FA7 31HR6640 book Page 11 Friday May 4 2018 10 57 AM ...

Page 22: ...Instruments Controls 12 Operation Component Locations rear cargo rack front cargo rack rear brake pedal recoil starter Canada only 19 TRX500FA5 FA6 FA7 31HR6640 book Page 12 Friday May 4 2018 10 57 AM ...

Page 23: ...nstruments Controls 13 Operation Component Locations flag pole bracket trailer hitch storage compartment accessory socket utility box 19 TRX500FA5 FA6 FA7 31HR6640 book Page 13 Friday May 4 2018 10 57 AM ...

Page 24: ...the indicators frequently Their functions are described on the following pages 4 PGM FI indicator 5 high coolant temperature indicator 1 neutral indicator 2 reverse indicator 7 multi function display 6 PS Electric Power Steering indicator TRX500FA6 FA7 8 mode select button 5 2 4 1 7 6 3 8 3 differential lock indicator 19 TRX500FA5 FA6 FA7 31HR6640 book Page 14 Friday May 4 2018 10 57 AM ...

Page 25: ...econds 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 come 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 loc...

Page 26: ...e 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 f...

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

Page 28: ... when low L range is engaged page 23 Maintenance minder indicator Shows when specified maintenance interval is reached page 33 Speedometer Shows riding speed Fuel gauge Shows approximate fuel supply available page 25 Digital clock Shows the time hour and minutes page 27 Odometer Shows accumulated mileage page 28 Tripmeter Shows mileage per trip page 28 Coolant temperature gauge Shows approximate c...

Page 29: ...f multi function display Adjusts the digital clock page 27 Changes the speed and mileage units page 22 Resets the tripmeter to zero 0 page 28 This button also used to reset the maintenance tripmeter and maintenance hour meter page 32 19 TRX500FA5 FA6 FA7 31HR6640 book Page 19 Friday May 4 2018 10 57 AM ...

Page 30: ...push the mode select button 8 Multi function Display 4WD indicator Gear position indicator LOW 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 LOW indicator 5 maintenance minder indicator 3 gear position indicator 6 lower part of the multi func...

Page 31: ...re 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 25 Digital clock page 27 Odometer page 28 Tripmeter page 28 Coolant temperature gauge page 29 When ATV is moving When ATV is not moving Hour me...

Page 32: ...ge the speed and mileage units press and hold the mode select button 1 for more than 5 seconds in odometer mode page 28 with the ATV stopped The 4WD indicator 1 shows when the 4WD mode engages page 37 Speed and Mileage Unit Changing 4WD Indicator 1 mode select button 1 1 4WD indicator 1 19 TRX500FA5 FA6 FA7 31HR6640 book Page 22 Friday May 4 2018 10 57 AM ...

Page 33: ...rs Displays The LOW indicator 1 will be displayed when low L range is engaged with the ignition switch in the ON q position page 95 LOW Indicator 1 LOW indicator 1 19 TRX500FA5 FA6 FA7 31HR6640 book Page 23 Friday May 4 2018 10 57 AM ...

Page 34: ...perly 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 still shows check that the range select lever is securely in a gear rock the vehicle back and forth Make sure the gear posit...

Page 35: ...e display is in when the fuel level reaches only 1st segment 3 the display will automatically switch to the fuel gauge display You should refuel as soon as possible The amount of fuel remaining when the fuel gauge reaches the 1st segment is approximately 1 82 US gal 6 9 ℓ Fuel Gauge 2 1 fuel gauge 1 2 fuel mark 3 3 1st segment 19 TRX500FA5 FA6 FA7 31HR6640 book Page 25 Friday May 4 2018 10 57 AM ...

Page 36: ...fuel mark blinks you should refuel as soon as possible The amount of fuel reserve is approximately 1 29 US gal 4 9 ℓ Fuel gauge failure If the fuel gauge E F 6 is blinking the fuel gauge function has failed See your dealer 4 4 E _ _ _ _ _ F 5 LO FUEL 5 6 E F 6 19 TRX500FA5 FA6 FA7 31HR6640 book Page 26 Friday May 4 2018 10 57 AM ...

Page 37: ...on 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 ignitio...

Page 38: ...ge per trip since you last reset the tripmeter while the ignition switch is ON q with the TRIP mark 2 The tripmeter returns to 0 0 when the read out exceeds 999 9 To 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 1 2 1 tripmeter 3 mode select button 2 TRIP mark 3 19 TRX500FA5 FA6 FA...

Page 39: ...e 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 5 3 1 coolant temperature gauge 2 coolant temperature mark 1 3 1st segment 4 4th segment 5 Lo 4 2 19 TRX500FA5 FA6 FA7 31HR6640 book Page 29 Friday May 4 2018 10 57 AM ...

Page 40: ...and check the reserve tank coolant level Read pages 230 231 and do not ride the ATV until the problem has been corrected NOTICE Continuing to ride with an overheated engine can cause serious engine damage If the C H 8 blinks the meter input signal fails See your dealer 6 5th segment 7 high coolant temperature indicator 7 6 8 8 C H 19 TRX500FA5 FA6 FA7 31HR6640 book Page 30 Friday May 4 2018 10 57 ...

Page 41: ...s 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 read out exceeds 99 999 9 Hour meter 1 2 1 hour meter 2 hour meter mark 19 TRX500FA5 FA6 FA7 31HR6640 book Page 31 Friday May 4 2018 10 57 AM ...

Page 42: ...intenance minder indicator The maintenance tripmeter decreases from 600 miles 1 000 km after reset The maintenance hour meter decreases from 100 hour after reset Initial setting of the maintenance tripmeter is 100 miles 150 km Initial setting of the maintenance hour meter is 20 hour Maintenance Tripmeter Maintenance Hour meter 3 1 maintenance tripmeter 3 maintenance hour meter 2 maintenance minder...

Page 43: ...aintenance Appears at 100 miles 150 km or 20 operating hours whichever comes first Regular Maintenance Interval 1 Appears 600 miles 1 000 km or 100 operating hours 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 600 miles 1 000 km or 100 operating ho...

Page 44: ...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 2 maintenance minder indicator ...

Page 45: ...or the ON q position The ignition switch is also used to reset the maintenance tripmeter and the maintenance hour meter page 34 Ignition Switch Key Position Function ON q Electrical circuits on OFF w No electrical circuits function CENTER OF HANDLEBAR OFF ON 1 q ON w OFF 1 ignition switch 19 TRX500FA5 FA6 FA7 31HR6640 book Page 35 Friday May 4 2018 10 57 AM ...

Page 46: ...ols Features The range select lever 1 has two positions Drive D Low L See Shifting Gears page 95 Range Select Lever LEFT SIDE OF FUEL TANK 1 range select lever 1 19 TRX500FA5 FA6 FA7 31HR6640 book Page 36 Friday May 4 2018 10 57 AM ...

Page 47: ...t 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 syste...

Page 48: ...e locking all four wheels together changes the way the vehicle handles and increases the amount of room necessary to turn a speed limiter restricts the speed to 20 mph 32 km h Pushing and holding the start override button in this mode allows you to momentarily over ride the 20 mph 32 km h speed limiter up to 40 mph 64 km h to help you free the vehicle in more severe conditions You should only use ...

Page 49: ...nd 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 4WD mode front differential...

Page 50: ...he 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 override button 3 2 differentia...

Page 51: ... starter motor will crank the engine The starter motor will not operate if the engine stop switch is in the OFF r position when the start override button is pushed To activate the speed limiter over ride mode see Front Differential Lock and Speed Limiter Over Ride Differential Lock Switch and Start Override Button page 38 Start Override Button LEFT HANDLEBAR 1 start override button START or SPEED ...

Page 52: ... 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 1 engine stop switch r OFF e RUN 19 TRX500FA5 FA6 FA7 31HR6640 book Page 42 Friday May 4 201...

Page 53: ... switch 2 is used to change between the high and low beams of the headlights and to activate the assist headlight To operate turn the switch to HI u for high beam of the headlights and activate the assist headlight LO i for low beam of the headlights and deactivate the assist headlight Headlight Switch y t Headlight Dimmer Switch u i LEFT HANDLEBAR 1 2 1 headlight switch y ON t OFF u HI i LO 2 hea...

Page 54: ...e recoil starter 1 is used to start the engine when the battery is low See Using the Recoil Starter Canada only page 88 Recoil Starter Canada only RIGHT SIDE 1 recoil starter 1 19 TRX500FA5 FA6 FA7 31HR6640 book Page 44 Friday May 4 2018 10 57 AM ...

