Page 1 2009 Honda TRX500FM/FPM FOURTRAX FOREMAN 4 4 with Power Steering × OWNER’S MANUAL FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. USA only: It conforms to US EPA Noise Emission regulations, but does not...
Page 2 Introduction Congratulations on choosing your Honda ATV. When you own a Honda, you’re part of a worldwide family of satisfied customers − people who appreciate Honda’s reputation for building quality into every product. Your Honda was designed as a recreational ATV for off-road use by one rider only.
Page 3 Honda dealer knows your ATV best and is dedicated to your complete satisfaction. Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important product information.
Page 4 A Few Words About Safety Your safety, and the safety of others, is very important. And operating this ATV safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.
Page 5 A Few Words About Safety These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions.
Page 6 Contents These pages give an overview of the contents of your owner’s manual. The first page of each section lists the topics covered in that section. ATV Safety ..................Important safety information you should know, plus a look at the safety-related labels on your ATV.
Page 7 Contents Servicing Your Honda ..............Why your ATV needs regular maintenance, what you need to know before servicing your Honda, an owner maintenance schedule, and instructions for specific maintenance and adjustment items. Tips ....................How to store and transport your ATV and how to be an environmentally responsible rider.
Page 9 ATV Safety This section presents some of the most important information and recommendations to help you ride your ATV safely. Please take a few moments to read these pages. This section also includes information about the location of safety labels on your ATV. Important Safety Information ...............
Page 10 Important Safety Information Your ATV can provide many years of service and pleasure if you take responsibility for your own safety and understand the challenges you can meet while riding. There is much that you can do to protect yourself when you ride. You’ll find many helpful recommendations throughout this manual.
Page 11 Important Safety Information Ride Off-road Only Your ATV is designed and manufactured for off-road use only. The tires are not made for pavement, and the ATV does not have turn signals and other features required for use on public roads. If you need to cross a paved or public road, get off and walk your ATV across.
Page 12 So don’t drink and ride, and don’t let your friends drink and ride either. Keep Your Honda in Safe Condition It’s important to keep your ATV properly maintained and in safe riding condition. Having a breakdown can be difficult, especially if you are stranded off-road far from your base.
Page 13 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 Honda dealer for replacements. ATV Safety...
Page 14 Safety Labels ATV Safety...
Page 15 Safety Labels TRX500FM TRX500FPM ATV Safety...
Page 16 Safety Labels (For Canada) ATV Safety...
Page 17: Table Of Contents
Instruments & Controls This section shows the location of all indicators and controls you would normally use before or while riding your ATV. The items listed on this page are described in this section. Instructions for other components are presented in other sections of this manual where they will be most useful.
Page 18 Instruments & Controls Controls & Features ................Fuel Valve ..................Choke Knob ..................Ignition Switch .................. 2WD/4WD Select Switch ..............Start Button ..................Engine Stop Switch ................Headlight Switch ................Headlight Dimmer Switch ..............Starting Primer Knob ................ Recoil Starter ..................
Page 19: Operation Component Locations
Operation Component Locations reverse selector knob parking brake lock lever choke knob headlight switch front brake lever rear brake lever/ parking brake lever 2WD/4WD select switch throttle lever headlight dimmer switch engine stop switch start button ignition switch Instruments & Controls...
Page 20 Operation Component Locations rear cargo rack seat lock lever front cargo rack starting primer knob recoil starter rear brake pedal Instruments & Controls...
Page 21 Operation Component Locations accessory socket fuel valve utility box flag pole bracket trailer hitch shift lever storage compartment Instruments & Controls...
Page 22: Indicators & Displays
Indicators & Displays The indicators and displays on your ATV keep you informed, alert you to possible problems, and make your riding safer and more enjoyable. Refer to the indicators frequently. Their functions are described on the following pages. TRX500FM TRX500FPM (4) (5) (6) (7) (4) (5) (6) (7)
Page 23 ) and remain on until you shift out of reverse or neutral. If one of these indicators does not come on when it should, have your Honda dealer check for problems. Display Check When the ignition switch is turned ON (...
Page 24 Lights when the drive mode is in the 4WD mode. The 4WD indicator blinks if there is a possible problem with the 2WD/4WD select system. See your Honda dealer as soon as possible. Lamp Check High oil Lights when engine oil temperature...
Page 25 Indicators & Displays Multi-function The display includes the following display functions. Display Check. Gear position Shows the gear position (page indicator Speedometer Shows riding speed. Fuel gauge Shows approximate fuel supply available (page Oil change Lights when specified maintenance indicator interval for engine oil change is reached (page Odometer...
Page 26: Multi-Function Display
Indicators & Displays Multi-function Display The multi-function display ( ) includes the following functions: Gear position indicator Tripmeter Oil change indicator Digital clock Speedometer Hourmeter Odometer Fuel gauge TRX500FM: The digital clock will reset if the battery is disconnected. TRX500FPM: The digital clock and tripmeter will reset if the battery is disconnected.
Page 27: Gear Position Indicator
If the gear position indicator shows ‘‘- -’’ and blinks, turn the ignition switch to the OFF ( ) position, and then turn it back to the ON ( position again. If the gear position indicator still shows ‘‘- -’’ and blinks, see your Honda dealer. TRX500FM TRX500FPM (1) gear position indicator...
Page 28: Oil Change Indicator
Indicators & Displays Oil Change Indicator The oil change indicator ( ) appears in the display when the mileage or operating hours on your ATV approaches the oil change interval specified on the maintenance schedule. Reset the indicator after each oil change. To reset the indicator, press and hold both the odometer/tripmeter select button ( ) and RESET button ( ) for more than 2 seconds.
Page 29: Odometer/Tripmeter
Indicators & Displays Odometer/Tripmeter The odometer/tripmeter display has two functions, odometer ( ) and tripmeter. The tripmeter has two sub modes, tripmeter A ( ) and tripmeter B ( ). The odometer registers total distance traveled in miles while the ignition switch is ON ( ).
Page 30 Indicators & Displays To reset the tripmeter to zero, press and hold the RESET button ( ) for more than 2 seconds with the display in the tripmeter A or tripmeter B mode. (5) RESET button Instruments & Controls...
Page 31: Hourmeter
Indicators & Displays Hourmeter The hourmeter ( ) shows accumulated hours while the ignition is ON ( ). The hourmeter provides accurate service period information for initial and regular maintenance. TRX500FM TRX500FPM (1) hourmeter Instruments & Controls...
Page 32: Digital Clock
Indicators & Displays Digital Clock Shows hour and minute while the ignition is ON ( ). To adjust the time, proceed as follows: Turn the ignition switch ON ( ). TRX500FM: To put the clock in the adjust mode with the hour and minute display flashing, press and hold the adjust button ( ) for more than 2 seconds.
Page 33 Indicators & Displays TRX500FM TRX500FPM (1) adjust button (3) minute select button (2) hour select button Instruments & Controls...
Page 34: Fuel Gauge
0.66 US gal (2.5 ) TRX500FM TRX500FPM (1) fuel gauge (3) segment E (2) segment RES (4) low fuel indicator All segments will flash, when the fuel gauge function is fails. See your Honda dealer. TRX500FM TRX500FPM Instruments & Controls...
Page 35: Controls & Features
Controls & Features Fuel Valve LEFT SIDE (1) fuel valve The manual fuel valve ( ) is located on the left side of the fuel tank cover. The three-way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor.
Page 36: Choke Knob
Controls & Features Choke Knob CENTER OF HANDLEBAR (1) choke knob (A) fully ON (B) fully OFF The choke knob ( ) may be used when starting the engine. See page Instruments & Controls...
Page 37: Ignition Switch
Controls & Features Ignition Switch The ignition switch ( ) is used for starting and stopping the engine (page ). Insert the key and turn it to the right for the ON ( position. Key Position Function ON ( Electrical circuits on. OFF ( No electrical circuits function.
Page 38: 2Wd/4Wd Select Switch
Controls & Features 2WD/4WD Select Switch Your ATV is equipped with a 2WD/4WD select switch ( ), which permits a choice between the ‘‘2WD’’ and ‘‘4WD’’ drive modes. Select a drive mode that’s suitable for your riding. The 2WD/4WD select switch is located above the throttle lever. To select the drive mode, slide the 2WD/4WD select switch to the desired position.