Page 55: ...ver 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 throttle lever 1 A to open the throttle 19 TRX500FA5 FA6 FA7 31HR6640 book Page 45 Friday May 4 2018 10 57 AM ...

Page 56: ...de select switch 1 has two positions AUTO automatic shift mode and ESP manual shift mode See Shifting Gears page 89 Drive Mode Select Switch 1 drive mode select switch RIGHT HANDLEBAR 1 19 TRX500FA5 FA6 FA7 31HR6640 book Page 46 Friday May 4 2018 10 57 AM ...

Page 57: ... ESP manual shift mode These gearshift switches are used to select the next higher or lower gear in the transmission To operate press the upshift switch 1 to engage the next higher gear or press the downshift switch 2 to engage the next lower gear See Shifting Gears page 89 and Riding in Reverse page 96 Gearshift Switch LEFT HANDLEBAR 1 upshift switch 1 2 2 downshift switch 19 TRX500FA5 FA6 FA7 31...

Page 58: ...ing brake lever is used to slow or stop your ATV To operate pull the lever For information on braking techniques see page 98 The rear brake pedal is used to slow or stop your ATV To operate depress the pedal For information on braking techniques see page 98 Front Brake Lever Rear Brake Lever Parking Brake Lever Rear Brake Pedal 19 TRX500FA5 FA6 FA7 31HR6640 book Page 48 Friday May 4 2018 10 57 AM ...

Page 59: ...ver 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 2 1 P R lever 2 rear brake lever parking brake lever LEFT HANDLEBAR 19 TRX500FA5 FA6 FA7 31HR6640 book Page 49 Friday May 4 2018 10 57 AM ...

Page 60: ...ing see page 113 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 brake light is activated by applying the parking brake When using the parking brake be sure turn the ignition switch to OFF w to avoid discharging the battery To shift the transmission into reverse See R...

Page 61: ...ealer 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 flag pole bracket 1 19 TRX500FA5 FA6 FA7 31HR6640 book Page 51 Friday May 4 2018 10 57 AM ...

Page 62: ...oper 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 69 Trailer Hitch REAR 1 trailer hitch 1 2 ball 2 19 TRX500FA5 FA6 FA7 31HR6640 book Page 52 Friday May 4 2018 10 57 AM ...

Page 63: ... 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 1 accessory socket 2 front center cover 3 accessory socket cap 2 1 3 19 TRX500FA5 FA6 FA7 31HR6640 book Page 53...

Page 64: ...ery The accessory socket s rated capacity is DC 12 V 120 Watts 10 A or less If you exceed this limit you may blow a fuse See If a Fuse Blows page 232 When you are 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 54 Friday May 4 2018 10 57 AM ...

Page 65: ...e 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 1 utility box 2 utility box cover 3 stud 3 2 1 19 TRX500FA5 FA6 FA7 31HR6640 book Page 55 Friday May 4 2018 10 57 AM ...

Page 66: ...w the rear cargo rack 2 To open the compartment unhook the rubber strap 3 Be careful not to flood this area when washing your ATV Storage Compartment REAR 1 storage compartment 1 3 rubber strap 2 2 rear cargo rack 3 19 TRX500FA5 FA6 FA7 31HR6640 book Page 56 Friday May 4 2018 10 57 AM ...

Page 67: ...f 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 ind...

Page 68: ...Instruments Controls 58 19 TRX500FA5 FA6 FA7 31HR6640 book Page 58 Friday May 4 2018 10 57 AM ...

Page 69: ...your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride 60 Protective Apparel 60 Rider Training 62 Age Recommendation 63 No Passengers 63 No Alcohol or Drugs 64 Is Your ATV Ready to Ride 65 Pre ride Inspection 65 Load Limits Guidelines 69 Loading 69 Load Limits 70 Loading Guidelines 71 Accessories Modifications 72 Accessories 72 Modif...

Page 70: ...any alcohol or drugs in your system For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gloves long pants 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 ...

Page 71: ...protect your feet ankles and lower legs Off road motorcycle gloves to help protect your hands Riding pants with knee and hip pads a riding jersey with padded elbows and a chest shoulder protector WARNING 3WARNING 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 a crash Alway...

Page 72: ...ion about the ASI training course nearest you call the national toll free number 800 887 2887 USA only Other riding tips can be found in the Tips Practice Guide for the ATV Rider booklet that came with your ATV USA only Rider Training WARNING 3WARNING Operating this ATV without proper instruction could increase your risk of a crash which could lead to serious injury or death Beginning and inexperi...

Page 73: ...r cargo racks Age Recommendation WARNING 3WARNING A child using an ATV that is not recommended for their age could lose vehicle control while riding resulting in severe injury or death A child under 16 should never operate an ATV with engine size greater than 90cc No Passengers WARNING 3WARNING Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV and could ...

Page 74: ...ult your doctor to be sure it is safe to operate a vehicle after taking medication No Alcohol or Drugs WARNING 3WARNING Operating this ATV after consuming alcohol or drugs can seriously affect your judgment 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 19 TRX500FA5 FA6 FA7 31...

Page 75: ...ealer There may be damage or other problems you cannot see Check the following items before you get on the ATV WARNING 3WARNING Improperly maintaining this ATV or 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 ...

Page 76: ...s 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 164 and check the...

Page 77: ...ay 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 165 Brakes Squeeze the front and rear brake levers and step on the rear brake pedal to check that the controls operate normally Depress the rear brake pedal several times then check for proper rear brake lever parking brake lever...

Page 78: ...eadlights and Headlight Dimmer Switch Check for proper function page 43 Engine Stop Switch Check for proper function page 42 Steering Check that the wheels turn properly as you steer the handlebar Move the handlebar right and left and check that there is no excessive backlash 19 TRX500FA5 FA6 FA7 31HR6640 book Page 68 Friday May 4 2018 10 57 AM ...

Page 79: ...t 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 W...

Page 80: ...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 573 lb 260 kg includes the weight of the rider all cargo and accessories front cargo rack weight limit rear cargo rack weight limit tow weight limit 99 lb 45 kg 187 lb 85 kg 1 322 lb 600 kg Combined weight of the trailer and a...

Page 81: ... 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...

Page 82: ... 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 capacit...

Page 83: ...and braking making it unsafe to ride We also advise you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make your ATV illegal in your area Removing or modifying your lights exhaust system emission control system or other equipment can also make your ATV illegal Modifications 19 TRX500FA5 FA6 FA7 31HR66...

Page 84: ...Before Riding 74 19 TRX500FA5 FA6 FA7 31HR6640 book Page 74 Friday May 4 2018 10 57 AM ...

Page 85: ... life refer to Break in Guidelines page 249 Safe Riding Precautions 77 Off road Use Only 77 Keep Hands and Feet on Controls 78 Control Speed 79 Use Care on Unfamiliar or Rough Terrain 80 Do Not Perform Stunts 81 Starting Stopping the Engine 82 Preparation 83 Starting Procedure 84 Flooded Engine 85 Bank Angle Sensor Ignition Cut off System 85 Stalled Engine 86 How to Stop the Engine 87 Using the Re...

Page 86: ...our ATV 100 Making Turns 100 Skidding or Sliding 102 Riding Up Hills 103 Riding Down Hills 107 Crossing or Turning on Hills or Slopes 108 Riding Over Obstacles 110 Riding Through Water 111 Parking 113 19 TRX500FA5 FA6 FA7 31HR6640 book Page 76 Friday May 4 2018 10 57 AM ...

Page 87: ...r 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 3WARNING Operating this ATV on paved surfaces may serious...

Page 88: ...or one foot from the footpegs can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV WARNING 3WARNING Operating this 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 3WARNING Removing ha...

Page 89: ...er operating conditions plus your own skills and experience Control Speed WARNING 3WARNING Operating this ATV at excessive speeds increases your chances of losing control of the ATV which can result in a crash Always go at a speed that is proper for your vehicle the terrain visibility and other operating conditions and your experience 1 1 footpeg 19 TRX500FA5 FA6 FA7 31HR6640 book Page 79 Friday M...

Page 90: ...en rocks bumps or holes in time to react Use Care on Unfamiliar or Rough Terrain WARNING 3WARNING Failure to use extra care when operating this ATV on unfamiliar 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 19 TRX500FA5 FA6 FA7 31HR6640 bo...