Page 39: Start Button
Controls & Features Start Button LEFT HANDLEBAR (1) start button START (2) engine stop switch The start button ( ) is used for starting the engine. Pushing the button in starts the engine. See Starting Procedure, page When the start button is pushed, the starter motor will crank the engine. The starter motor will not operate if the engine stop switch is in the OFF ) position when the start button is pushed.
Page 40: Headlight Switch
Controls & Features Headlight Switch LEFT HANDLEBAR (1) headlight switch (2) headlight dimmer switch The headlight switch ( ) is used to turn the headlights and assist headlight ON ( ) or OFF ( ). To operate, turn the switch to ON ) or OFF ( Headlight Dimmer Switch The headlight dimmer switch ( ) is used to change between the high...
Page 41: Starting Primer Knob
Controls & Features Starting Primer Knob RIGHT SIDE (1) starting primer knob The starting primer knob ( ) is located on the carburetor float bowl. The knob may be used when starting the engine in extremely cold − weather ( 15°C, 5°F). See Starting Procedure, page Recoil Starter...
Page 42: Throttle Lever
Controls & Features Throttle Lever RIGHT HANDLEBAR (1) throttle lever (A) to open the throttle The throttle controls engine rpm (speed). To increase engine rpm, press the throttle lever ( ) with your thumb. To reduce engine rpm, release pressure on the throttle lever. The throttle will automatically return to the closed position (engine idle) when you remove your thumb.
Page 43: Reverse Selector Knob
Controls & Features Reverse Selector Knob The reverse selector knob ( ), located on the rear brake lever/parking brake lever ( ), is used to shift into reverse. To operate, with your ATV stopped and the transmission in neutral (make sure the gear position indicator shows ‘‘N’’), push in the knob, squeeze the rear brake lever/ parking brake lever, then depress the shift lever.
Page 44: Front Brake Lever
Controls & Features Front Brake Lever The front brake lever is used to slow or stop your ATV. To operate, pull the lever. For information on braking techniques, see page Rear Brake Lever The rear brake lever is used to slow or stop your ATV. To operate, pull the lever.
Page 45: Parking Brake
Controls & Features Parking Brake LEFT HANDLEBAR (1) lock lever (A) to lock (2) rear brake lever/parking brake lever The lock lever ( ) on the rear brake lever/parking brake lever ( ) allows it to be used as a parking brake. To operate, first squeeze the rear brake lever/parking brake lever using your left hand and then lock it with the lock lever using your right hand.
Page 46: Flag Pole Bracket
Flag Pole Bracket RIGHT REAR (1) flag pole bracket Flag poles are optional equipment available from your Honda dealer. To mount a pole in the bracket ( ), follow the instructions that come with the flag pole kit. Flag poles are required in some riding areas. Check local regulations before riding.
Page 47: Trailer Hitch
Controls & Features Trailer Hitch REAR (1) trailer hitch (2) ball The trailer hitch ( ) is located on the rear axle housing. To use the hitch, you’ll need a proper size ball ( ) as specified by the trailer manufacturer.
Page 48: Accessory Socket
Controls & Features Accessory Socket LEFT FRONT (1) accessory socket (3) accessory socket cap (2) assist headlight The accessory socket ( ) is attached to the left side under the assist headlight ( ). You can use the accessory socket to power a trouble light, spotlight, CB radio, or cell phone, etc.
Page 49 Controls & Features Be sure the engine is on and the headlights are turned off before using the accessory socket, otherwise you may drain the battery. The accessory socket’s rated capacity is DC 12V, 120 Watts (10A) or less. If you exceed this limit, you may blow a fuse. See If a Fuse Blows, page When you are done using an accessory, unplug it, and cover the socket...
Page 50: Utility Box
Controls & Features Utility Box The utility box ( ) is located on the left side of the front fender. You may store small, lightweight items in the box. To open: Lift the D-ring ( ) on the quick-release fastener. Turn it counterclockwise until it releases.