Page 91: ...essively rough slippery or loose terrain could cause loss of traction or vehicle control which could result in a crash including an overturn Do not operate on 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 3WARNING Attemptin...

Page 92: ...ansmission will automatically return to neutral N when the ignition switch is turned to the ON q position The starter motor will operate when the transmission is in neutral or the front brake lever is pulled in WARNING 3WARNING 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 colorless odo...

Page 93: ... 2 Turn the ignition switch 1 to ON q Confirm the following The transmission is in neutral and the neutral indicator 2 is ON and the gear position indicator shows N The engine stop switch 3 is set to RUN e Preparation 1 1 ignition switch 3 2 neutral indicator 3 engine stop switch 2 19 TRX500FA5 FA6 FA7 31HR6640 book Page 83 Friday May 4 2018 10 57 AM ...

Page 94: ...rottle completely closed press the start override button The engine will not start if the throttle is fully open because the electronic control module cuts off the fuel supply Snapping the throttle or fast idling for more than 5 minutes may cause exhaust pipe and muffler discolorations Starting Procedure 19 TRX500FA5 FA6 FA7 31HR6640 book Page 84 Friday May 4 2018 10 57 AM ...

Page 95: ...ine 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 218 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 ignitio...

Page 96: ...t override button Do not press the throttle lever while starting in gear The engine will not start if the throttle is fully open because the electronic control module cuts off the fuel supply Once you have started the engine release the front brake lever then apply throttle gradually Stalled Engine 19 TRX500FA5 FA6 FA7 31HR6640 book Page 86 Friday May 4 2018 10 57 AM ...

Page 97: ...gine 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 How to Stop the Engine 19 TRX500FA5 FA6 FA7 31HR6640 book Pa...

Page 98: ...lowly approximately 4 in 100 mm 4 Pull the grip up briskly and fully 5 After the engine starts allow the starter grip to return slowly Pull the recoil starter grip 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 S...

Page 99: ...ndicator shows D for forward gears N for neutral and R for reverse Select gear position with the gear shift switches ESP manual shift mode In this mode you can shift gears much like a manual transmission but without operating a clutch You can select five forward gears neutral and reverse by operating the gearshift switches The gear position indicator will show 1 2 3 4 or 5 for forward gears N for ...

Page 100: ... R Manual 1 5 N R Two gearshift switches are located next to the left handlebar grip upshift and downshift To shift between a forward gear D or 1 neutral N or reverse R bring the ATV to complete stop and press a shift switch to select gear position Select neutral N when you start the engine or if it is necessary to stop briefly with the engine idling The gear position indicator shows N 1 1 drive m...

Page 101: ...ine and letting it warm up follow these procedures 1 With the transmission in neutral release the parking brake page 50 but continue to squeeze the rear brake lever parking brake lever 2 With the throttle closed select AUTO automatic shift mode and then press the upshift switch once to shift into drive D 3 The gear position indicator shows D 4 Release the rear brake lever parking brake lever and i...

Page 102: ...gear position indicator shows 1 4 Release the rear brake lever parking brake lever and increase engine speed by gradually opening the throttle 5 When speed increases release the throttle and upshift to 2nd gear by pressing the upshift switch once 6 Repeat this sequence to progressively upshift to 3rd 4th and 5th top gear 7 To downshift press the downshift switch 3 once Remember to close the thrott...

Page 103: ...tomatically downshift to the next lower gear If the ATV is at a complete stop 2nd gear 3rd gear 4th gear or 5th gear cannot be selected 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 224 m p h k m h ...

Page 104: ...nd the normal shifting points Downshift to a lower gear before you feel the engine laboring lugging at low rpm Avoid downshifting to help slow your ATV when engine 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 Shi...

Page 105: ...ransmission may be damaged Drive D range Drive is the normal position use this range for normal riding Low L range Use this range to get more power when climbing for maximum engine braking when going down steep hills and for towing If the range select lever will not move easily to another gear range rock the vehicle back and forth slightly to line up the gears in the sub transmission LEFT SIDE OF ...

Page 106: ...ar 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 3WARNING 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 rev...

Page 107: ...ot be shifted from neutral back into reverse when the engine speed is above 2 300 rpm or speed of your ATV is above 2 mph 3 km h The transmission cannot be shifted from reverse up to neutral when the engine speed is above 2 300 rpm or if the speed of your ATV is above 1 mph 1 5 km h If you turn the ignition switch to the OFF w position while in reverse the transmission will automatically return to...

Page 108: ... 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 when your ATV is in the ESP mode Gradually increase braking as you feel the brakes slowing your speed The increase in engine compression from downshifting will help slow your ATV when your ATV is in t...

Page 109: ...e 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 19 TRX500FA5 FA6 FA7 31HR6640 boo...

Page 110: ...ifferential lock mode will cause steering to be heavy and increase turning radius Making Turns WARNING 3WARNING Turning improperly can make the ATV go out of control 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 19 TRX500FA5 FA6...

Page 111: ...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 ...

Page 112: ...r 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 3WARNING Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly which...

Page 113: ...t 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 3WARNING 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 ...

Page 114: ...ear 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 104 ...

Page 115: ...n 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 either brake 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 ve...

Page 116: ...own 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...

Page 117: ...and survey the terrain below Never ride past the limit of your visibility Never go down a hill at high speed Riding Down Hills WARNING 3WARNING Going down a hill 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 107 F...

Page 118: ...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 S...

Page 119: ...ou 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 ...

Page 120: ... and be prepared to stop Never try to ride over large obstacles such as large rocks or fallen logs Riding Over Obstacles WARNING 3WARNING Improperly operating over 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 110 Friday M...

Page 121: ...ntrol system malfunction Have your ATV dealer inspect the oxygen sensor immediately after water enters the muffler Riding Through Water WARNING 3WARNING The ATV tires 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 a crash Never operate this ATV in fast flowing water or in water deeper than that s...

Page 122: ...void 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 112 Friday May 4 2018 10...

Page 123: ...arking brake When using the parking brake be sure to turn the ignition switch to OFF w to avoid discharging the battery Parking on a Steep Incline or a Loose or 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...

Page 124: ...Basic Operation Riding 114 19 TRX500FA5 FA6 FA7 31HR6640 book Page 114 Friday May 4 2018 10 57 AM ...

Page 125: ...the U S Environmental Protection Agency EPA and Environment Climate Change Canada ECCC see page 250 USA only Maintenance replacement or repair of the emission control devices and systems may be performed by any ATV repair establishment or individual using parts that are certified to EPA standards Before You Service Your Honda The Importance of Maintenance 117 Maintenance Safety 118 Important Safet...

Page 126: ... Rear Final Gear Oil 146 Front Final Gear Oil 149 Coolant 151 Air Cleaner 159 Engine Throttle 165 Reverse Inhibitor System 167 Spark Plug 168 Valves 171 Spark Arrester 172 Chassis Suspension 173 Brakes 176 Tires 185 Guards 192 Drivetrain Boots 193 Electrical Battery 194 Appearance Care 199 19 TRX500FA5 FA6 FA7 31HR6640 book Page 116 Friday May 4 2018 10 57 AM ...

Page 127: ... 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 3WARNING Improperly maintaining this ATV or failing to correct a probl...

Page 128: ... 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 3WARNING Failure to properly follow maintenance instruction...

Page 129: ...the tools and skills required To reduce the possibility of a fire or explosion be careful when working around gasoline Use only non flammable solvent not gasoline to clean parts Keep 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...

Page 130: ...echanical 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 Hond...

Page 131: ...intenance 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 the owner has proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual p...

Page 132: ...EGULAR Refer to page MAINT MAINT INTERVAL mi 100 600 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 FUEL LINE I THROTTLE OPERATION I 165 AIR CLEANER NOTE 1 C C 159 AIR CLEANER HOUSING DRAIN TUBE NOTE 2 I I 164 SPARK PLUG I I 168 VALVE CLEARANCE I I I 171 ENGINE OIL INITIAL 100 mi 150 km 20 operating hours or 1 month R 137 ENGINE OIL FILTER REGULAR Every 600 mi 1 000 km 100 operatin...

Page 133: ...AL mi 100 600 1200 km 150 1000 2000 MONTH 1 6 12 ITEMS NOTE HOURS 20 100 200 DRIVETRAIN BOOTS I I 193 FRONT REAR FINAL GEAR OIL R EVERY 2 YEARS I 146 149 RANGE SELECT SYSTEM I BRAKE FLUID NOTE 3 I I 176 BRAKE PADS WEAR NOTE 1 2 I 180 BRAKE LIGHT SWITCH I I I 184 BRAKE SYSTEM I I I 176 REVERSE INHIBITOR SYSTEM I I I 167 GUARDS I I 192 SUSPENSION I I 173 SPARK ARRESTER C C 172 NUTS BOLTS FASTENERS I...

Page 134: ...00 mile 150 km or 1 month or 20 hours initial maintenance is considered a normal owner operating cost and will be charged for by your dealer Use the space under Notes to record anything you want to remind yourself about or mention to your dealer Miles km or months or hours ODO or HOUR Date Performed By Notes 100 150 or 1 or 20 600 1 000 or 6 or 100 1 200 2 000 or 12 or 200 1 800 3 000 or 18 or 300...

Page 135: ... Maintenance Component Locations front brake fluid reservoir front brake lever fuel fill cap throttle lever P R lever rear brake lever parking brake lever reverse assist lever 19 TRX500FA5 FA6 FA7 31HR6640 book Page 125 Friday May 4 2018 10 57 AM ...

Page 136: ...ke caliper rear brake light switch rear brake pedal engine oil filter air cleaner front final gear oil fill cap front final gear oil drain bolt rear brake lever parking brake lever adjuster seat latch rear brake caliper engine oil fill cap 19 TRX500FA5 FA6 FA7 31HR6640 book Page 126 Friday May 4 2018 10 57 AM ...

Page 137: ... TRX500FA6 FA7 rear suspension spring pre load adjuster spark plug engine oil dipstick rear final gear oil fill cap rear final gear oil drain bolt coolant reserve tank spark arrester air cleaner housing drain tube owner s manual air pressure gauge 40 A spare fuse 19 TRX500FA5 FA6 FA7 31HR6640 book Page 127 Friday May 4 2018 10 57 AM ...

Page 138: ...e tool kit or the gear change tool be sure to use the rubber band 3 to fasten the tool kit and the gear change tool securely An optional larger tool kit may be available Check with your dealer s parts department REAR 1 2 1 tool kit 2 gear change tool 3 rubber band 3 19 TRX500FA5 FA6 FA7 31HR6640 book Page 128 Friday May 4 2018 10 57 AM ...

Page 139: ...nual 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 131 Be careful not to flood this area when washing your ATV 1 owner s manual 4 air pressure gauge REAR FENDER COVER UNDERSIDE 5 40 A spare fuse 2 plastic document bag 5 1 2 4 6 3 rear fender cover 6 rubber band 3 19 TRX500FA5 FA6 ...

Page 140: ...nual air pressure gauge and 40 A spare fuse 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 2 6 7 1 3 4 1 seat latch 2 seat 3 front prongs 5 hooks 6 studs 7 grommets 4 tank ...

Page 141: ...re fuse Removal 1 Remove the seat page 130 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 2 studs 3 grommets 4 rear fender cover 5 tabs 2 5 3 4 1 19 TRX500FA5 FA6 FA7 31HR6640 book Page 13...

Page 142: ...ce Removal 1 Remove the seat page 130 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 2 3 1 studs 2 tank cover assembly 3 tabs 1 3 19 TRX500FA5 FA6 FA7 31HR6640 book Page 132 Friday May 4 2018 10 57 AM ...

Page 143: ...ull up the center pin to release the lock 2 Pull out the clip of the hole Installation 1 Insert the clip into the hole 2 Press down the center pin securely to lock the clip 1 2 1 2 19 TRX500FA5 FA6 FA7 31HR6640 book Page 133 Friday May 4 2018 10 57 AM ...

Page 144: ...uels see page 254 Use of lower octane gasoline can cause persistent pinging or spark knock a loud rapping noise which if severe can lead to engine damage Light 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 gasoline If pinging or spark knock persists ...

Page 145: ...l 4 9 ℓ When there is only one segment left in the fuel gauge page 25 fuel will be low and you should refuel as soon as possible Refer to Safety Precautions on page 119 Fuel Capacity Refueling Procedure 1 1 fuel fill cap 2 lower edge of filler neck 2 19 TRX500FA5 FA6 FA7 31HR6640 book Page 135 Friday May 4 2018 10 57 AM ...

Page 146: ...lacement part or equivalent NOTICE Gasoline can damage the matte and camouflage coating Do not allow spilled gasoline to pool on matte and camouflage colored bodywork Also do not allow gasoline soaked rags to be placed on matte and camouflage bodywork WARNING 3WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat ...

Page 147: ...t 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 122 When running in very dusty conditions oil changes should be performed more frequently than specifi...

Page 148: ...rcular 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 sug...

Page 149: ...ed 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 139 Friday May 4 2018 10 57 AM ...

Page 150: ... 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 for 2 3 minutes 4 Remove the oil check lid 1 by disengaging the stud 2 from the grommet 3 and releasing the tabs 4 from the slits Checking Adding Oil LEFT SIDE 3 grommet 2 4 3...

Page 151: ... 6 Insert the dipstick without screwing it in then remove the dipstick and check the oil level The oil level should be between the upper level mark 6 and the lower level mark 7 on the dipstick LEFT SIDE 5 dipstick 7 lower level mark 6 upper level mark 5 6 7 19 TRX500FA5 FA6 FA7 31HR6640 book Page 141 Friday May 4 2018 10 57 AM ...

Page 152: ... and add the specified oil into the fill cap hole up to the upper level mark on the dipstick Do not over fill 8 Reinstall the engine oil fill cap and dipstick 9 Install the tank cover assembly 10 Install the seat 11 Install the oil check lid NOTICE Running the engine with an improper oil level can cause serious engine damage RIGHT SIDE 8 engine oil fill cap 8 19 TRX500FA5 FA6 FA7 31HR6640 book Pag...

Page 153: ...osing of the drained fluid page 214 If you do not have the skills or the tools see your dealer Change the oil with the engine warm to assure complete and rapid draining Drain the Engine Oil 1 With the ATV on the level ground remove the seat page 130 and the tank cover assembly page 132 and then remove the engine oil fill cap from the front right crankcase cover 2 Place an oil drain pan under the c...

Page 154: ...5 facing inward toward the engine Make sure the spring 6 and the OUT SIDE TOWARDS FILTER COVER mark 7 faces away from the engine toward the oil filter cover Use only 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 ...

Page 155: ...2 5 kgf m 2 Fill the crankcase with the recommended grade oil approximately 4 0 US qt 3 8 ℓ 3 Reinstall the engine oil fill cap and dipstick 4 Start the engine and let it idle for 3 5 minutes 5 Stop the engine wait for 2 3 minutes and check the oil level Make sure the oil is between the upper and lower level marks on the dipstick If necessary add more oil but do not overfill 6 Check that there are...

Page 156: ...il 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 suggested oil Honda shaft drive oil or equivalent Changing Oil 19 TRX500FA5 FA6 FA7 31HR6640 book Page 146 Friday May 4 2018 10 57 AM ...

Page 157: ...washer 4 4 After the oil has completely drained reinstall the drain bolt with a new sealing washer and tighten it to the specified torque 9 lbf ft 12 N m 1 2 kgf m 5 Pour the drained oil into a suitable container and dispose of it in an approved manner page 214 NOTICE Improper disposal of drained fluids is harmful to the environment 19 TRX500FA5 FA6 FA7 31HR6640 book Page 147 Friday May 4 2018 10 ...

Page 158: ...e lower edge of the oil fill inspection hole 5 7 Coat a new O ring with grease and install it into the fill cap groove and tighten it to the specified torque 9 lbf ft 12 N m 1 2 kgf m REAR 5 4 1 2 3 1 oil drain bolt 2 oil fill cap 3 O ring 4 sealing washer 5 oil fill inspection hole 19 TRX500FA5 FA6 FA7 31HR6640 book Page 148 Friday May 4 2018 10 57 AM ...

Page 159: ...il 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 suggested oil Honda shaft drive oil or equivalent Changing Oil 19 TRX500FA5 FA6 FA7 31HR6640 book Page 149 Friday May 4 2018 10 57 AM ...

Page 160: ...le container and dispose of it in an approved manner page 214 NOTICE Improper disposal of drained fluids is harmful to the environment 6 Fill the front final gear case with the recommended oil 11 0 US oz 325 cm3 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 torqu...

Page 161: ...abel Use only distilled water as a part of the coolant solution Water that is high in mineral content or salt may be harmful to the aluminum engine NOTICE Using coolant with silicate 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 s...