Page 51: Storage Compartment
Controls & Features Storage Compartment The storage compartment ( ) is located below the rear cargo rack ( ). To open the compartment, unhook the rubber strap ( ). Be careful not to flood this area when washing your ATV. REAR (1) storage compartment (2) rear cargo rack...
Page 52: Ps (Electric Power Steering)
If the PS indicator lights at any time while riding, reduce speed and take your ATV to a Honda dealer as soon as possible. Continuing to ride with a PS system problem can cause system damage.
Page 53: Before Riding
Before Riding Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, what items you should check on your ATV, and adjustments to make for your comfort, convenience, or safety.
Page 54: Are You Ready To Ride
Are You Ready to Ride? Before you ride your ATV for the first time, we urge you to: Read this owner’s manual and the labels on your ATV carefully. Make sure you understand all the safety messages. Know how to operate all the controls. Before each ride, be sure: You feel well and are in good physical and mental condition.
Page 55 Are You Ready to Ride? An open-face helmet offers some protection, but a full-face helmet offers more. Regardless of the style, look for a DOT (Department of Transportation) sticker on any helmet you buy (USA only). Always wear a face shield or goggles to protect your eyes and help your vision. Operating this ATV without wearing an approved motorcycle helmet, eye protection, and protective clothing could increase your...
Page 56: Rider Training
Beginning and inexperienced operators should complete the certified training course offered by Honda. They should then regularly practice the skills learned in the course and the operating techniques described in the owner’s manual.
Page 57: Age Recommendation
Are You Ready to Ride? Age Recommendation The minimum recommended age for this ATV model is 16. For safety, never let children under 16 years old operate this vehicle. A child using an ATV that is not recommended for their age could lose vehicle control while riding, resulting in severe injury or death.
Page 58: No Alcohol Or Drugs
Are You Ready to Ride? No Alcohol or Drugs Alcohol, drugs and ATVs don’t mix. Even a small amount of alcohol − can impair your ability to operate an ATV safely. Likewise, drugs − even if prescribed by a physician can be dangerous while operating an ATV.
Page 59: Is Your Atv Ready To Ride
If your ATV has overturned or been involved in a collision, do not ride the vehicle until it has been inspected by your Honda dealer. There may be damage or other problems you cannot see. Improperly maintaining this ATV or failing to...
Page 60 Is Your ATV Ready to Ride? Tires Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damage or excessive wear (page Driveshaf t Boots Check for damage (page Nuts & Bolts Check the wheels to see that the axle nuts are tightened.
Page 61 Move the handlebar right and left and check that there is no excessive backlash. Remember, be sure to take care of any problem you find, or have your Honda dealer correct it before you ride. Before Riding...
Page 62: Load Limits & Guidelines
Load Limits & Guidelines Your Honda was designed as a rider-only ATV. It was not designed to carry a passenger. It can carry cargo on the cargo racks, however, carrying cargo anywhere else or carrying a passenger could interfere with your balance and control of the ATV.
Page 63: Load Limits
Load Limits & Guidelines Load Limits Following are the load limits for your ATV: There are limits to how much weight can be carried on your ATV and be pulled in a trailer. The following load limits apply to standard equipment only. Modifying your ATV, using non-standard equipment, or riding on terrain that is not flat and smooth could further reduce these limits.
Page 64: Loading Guidelines
Load Limits & Guidelines Loading Guidelines Carrying cargo or pulling a trailer will affect how your ATV handles and greatly reduce its ability in accelerating, braking and making turns and other maneuvers. Be sure to observe the weight limits and follow these guidelines: Check that the tires are properly inflated.
Page 65: Accessories & Modifications
Honda cannot test all other accessories, you must be personally responsible for proper selection, installation, and use of non-Honda accessories. Check with your Honda dealer for assistance and always follow these guidelines: Make sure the accessory does not obscure any lights, reduce ground clearance, limit suspension travel or steering travel, or interfere with operating any controls.
Page 66: Modifications
Accessories & Modifications Modifications We strongly advise you not to remove any original equipment or modify your ATV in any way that would change its design or operation. Such changes could seriously impair your ATV’s handling, stability, and braking, making it unsafe to ride. 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...