Page 162: ...119 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...

Page 163: ... 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 stud 4 7 6 grommet 7 reserve tank cap 5 6 19 TRX500FA5 FA6 FA7 31HR6640 book Page 153 Friday May 4 2018 10 57 AM ...

Page 164: ...58 To properly dispose of drained coolant refer to You the Environment page 214 NOTICE Improper disposal of drained fluids is harmful to the environment Coolant Replacement WARNING 3WARNING 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 19 TRX500FA5 FA6 FA7 31H...

Page 165: ... 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 TRX500FA5 The right left and center radiator grill covers must be removed to clean the radiator core TRX500FA6 FA7 The left and center radiator grill covers must be removed to clean the radiator core Radiator Core 19 TRX500FA5 FA6 FA7 31HR6640 book Page 155 Friday May...

Page 166: ...id page 153 2 Remove the reserve tank 1 by removing the bolt 2 and clips 3 page 133 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 2 bolt 3 clips 4 hoses 2 3 1 3 4 19 TRX500FA5 FA6 FA7 31HR6640 book Page 156 Friday May 4 2018 10 57 AM ...

Page 167: ...rill cover 11 by releasing the tab A tab B tab C hook A hook B and hose 12 then remove the center radiator grill cover 13 LEFT FRONT 3 clips 5 left radiator grill cover 6 tab A 7 tab B 8 tab C 9 hook A 10 hook B 10 6 7 3 8 5 9 RIGHT FRONT TRX500FA5 11 3 12 13 9 8 10 6 7 11 right radiator grill cover 12 hose 13 center radiator grill cover 19 TRX500FA5 FA6 FA7 31HR6640 book Page 157 Friday May 4 201...

Page 168: ...r 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 TRX500FA6 FA7 9 14 13 10 7 6 6 tab A 7 tab B 9 hook A 10 hook B 13 center radiator grill cover 14 radiator core 19 TRX500FA5 FA6 FA7 31HR6640 book Page 158 Friday May 4 2018 10 57 AM ...

Page 169: ...ervice 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 milea...

Page 170: ...age 130 2 Unlatch the spring hooks 1 and retainer clips 2 3 Remove the air cleaner housing cover 3 Cleaning UNDER SEAT 1 spring hooks 3 air cleaner housing cover 1 3 2 2 2 retainer clips 19 TRX500FA5 FA6 FA7 31HR6640 book Page 160 Friday May 4 2018 10 57 AM ...

Page 171: ... 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 Pro Honda Foam Filter Oil or an equivalent Canada Honda Foam Filter Oil or an equivalent over the entire surface of the air cleaner Use both hands to evenly spread the oil into the air cleaner Gently squeeze out any...

Page 172: ...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 UNDER SEAT 8 FRONT mark 9 9 tab 8 9 19 TRX500FA5 FA6 FA7 31HR6640 book Page 162 Friday May 4 2018 10 57 AM ...

Page 173: ...leaner Do not push the dust cover 1 too far into the breather joint 2 If the dust cover is dirty clean it Dust Cover UNDER SEAT 1 2 1 dust cover 2 breather joint 19 TRX500FA5 FA6 FA7 31HR6640 book Page 163 Friday May 4 2018 10 57 AM ...

Page 174: ...posits 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 1 drain tube 3 air cleaner housing 2 1 2 clip 3 19 TRX500FA5 FA6 FA7 31HR6640 book Page 164 Friday May 4 2018 10 57 AM ...

Page 175: ... 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 1 throttle lever 2 rubber sleeve 3 throttle cable adjuster 4 lock nut A decrease freeplay B increase freeplay 1 8 5 16 in 3 8 mm 2 A B 3 4 1 1...

Page 176: ...ions 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...

Page 177: ...sting 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 Inhibitor System Adjustment LEFT HANDLEBAR 1 1 dust cover 3 2 4 5 2 reverse assist lever 3 rubber sleeve ...

Page 178: ...ver assembly page 132 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 LEFT SIDE 1 spark plug cap 1 19 T...

Page 179: ... 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 0 039 0 043...

Page 180: ...osen 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 ...

Page 181: ...r 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 Service Manual Otherwise the valves should be adjusted by your dealer Valve Inspection intake 0 006 in 0 15 mm exhaust 0 009 in 0 23 mm 19 TRX500FA5 FA6 FA7 31HR6640 book Page 171 Friday May 4 2018 10 57 AM ...

Page 182: ...nment The use of safety glasses is recommended for this procedure Because of the possible fire hazard check that there are no combustible materials in the area before purging the spark arrester 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 creatin...

Page 183: ...ubtracting 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 whi...

Page 184: ...juster 1 has 5 positions for different load or riding conditions Use the pin spanner 2 to adjust the shock spring pre load Suspension Spring Pre Load 1 FRONT REAR 2 1 2 1 2 3 4 5 1 2 3 4 5 1 spring pre load adjuster 2 pin spanner 19 TRX500FA5 FA6 FA7 31HR6640 book Page 174 Friday May 4 2018 10 57 AM ...

Page 185: ...y loaded Also increase spring pre load for stiffer suspension Make sure that both shock absorbers are adjusted to the same position Always adjust the shock absorber 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 175 Friday May 4 2018 10 57 AM ...

Page 186: ...ver or brake pedal freeplay does not feel within the normal range while riding check the brake pads for wear page 180 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 The recommended brake fluid is Honda DOT 4 Brake Fluid or any brake fluid of equal quality and performan...

Page 187: ... 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 19 TRX50...

Page 188: ...bove the LOWER level mark 1 If the level is at or below the LOWER level mark check the brake pads for wear page 180 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks 1 RIGHT HANDLEBAR 1 LOWER level mark 19 TRX500FA5 FA6 FA7 31HR6640 book Page 178 Friday May 4 2018 10 57 AM ...

Page 189: ... pads for wear page 176 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 REAR 1 UPPER level mark 2 LOWER level mark 1 2 19 TRX500FA5 FA6 FA7 31HR6640 book Page ...

Page 190: ...lar 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 2 1 wear indicator 2 edge of reference mark 1 2 19 TRX500FA5 FA6 FA7 31HR6...

Page 191: ...ndicator 1 If the wear indicator aligns with the reference mark 2 both pads must be replaced see your dealer for this replacement RIGHT REAR 2 1 2 reference mark 1 wear indicator 19 TRX500FA5 FA6 FA7 31HR6640 book Page 181 Friday May 4 2018 10 57 AM ...

Page 192: ...r 1 moves before the brake starts to take hold Freeplay measurement at the tip of the end of the brake lever should be 1 1 3 16 in 25 30 mm 3 If necessary adjust to the specified range Rear Brake Lever Freeplay 1 LEFT HANDLEBAR 1 rear brake lever parking brake lever 1 1 3 16 in 25 30 mm 19 TRX500FA5 FA6 FA7 31HR6640 book Page 182 Friday May 4 2018 10 57 AM ...

Page 193: ...out on the adjusting nut is properly seated on the brake arm pin 3 Check that the brake lever and brake pedal assemblies are positioned properly and the securing bolts are tight Make sure that the brake cables brake arm spring P R lever and fasteners are in good condition Other Inspections 2 RIGHT REAR 2 brake lever adjusting nut 3 3 brake arm pin B A A increase freeplay B decrease freeplay 19 TRX...

Page 194: ... from time to time Adjustment is done by turning the adjusting nut 2 Hold the rear brake light switch and turn the nut in direction A if the switch operates too late and in direction B if the switch operates too soon Brake Light Switch Adjustment RIGHT REAR 1 rear brake light switch 1 2 A B 2 adjusting nut 19 TRX500FA5 FA6 FA7 31HR6640 book Page 184 Friday May 4 2018 10 57 AM ...

Page 195: ...lect your riding area with care The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations for tire repair and replacement WARNING 3WARNING Using tires 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 owne...

Page 196: ...y underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Overinflated tires 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 Air Pressure 19 TRX500FA5 FA6 FA7 31HR6640 book Page 186 Friday May 4 2018 10 57 AM ...

Page 197: ...s will be higher If you let air out of warm tires to match the recommended cold tire pressures the tires will be underinflated Be sure to check tire pressure at the riding site since changes in altitude can affect air pressure The recommended cold tire pressures are FRONT REAR RECOMMENDED PRESSURE 4 4 psi 30 kPa 4 4 psi 30 kPa 19 TRX500FA5 FA6 FA7 31HR6640 book Page 187 Friday May 4 2018 10 57 AM ...