Page 67: Basic Operation & Riding
Basic Operation & Riding This section gives basic riding instructions, including how to start and stop your engine, and how to use the throttle and brakes. It also provides important information on riding with cargo. To protect your new engine and enjoy optimum performance and service life, refer to Break-in Guidelines (page For information about carburetor adjustment for riding at high altitude, see page...
Page 68 Basic Operation & Riding Braking ....................Riding Your ATV ................. Making Turns ..................Skidding or Sliding ................Riding Up Hills ................. Riding Down Hills ................Crossing or Turning on Hills or Slopes ..........Riding Over Obstacles ..............Riding Through Water ..............
Page 69: Safe Riding Precautions
Safe Riding Precautions Before riding your ATV for the first time, please review the ATV Saf ety section beginning on page 1, and the Bef ore Riding section beginning on page Even if you have ridden other ATVs, take time to become familiar with how this ATV works and handles.
Page 70: Keep Hands And Feet On Controls
Safe Riding Precautions You should never ride your ATV on public streets, roads or highways, even if they are not paved. Drivers of street vehicles may have difficulty seeing and avoiding you, which could lead to a collision. In many states it is illegal to operate ATVs on public streets, roads and highways.
Page 71: Control Speed
Safe Riding Precautions Control Speed Riding at excessive speed increases the chance of an accident. In choosing a proper speed, you need to consider the capability of your vehicle, the terrain, visibility and other operating conditions, plus your own skills and experience. Operating this ATV at excessive speeds increases your chances of losing control of the ATV, which can result in an accident.
Page 72: Use Care On Unfamiliar Or Rough Terrain
Safe Riding Precautions Use Care on Unfamiliar or Rough Terrain Before riding in a new area, always check the terrain thoroughly. Don’t ride fast on unfamiliar terrain or when visibility is limited. (It’s sometimes difficult to see obstructions like hidden rocks, bumps, or holes in time to react.) Failure to use extra care when operating this ATV on unfamiliar terrain could result in the ATV...
Page 73: Do Not Perform Stunts
Safe Riding Precautions Never ride past the limit of visibility. Maintain a safe distance between your ATV and other off-road vehicles. Always exercise caution, and use extra care on rough, slippery and loose terrain. Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction or vehicle control, which could result in an accident, including an...
Page 74: Starting & Stopping The Engine
Starting & Stopping the Engine Always follow the proper starting procedure described below. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your ATV’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.
Page 75: Starting Procedure
Starting & Stopping the Engine Starting Procedure To restart a warm engine, follow the procedure for ‘‘High Air Temperature.’’ − − Normal Air Temperature 10° 35°C (50° 95°F) CENTER OF HANDLEBAR (1) choke knob (A) fully ON (B) fully OFF If the engine is cold, pull the choke knob ( ) up all the way to fully ON ( ) position.
Page 76 Starting & Stopping the Engine High Air Temperature 35°C (95°F) or above LEFT HANDLEBAR (2) start button Do not use the choke. With the throttle slightly open, press the start button ( ). Low Air Temperature 10°C (50°F) or below Follow the procedure for ‘‘Normal Air Temperature.’’...
Page 77: Flooded Engine
Starting & Stopping the Engine Flooded Engine If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine: Leave the engine stop switch set to RUN ( Push the choke knob down all the way to fully OFF. Open the throttle fully.
Page 78: How To Stop The Engine
Starting & Stopping the Engine How to Stop the Engine Normal Engine Stop To stop the engine, make sure the transmission is in neutral by checking that the neutral indicator light is on, then turn the ignition switch OFF The engine stop switch should normally remain in the RUN ( position even when the engine is OFF.
Page 79: Using The Recoil Starter
Pull the grip up briskly and fully. After the engine starts, allow the starter grip to return slowly. If the starter grip does not return smoothly (because of dirt in the assembly), see your Honda dealer. RIGHT SIDE (1) right side cover (2) starter grip Basic Operation &...
Page 80: Shifting Gears
Shifting Gears UPSHIFTING SEQUENCE DOWNSHIFTING SEQUENCE Your ATV has five forward gears: 1, 2, 3, 4, and 5. The shift lever is located near the left footpeg. One full stroke of the shift lever shifts the transmission to the next higher or lower gear in the shifting sequence.
Page 81 Shifting Gears After starting the engine and letting it warm up, follow these procedures: With the transmission in neutral, release the parking brake, but continue squeezing the rear brake lever. With the throttle closed, raise the shift lever one full stroke to shift into 1st (first) gear.
Page 82: Riding In Reverse
Riding in Reverse If you need to ride in reverse, make sure the area behind you is clear and only operate the ATV at low speed. Improperly operating in reverse could cause you to hit an obstacle or person behind you, resulting in serious injury.
Page 83 Riding in Reverse Your ATV may be equipped with a reverse speed limiter, which helps the vehicle to maintain a saf e speed while riding in reverse gear. Release the rear brake lever/parking brake lever. Open the throttle gradually and ride slowly. Do not open the throttle suddenly or make abrupt turns.
Page 84: Braking
Braking Your ATV is equipped with disc brakes on both front wheels which are hydraulically activated by operating the right brake lever. A single drum brake on the rear axle housing is mechanically activated by depressing the brake pedal or operating the left brake lever. Although the front and rear brakes have separate controls, all four wheels are interconnected when your ATV is in the 4WD mode.
Page 85 Braking Your ability to brake in a turn and to brake hard in an emergency situation are important riding skills. When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduce their effectiveness.
Page 86: Riding Your Atv
Riding Your ATV Making Turns Learn how to turn your ATV properly. Practice the techniques outlined in this section on level ground and at low speeds until you are confident in making turns. Turning improperly can make the ATV go out of control, causing a collision or overturn.
Page 87 Riding Your ATV Lean your body to the inside of a turn and forward. To make a turn on level ground: Steer the handlebar and lean your body toward the inside of the turn. Leaning helps balance the vehicle, and it feels more comfortable.
Page 88: Skidding Or Sliding
Riding Your ATV Skidding or Sliding The terrain surface can be a major factor affecting turns. Skidding during a turn is more likely to occur on slippery surfaces, such as snow, ice, mud and loose gravel. If you skid on ice, you may lose all directional control.
Page 89: Riding Up Hills
Riding Your ATV Riding Up Hills The ATV’s ability to safely climb hills largely depends on the rider’s skill and judgment. Begin by practicing on smooth, gentle slopes. As you gain experience, you’ll learn the hazards and your own limitations. You may then proceed to ride on more difficult terrain.
Page 90 Riding Your ATV Shift weight forward when climbing hills. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. To climb a hill, take a running start in an appropriate gear and speed for the conditions.
Page 91 Riding Your ATV Stalling the ATV and/or Rolling Backwards: If you incorrectly estimate climbing capability or terrain conditions, the ATV may not have enough power or traction to continue uphill. If this happens, the ATV can stall and/or roll backwards. Stalling, rolling backwards or improperly dismounting while climbing a hill could result in the ATV overturning.
Page 92 Riding Your ATV What to do after the ATV has stalled or rolled backwards: If the hill is too steep or too slippery, or if you have any doubt whether you can safely walk the ATV back down the hill, leave the vehicle where it is and get help.
Page 93: Riding Down Hills
Riding Your ATV Riding Down Hills It’s usually advisable to descend hills with the ATV pointed straight downhill. Avoid angles that would cause the vehicle to lean sharply to one side. 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.
Page 94: Crossing Or Turning On Hills Or Slopes
Riding Your ATV When you’ve selected a safe downhill path, shift into a lower gear, shift your weight back with your arms extended and braced against the handlebar, then go down slowly with the throttle closed. Use mainly the rear brake to control speed. Avoid using either the front brake or rear brake hard or abruptly when riding down hills.
Page 95 Riding Your ATV Crossing Hills or Slopes To maintain balance and stability when riding across a slope, you need to shift weight toward the uphill side of the vehicle. To do this, move your body off the center of the seat and lean toward the uphill side.
Page 96: Riding Over Obstacles
Riding Your ATV Riding Over Obstacles Before operating in a new area, check for obstacles. Watch out for bumps, rain ruts, potholes and other obstacles in the terrain. When you approach any obstacle, reduce your speed and be prepared to stop. Never try to ride over large obstacles, such as large rocks or fallen logs.