Page 198: ...o look for Bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Cuts slits or cracks in the tires Replace the tire if you can see fabric or cord Nails or other foreign objects embedded in the side of the tire or tread Excessive tread wear WARNING 3WARNING Operating this ATV with improper tires or with uneven tire pressure may cause loss of control and you ...

Page 199: ...ire tread measure the groove depth 1 in the center of the tire or check the wear indicator 2 For best performance you should replace a tire before the tread depth at the center reaches the following limits front 3 16 in 4 mm rear 3 16 in 4 mm 3 2 1 3 16 in 4 mm 1 groove depth 2 wear indicator 3 wear indicator location mark Replace NEW 19 TRX500FA5 FA6 FA7 31HR6640 book Page 189 Friday May 4 2018 1...

Page 200: ...or permanently repaired as soon as possible For more information on temporary repairs see If You Have a Flat Tire page 226 A permanent repair such as an internal plug patch can be made if a tire 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 tire repaired be sure the repair work is performed by a professional If you ha...

Page 201: ...ire The recommended tires for your ATV are When you replace a tire remember Have the tire replaced by your dealer if possible If you have a tire professionally replaced at a non Honda facility we recommended that you have the work checked by your dealer Tire Replacement WARNING 3WARNING Installing improper tires on your ATV can affect handling and stability This can cause a crash in which you can ...

Page 202: ...ft guards 5 protect the rubber driveshaft boots and the rear driveshafts Check the guards and plate for cracks damage or looseness at intervals shown in the Maintenance Schedule Have the guards and skid plate replaced if they are cracked or damaged If the guard and plate bolts are loose tighten them securely 1 1 engine guard 2 2 skid plate 3 front boot guards 4 front driveshaft guards 5 rear drive...

Page 203: ...ts 1 rubber propeller shaft boots 2 and rubber yoke joint boot 3 for cuts damage or leaking grease If necessary have your dealer replace them 1 1 rubber driveshaft boots 2 rubber propeller shaft boots 2 1 3 rubber yoke joint boot FRONT REAR 3 2 19 TRX500FA5 FA6 FA7 31HR6640 book Page 193 Friday May 4 2018 10 57 AM ...

Page 204: ...ectrical accessories on your ATV or do not ride frequently we recommend that you charge the battery frequently see Battery Charging page 198 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 195 If your battery seems weak and or is lea...

Page 205: ...ving the battery and slow charging it every 30 days see Battery Charging page 198 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 3WARNING 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 ...

Page 206: ... 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 4 1 rubber band 2 negative terminal lead 4 positive terminal lead 5 terminal nuts UNDER REAR FENDER COVER 3 2 1 5 3 battery 19 TRX500FA5 FA6 FA7 31HR6640 book Page 196 Friday ...

Page 207: ...allation 1 Check that the battery rubber 5 for damage If necessary replace the battery rubber 2 Make sure the battery rubber is properly installed 3 Reinstall the 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 After the batt...

Page 208: ...r 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 Char...

Page 209: ...ld damage the metal paint plastic and camouflage coating on your ATV Honda SxS If your ATV is still warm from recent operation give the engine and exhaust system time to 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 t...

Page 210: ...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...

Page 211: ...nd 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 aluminum Ap...

Page 212: ...th dirt mud or road salt Clean the wheels after riding through any of these substances Use a wet sponge and mild detergent Avoid stiff brushes steel wool or cleaners containing abrasives or chemical compounds After washing rinse with plenty of water and dry with a clean cloth Then apply a mild commercially available spray cleaner polish or wax For stained or dull looking wheels use a quality chrom...

Page 213: ...h 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 Do not use wax or polishing compounds on matte painted surfaces If a surface on your ATV is chipped or scratched your dealer has touch up paint to match your ATV s color Be sure to use your A...

Page 214: ...Servicing Your Honda 204 19 TRX500FA5 FA6 FA7 31HR6640 book Page 204 Friday May 4 2018 10 57 AM ...

Page 215: ... be an environmentally responsible ATV owner Preparing for a Ride 206 What to Take to the Riding Area 206 What to Take on the Trail 207 Transporting Your Honda 208 Storing Your Honda 210 Preparation for Storage 211 Removal from Storage 213 You the Environment 214 19 TRX500FA5 FA6 FA7 31HR6640 book Page 205 Friday May 4 2018 10 57 AM ...

Page 216: ...od sources of information Along with your ATV and riding gear you should take along some tools and supplies in case you have a problem For some of the difficulties you might encounter see Taking Care of the Unexpected which begins on page 216 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...

Page 217: ...elp 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 limits page 70 What to Take on the Trail 19 TRX500FA5 FA6 FA7 31HR6640 book Page 207 Friday May 4 2018 10 57 AM ...

Page 218: ...mend that you carry the vehicle in its normal operating position on all four wheels Do not incline the vehicle upright on its rear end This can damage the vehicle and leaking gasoline could be a hazard Follow these procedures 1 Set the parking brake 19 TRX500FA5 FA6 FA7 31HR6640 book Page 208 Friday May 4 2018 10 57 AM ...

Page 219: ...s 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 1 4 3 1 front cargo rack 2 front carry pipe 3 rear cargo rack 2 4 trailer hitch 19 TRX500FA5 FA6 FA7 31HR6640 book Page 209 Friday May 4 2018 10 57 AM ...

Page 220: ...gotten and it will be easier to get your ATV running again For more information about storage refer to the Honda Winter Storage Guide available from your dealer USA only 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 TRX500FA5 FA6 FA7 31HR6640 book Page 210 Friday May 4 2018 1...

Page 221: ...wing Remove the spark plug cap from the spark plug page 168 Remove the spark plug Do not connect the spark plug to the spark plug cap Pour a tablespoon 15 20 cc 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 override button several times to crank the engine and distribute the oil Reinstall ...

Page 222: ...a porous material Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate NOTICE Do not store your ATV in an upright position for extended periods of time The ATV should be stored with all four tires on the ground This can damage the vehicle and leaking gasoline could be a hazard WARNING 3WARNING The battery gives off explosive...

Page 223: ...ge the engine oil page 143 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 198 as required Install the battery 5 Perform a pre ride inspection page 65 then test ride your ATV at low speeds Removal from Storage 19 TRX500FA5 FA6 FA7 31HR6640 book Page 213 Friday May 4 2018 10 57 AM ...

Page 224: ...ose 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 ga...

Page 225: ... section before you ride Also review the tips in Preparing for a Ride page 206 General Guidelines 216 If Your Engine Quits or Won t Start 218 If the Transmission Is Not Functioning Properly 221 Emergency Gear Selection Operation 224 If You Have a Flat Tire 226 If the High Coolant Temperature Indicator Lights 230 If a Fuse Blows 232 If You Crash 237 If You Lose Your Key 238 If the Battery Is Low or...

Page 226: ...ause 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 tempora...

Page 227: ...our 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 19 TRX500FA5 FA6 FA7 31HR6640 book Page 217 Friday May 4 2...

Page 228: ... 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 override 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 ...

Page 229: ...rge the battery page 198 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 85 loose or unconnected spark plug cap Install the spark plug cap securely If ...

Page 230: ...our dealer sooty exhaust rich fuel mixture See your dealer detonates or pings under load If applicable switch to the recommended octane gasoline page 134 or change your brand of gasoline 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 W...

Page 231: ... 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 224 19 TRX500FA5 FA6 FA7 31HR6640 boo...

Page 232: ...osition 3 After the engine stops turn the ignition switch to the ON q position 4 Check the gear position indicator If these efforts do not restore proper operation have your ATV inspected by your dealer When the is blinking in the gear position indicator Restart the engine drive the ATV to a location where it can be loaded and transported to your dealer When the display on the gear position indica...

Page 233: ...page 50 3 Turn the ignition switch to the OFF w position 4 Loosen the screw 1 and release the lock plate 2 5 Locate the emergency valve access hole 4 inside the left front fender Using a screwdriver turn the emergency valve 3 all the way in With the engine running slowly open the throttle to move the ATV forward 6 See your dealer as soon as possible When the battery is low or dead See If the Batte...

Page 234: ... If the transmission is in neutral go to step 5 If the transmission is not in neutral use the gear change tool to shift to neutral so you will be able to start the engine Refer to How to Shift Gears Manually page 225 5 Apply the parking brake page 50 6 Press the start override button to start the engine 7 Set 2nd gear position Refer to How to Shift Gears Manually page 225 8 Return the gear change ...