Page 97: Riding Through Water
Riding Your ATV Riding Through Water Your ATV is designed to travel through water up to approximately 10 inches (254 mm) deep. Before crossing a stream, make sure the water is not too deep or flowing too fast. 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 an accident.
Page 98: Parking
Parking Look for level parking area. Make sure the ground surface is firm. After bringing your ATV to a stop, hold the brakes while you shift into neutral. Set the parking brake. Turn the ignition switch OFF ( If you’re finished riding for the day, turn the fuel valve OFF. If it is necessary to start the engine when your ATV in gear and is stopped on a grade, rock the vehicle back and forth to allow shifting the transmission into neutral.
Page 99: Servicing Your Honda
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. Bef ore You Service Your Honda The Importance of Maintenance ............
Page 100 Servicing Your Honda Service Procedures Fluids & Filters Fuel ....................Engine Oil & Filter ................Gear Case Oil ..................Differential Oil .................. Air Cleaner ..................Engine Throttle ....................Carburetor Choke Cable & Knob ............Clutch System ................... Reverse Lock System ................
Page 101: The Importance Of Maintenance
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 Honda dealer inspects all major parts, even if you are able to make some repairs.
Page 102: Maintenance Safety
Other tasks that are more difficult and require special tools are best performed by professionals. Removing the wheels should normally be handled only by a Honda technician or other qualified mechanic. Instructions are included in this manual only to assist in emergency service.
Page 103: Important Safety Precautions
Keep cigarettes, sparks, and flames away from all fuel-related parts. Remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new Honda Genuine Parts or other equivalents for repair and replacement.
Page 104: Maintenance Schedule
Other items involve more extensive procedures and may require special training, tools, and equipment. We recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools and equipment.
Page 105 ) may require more technical information and tools. Consult your Honda dealer. ＊ Should be serviced by your Honda dealer, unless you have the proper tools and service data, and are mechanically qualified. Refer to the official Honda Service Manual (page ＊＊...
Page 106 12 months: R ENGINE OIL FILTER ENGINE IDLE SPEED Should be serviced by your Honda dealer, unless you have the proper tools and service data, and are mechanically qualified. Refer to the official Honda Service Manual (page Servicing Your Honda...
Page 107 − STEERING SYSTEM Should be serviced by your Honda dealer, unless you have the proper tools and service data, and are mechanically qualified. Refer to the official Honda Service Manual (page In the interest of safety, we recommend these items be serviced only by your Honda dealer.
Page 108: Maintenance Record
Miles (km) or ODO or Date Performed Notes hours HOUR 100 (150) or 600 (1,000) or 1,200 (2,000) or 1,800 (3,000) or 2,400 (4,000) or 3,000 (5,000) or 3,600 (6,000) or 4,200 (7,000) or 4,800 (8,000) or Servicing Your Honda...
Page 109: Maintenance Component Locations
Maintenance Component Locations front brake fluid reservoir rear brake lever/ parking brake lever front brake lever throttle lever fuel fill cap choke knob Servicing Your Honda...
Page 110 Maintenance Component Locations air cleaner housing drain tube air cleaner owner’s manual differential oil filler cap differential oil drain bolt rear brakelight switch throttle stop screw front brake caliper (engine idle speed) engine oil filter rear brake pedal Servicing Your Honda...
Page 111 PS fuse (TRX500FPM only) clutch spark arrester gear case oil filler cap gear case oil drain bolt engine oil filler cap/dipstick engine oil drain bolt Servicing Your Honda...
Page 112: Tool Kit
After using the tools, be sure to use the rubber band ( ) to fasten the tool kit securely. The air pressure gauge should be stored in the tool kit. An optional, larger tool kit may be available. Check with your Honda dealer’s parts department. UNDER SEAT...
Page 113: Owner's Manual Storage
The owner’s manual should be stored in the plastic bag and fastened with the rubber band ( ). Be careful not to flood this area when washing your ATV. SEAT UNDERSIDE (1) owner’s manual (3) rubber band (2) seat Servicing Your Honda...
Page 114: Seat Removal
Slide the seat ( ) back and lift it. Installation Insert the front prongs ( ) into the hooks ( ) on the frame and press the studs ( ) into the grommets ( ). Press down on the seat until locks. Servicing Your Honda...