Page 235: ... again Return the gear change tool to the storage location Do not attempt to shift gears manually using the gear change tool while riding If the transmission is 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 ...

Page 236: ...ossible have the tire permanently repaired by your dealer Any tire 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 tire pump and a repair kit with the vehicle If the leak is more serious or a temporary repair doesn t hold the tire must be replaced The tire will also need to be replac...

Page 237: ...orary tire repair can be risky If the temporary repair fails you can crash and be seriously injured or killed If you must ride with a temporary tire repair ride slowly and carefully until the tire is permanently repaired or replaced 19 TRX500FA5 FA6 FA7 31HR6640 book Page 227 Friday May 4 2018 10 57 AM ...

Page 238: ...our ATV on a firm level surface Emergency Wheel Removal Installation 1 2 Wheel nuts 47 lbf ft 64 N m 6 5 kgf m Wheel nuts 62 lbf ft 84 N m 8 6 kgf m TRX500FA5 FA6 Steel wheel model TRX500FA7 Aluminum wheel model 1 1 1 2 1 wheel nuts 2 wheel rim 19 TRX500FA5 FA6 FA7 31HR6640 book Page 228 Friday May 4 2018 10 57 AM ...

Page 239: ...y Installation 1 Position the wheel 2 Position each wheel nut so that the tapered side faces the wheel rim 2 3 Hand tighten the wheel nuts on the wheel then lower the ATV to the ground before tightening the nuts in a crisscross rather than circular pattern to the specified torque If a torque wrench was not used for installation see your dealer as soon as possible to verify proper assembly Improper...

Page 240: ...ne 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 ...

Page 241: ...recommended oil page 140 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 ...

Page 242: ...e looking elsewhere for another possible cause of the problem Replace any blown fuses and check component operation The main fuse and the circuit fuses are located under the rear fender cover TRX500FA6 FA7 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 ES shift motor fuse 30 A other fuses 20 A 3 10 A EPS Electric Powe...

Page 243: ...31 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 129 If the main fuse 2 is blown install the spare fuse 6 7 Install the fuse cover 2 main fuse 1 5 fuse box cover 5 6 spare fuse UNDER REAR FENDER COVER 6 3 fuse cover 3 2 4 main fuse 2 4 19 TRX500FA5 FA6...

Page 244: ...ting 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 TRX500FA5 FA6 FA7 31HR6640 book Page 234 Frid...

Page 245: ...page 130 3 Remove the rear fender cover page 131 4 To access the EPS fuse 1 remove the EPS fuse box cover 2 If the EPS block fuse is blown install the spare fuse page 129 5 Install the EPS fuse box cover 6 Install the rear fender cover 7 Install the seat 2 UNDER REAR FENDER COVER 1 EPS fuse 2 EPS fuse box cover 1 19 TRX500FA5 FA6 FA7 31HR6640 book Page 235 Friday May 4 2018 10 57 AM ...

Page 246: ... 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 TRX500...

Page 247: ... 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 ...

Page 248: ... 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 1 1 key number 19 TRX500FA5 FA6 FA7 ...

Page 249: ...d 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 the storage compartment page 128 5 Use the gear change tool to shift ...

Page 250: ...plies 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 19 ...

Page 251: ...ns capacities and other technical data plus information on government requirements and how to break in your ATV Vehicle Identification 242 Specifications 244 Break in Guidelines 249 Emission Control Systems 250 Oxygenated Fuels 254 19 TRX500FA5 FA6 FA7 31HR6640 book Page 241 Friday May 4 2018 10 57 AM ...

Page 252: ...e numbers in the Quick Reference section at the rear of this manual The VIN 1 is stamped on the front of the frame Remove the radiator cap lid page 153 The engine number 2 is stamped on the upper side of the rear crankcase Serial Numbers FRONT 1 1 VIN LEFT REAR 2 engine number 2 19 TRX500FA5 FA6 FA7 31HR6640 book Page 242 Friday May 4 2018 10 57 AM ...

Page 253: ... left side of the frame The color code is helpful when ordering replacement parts You may record the color and code in the Quick Reference section at the rear of this manual Color Label Code LEFT SIDE 1 1 color label 19 TRX500FA5 FA6 FA7 31HR6640 book Page 243 Friday May 4 2018 10 57 AM ...

Page 254: ...ng reserve fuel tank reserve 1 29 US gal 4 9 ℓ engine oil capacity after disassembly 4 6 US qt 4 4 ℓ after draining 3 8 US qt 3 6 ℓ after draining oil filter change 4 0 US qt 3 8 ℓ 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 Pro Honda GN4 4 strok...

Page 255: ... ℓ Capacities passenger capacity operator only maximum weight capacity 573 lb 260 kg rider all cargo and accessories Engine Specifications displacement 29 0 cu in 475 cm3 bore stroke 3 62 2 81 in 92 0 71 5 mm compression ratio 9 5 1 spark plug standard BKR5E 11 NGK or K16PR U11 DENSO spark plug gap 0 039 0 043 in 1 00 1 10 mm valve clearance cold intake 0 006 in 0 15 mm exhaust 0 009 in 0 23 mm id...

Page 256: ... 153 transmission ratio 1st 3 058 2nd 2 157 3rd 1 588 4th 1 181 5th 0 848 reverse 3 996 final drive shaft Chassis Suspension caster 1 trail 0 04 in 1 mm tire size front AT25 8 1211 MAXXIS MU25 tire size rear AT25 10 1211 MAXXIS MU26 tire pressure front rear cold front 4 4 psi 30 kPa rear 4 4 psi 30 kPa 19 TRX500FA5 FA6 FA7 31HR6640 book Page 246 Friday May 4 2018 10 57 AM ...

Page 257: ...ight 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 TRX500FA6 FA7 LED Fuses main 1 40 A main 2 10 A ES shift motor 30 A other 20 A 3 10 A EPS Electric Power Steering TRX500FA6 FA7 40 A 19 TRX500FA5 FA6 FA7 31HR6640 book Page 247 Friday May 4 2018 10 57 AM ...

Page 258: ...lt 9 lbf ft 12 N m 1 2 kgf m rear final gear oil fill cap 9 lbf ft 12 N m 1 2 kgf m front final gear oil drain bolt 9 lbf ft 12 N m 1 2 kgf m front final gear oil fill cap 9 lbf ft 12 N m 1 2 kgf m wheel nuts TRX500FA5 FA6 Steel wheel model 47 lbf ft 64 N m 6 5 kgf m TRX500FA7 Aluminum wheel model 62 lbf ft 84 N m 8 6 kgf m 19 TRX500FA5 FA6 FA7 31HR6640 book Page 248 Friday May 4 2018 10 57 AM ...

Page 259: ...liability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts rapid acceleration and constant rpm operation 19 TRX500FA5 FA6 FA7 31HR6640 book Page 249 Friday May 4 2018 10 57 AM ...

Page 260: ...fe when operated and maintained according to the instructions provided The Vehicle Emission Control Information Label 1 is attached on the left front of the frame Canada only The Vehicle Emission Control Information Label 2 is attached on the left side of the frame LEFT FRONT 1 2 vehicle emission control information label Canada only LEFT SIDE 2 1 vehicle emission control information label 19 TRX5...

Page 261: ...carbon monoxide oxides of nitrogen and hydrocarbons Exhaust Emission Control System The exhaust emission control system includes a PGM FI system and oxygen sensor No adjustment to this system should be made although periodic inspection of the components is recommended The exhaust emission control system is separate from the crankcase emission control system Crankcase Emission Control System The en...

Page 262: ...nomy Federal regulations prohibit removing or disabling a device or element of design that may affect your engine s emission performance unless your ATV will be used exclusively in competition If you modify your engine for use in sanctioned competition events you must deface or destroy the emission control information label If you loan sell or give your competition modified Honda ATV to someone el...

Page 263: ...FOLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part of the intake system Lack of proper maintenance Removing or disabling any emissions compliance component or replacing any compliance component with a non compliant component Fuel Permeation Emission Control System This vehicle complies wi...

Page 264: ...to be posted on the pump The following are the EPA approved percentages of oxygenates for non road vehicles ETHANOL ethyl or grain alcohol up to 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol Do not use gasoline containing more than 10 ethanol by volume The use of gasoline containing a higher percentage e g...

Page 265: ...l system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Oxygenated fuels can damage paint and plastic Be careful not to spill fuel when filling t...

Page 266: ...Technical Information 256 19 TRX500FA5 FA6 FA7 31HR6640 book Page 256 Friday May 4 2018 10 57 AM ...

Page 267: ...section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 258 Warranty Coverage 259 Warranty Service 260 Contacting Honda 261 Your Honda Dealer 262 19 TRX500FA5 FA6 FA7 31HR6640 book Page 257 Friday May 4 2018 10 57 AM ...

Page 268: ...our Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician but most mechanically capable owners should find them easy to use if they have the proper tools and observe proper safety standards Special Honda tools are necessary for some procedures Order On Line www helminc com Order Toll Free 1 888 CYCLE93 1 888 292 5393 NOTE For Credit...

Page 269: ...a ca It is important to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage does not apply to normal wear or deterioration associated with using the ATV Your warranty coverage will not be voided if you choose to perform your own maintenance However you should have the proper tools and service information and be mechanically qualified Failur...

Page 270: ... If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the repair it is best to talk to the Service Manager of your dealer Sometimes in spite of the best intentions of all concerned a misunderstanding may occur If you aren t satisfied with your dealer s handling of the situation we suggest you d...

Page 271: ...ment on your experiences with your Honda or with your dealer please send your comments to the following address Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance CA 90509 2200 mailstop 100 4C 7B telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsimile 877 939 0909 E mail honda_cr ch honda...

Page 272: ...ada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the parts department The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage USA only Your Honda dealer can inform you about competition and other riding events in your are...

Page 273: ...Consumer Information 263 19 TRX500FA5 FA6 FA7 31HR6640 book Page 263 Friday May 4 2018 10 57 AM ...

Page 274: ...apparel protective 60 appearance care 199 authorized manuals 258 B bank angle sensor ignition cut off system 85 battery 194 brake light switch adjustment 184 brakes cables 183 fluid 176 front brake lever 48 pad wear 180 parking 48 rear brake lever 48 rear brake lever freeplay 182 rear brake pedal 48 braking 98 break in guidelines 249 19 TRX500FA5 FA6 FA7 31HR6640 book Page 264 Friday May 4 2018 10...

Page 275: ...33 color label 243 compartment owner s manual 129 storage 56 tool kit 128 component fails 240 consumer information 257 controls features 35 coolant temperature gauge 29 crash if you 237 crossing or turning on hills or slopes 108 customer service 261 D differential lock switch 38 digital clock 27 dimmer switch headlight 43 dipstick 140 display check 16 19 TRX500FA5 FA6 FA7 31HR6640 book Page 265 Fr...

Page 276: ...85 guard 192 number 242 oil 137 pinging 134 starting 82 stop switch 42 stopping 87 won t start 218 environment 214 exhaust system cleaning 66 purging 172 F final gear oil front 149 rear 146 flag pole bracket 51 flat tire 226 flooded engine 85 front boots guards 192 front differential lock 38 front driveshaft boots 193 19 TRX500FA5 FA6 FA7 31HR6640 book Page 266 Friday May 4 2018 10 57 AM ...

Page 277: ...es 232 G gap spark plug 168 245 gasohol 254 gasoline 134 gear shifting 89 gearshift switch 47 guards 192 H headlight dimmer switch 43 headlight switch 43 high coolant temperature indicator 14 17 230 hills crossing or turning on slopes 108 riding down hills 107 riding up hills 103 stopping on hills 105 Honda service manual 258 19 TRX500FA5 FA6 FA7 31HR6640 book Page 267 Friday May 4 2018 10 57 AM ...

Page 278: ...olant temperature indicator 14 17 230 LOW indicator 20 23 maintenance minder indicator 32 neutral indicator 14 17 PGM FI indicator 14 17 PS Electric Power Steering indicator TRX500FA6 FA7 14 18 reverse indicator 14 17 inspection pre ride 65 K key lost 238 number 238 kit tool 128 L labels safety 5 lamp check 15 lever P R 49 range select 36 19 TRX500FA5 FA6 FA7 31HR6640 book Page 268 Friday May 4 20...

Page 279: ...31 importance 117 minder indicator 32 precautions 119 record 124 safety 118 schedule 120 tripmeter 32 manual service 258 maximum weight limit 70 mode button 14 19 modifications 73 multi function display 20 N neutral indicator 14 17 noise emission control system 253 numbers serial 242 O obstacles riding over 110 odometer 28 19 TRX500FA5 FA6 FA7 31HR6640 book Page 269 Friday May 4 2018 10 57 AM ...

Page 280: ...plug spark 168 pre ride inspection 65 problems unexpected 216 propeller shaft boots 193 protective apparel 60 EPS Electric Power Steering TRX500FA6 FA7 57 R range select lever 36 rear driveshaft boots 193 rear driveshaft guards 192 rear fender cover removal 131 rear final gear oil 146 recoil starter Canada only 44 88 removal rear fender cover 131 seat 130 tank cover assembly 132 19 TRX500FA5 FA6 F...

Page 281: ... basic operation 75 clothing 60 over obstacles 110 precautions 77 preparing for 206 safety 2 safety precautions 77 through water 111 S safety important precautions 119 labels 5 riding precautions 77 schedule maintenance 120 seat removal 130 serial numbers 242 service customer 261 manuals 258 warranty 260 shifting gears 93 19 TRX500FA5 FA6 FA7 31HR6640 book Page 271 Friday May 4 2018 10 57 AM ...

Page 282: ... 105 start override button 41 starting engine 82 troubleshooting 218 stop switch engine 42 stopping engine 87 storage ATV 210 owner s manual 129 suspension adjustment 173 spring pre load 174 switch 4WD 37 differential lock 38 downshift 47 92 drive mode select 46 engine stop 42 headlight 43 headlight dimmer 43 ignition 35 upshift 47 92 19 TRX500FA5 FA6 FA7 31HR6640 book Page 272 Friday May 4 2018 1...

Page 283: ...er hitch 52 trailer towing operational guidelines 71 weight limits 70 training rider 62 transmission range select 95 transporting your ATV 208 tripmeter 28 trouble unexpected 215 troubleshooting starting 218 turning on hills or slopes 108 on level ground 100 U utility box 55 V valve clearance 171 vehicle identification no VIN 242 19 TRX500FA5 FA6 FA7 31HR6640 book Page 273 Friday May 4 2018 10 57 ...

Page 284: ...labels 5 warranty coverage 259 extended 259 service 260 washing your ATV 200 water riding through 111 weight limit 70 wheel removal 228 Y yoke joint boot 193 19 TRX500FA5 FA6 FA7 31HR6640 book Page 274 Friday May 4 2018 10 57 AM ...

Page 285: ...pensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly repairs are Engine oil insufficient quantity improper oil Air cleaner dirty leaking because of improper installation poor seal Record important information on the following page How To Avoid Costly Repairs 19 TRX500FA5 FA6 FA7 31HR6640...

Page 286: ...ference Quick Reference Engine No VIN Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 19 TRX500FA5 FA6 FA7 31HR6640 book Page 277 Friday May 4 2018 10 57 AM ...

Page 287: ...lever switches steering Fuel Capacity unleaded gasoline pump octane number 86 or higher 3 88 US gal 14 7 ℓ reserve 1 29 US gal 4 9 ℓ Engine Oil Capacity 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 Pro Honda GN4 4 stroke oil or equivalent after draining 3 8 US qt 3 6 ℓ aft...

Page 288: ...tandard BKR5E 11 NGK or K16PR U11 DENSO Coolant ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Honda HP Coolant or an equivalent distilled water Fuses main 1 40 A main 2 10 A ES shift motor 30 A other 20 A 3 10 A EPS Electric Power Steering TRX500FA6 FA7 40 A 19 TRX500FA5 FA6 FA7 31HR6640 book Page 279 Friday May 4 2018 10 57 AM ...

Page 289: ...rt override button 41 e RUN engine stop switch 42 r OFF engine stop switch 42 y ON headlight switch 43 t OFF headlight switch 43 u HI headlight dimmer switch 43 i LO headlight dimmer switch 43 AUTO automatic shift mode drive mode select switch 46 ESP manual shift mode drive mode select switch 46 upshift switch gearshift switch 47 downshift switch gearshift switch 47 Parking Brake Reverse Lever P R...

Page 290: ...own to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle 19 TRX500FA5 FA6 FA7 31HR6640 b...

Page 291: ...PRINTED IN USA WPCXXXX 2018 XX 19 00X31 HR6 6400 31HR6640 ...

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