Page 115: Fuel
If pinging or spark knock occurs at a steady engine speed under normal load, change brands of gasoline. If pinging or spark knock persists, consult your Honda dealer. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt, dust, or water in the fuel tank.
Page 116 ON position after refueling to avoid running out of fuel with no reserve. Refueling Procedure Refer to Saf ety Precautions on page (1) fuel fill cap (3) handlebar cover hole (2) breather tube (4) filler neck Servicing Your Honda...
Page 117 After refueling, turn the fuel fill cap clockwise until it clicks. Insert the breather tube into the handlebar cover hole. If the fuel valve was set to RES, turn the fuel valve ON. If you replace the fuel fill cap, use only a Honda Genuine replacement part. Servicing Your Honda...
Page 118: Engine Oil & Filter
Change the engine oil as specified in the maintenance schedule on page . When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule. Servicing Your Honda...
Page 119 SAE 10W-30 JASO T 903 standard ＊ suggested oil Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil. ＊ Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label.
Page 120 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) code number of the sales company of the oil (2) oil classification Servicing Your Honda...
Page 121 Start the engine in a well-ventilated area and let it idle for 3 5 − minutes. Stop the engine and wait 2 3 minutes. Unsnap and remove the left engine sub cover ( ). LEFT SIDE (1) left engine sub cover (cont’d) Servicing Your Honda...
Page 122 Reinstall the oil filler cap/dipstick. Install the left engine sub cover. Running the engine with an improper oil level can cause serious engine damage. LEFT SIDE (2) oil filler cap/dipstick (3) upper level mark (4) lower level mark Servicing Your Honda...
Page 123 Your ATV’s oil filter has very specific performance requirements. Use a new Honda Genuine oil filter specified for your model or a filter of equal quality. Using the wrong oil f ilter may result in leaks or engine damage.
Page 124 Engine Oil & Filter Install a New Engine Oil Filter: Remove the right engine sub cover ( ) by removing the screw ( ). RIGHT SIDE (1) right engine sub cover (2) screw Servicing Your Honda...
Page 125 Check that the oil filter cover O-rings ( ) are in good condition and then install a new oil filter. Use only the Honda Genuine oil filter or a filter of equivalent quality specified for your model. Using the wrong Honda filter or a non-Honda filter which is not of equivalent quality may cause engine damage.
Page 126 If necessary, add more oil but do not overfill. Check that there are no oil leaks. Install the left engine sub cover. If a torque wrench is not used for installation, see your Honda dealer as soon as possible to verify proper assembly. Servicing Your Honda...
Page 127: Gear Case Oil
Oil Recommendation type hypoid gear oil viscosity (weight) SAE 80 suggested oil Honda shaft drive oil or equivalent Changing Oil Refer to Saf ety Precautions on page Change the oil with the gear case at normal operating temperature to assure complete and rapid draining.
Page 128 Remove the oil level check bolt ( ). Make sure the oil level reaches the oil level check hole ( ). Install the oil filler cap and oil level check bolt. REAR (1) oil drain plug (3) oil level check bolt (2) oil filler cap (4) oil level check hole Servicing Your Honda...
Page 129: Differential Oil
Oil Recommendation type hypoid gear oil viscosity (weight) SAE 80 suggested oil Honda shaft drive oil or equivalent Changing Oil Refer to Saf ety Precautions on page Change the oil with the differential at normal operating temperature to assure complete and rapid draining.
Page 130 Make sure the oil level is at the lower edge of the oil filler inspection hole ( ). Install the oil filler cap. FRONT (1) oil drain plug (3) oil filler inspection hole (2) oil filler cap Servicing Your Honda...
Page 131: Air Cleaner
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. Using the wrong air cleaner may result in premature engine wear.
Page 132 Air Cleaner Cleaning Remove the seat (page UNDER SEAT (1) retainer clips (2) air cleaner housing cover Unlatch the retainer clips ( ). Remove the air cleaner housing cover ( ). Servicing Your Honda...
Page 133 Replace the air cleaner and/or sub air cleaner if it is damaged. UNDER SEAT (10) (9) (5) (3) element holder (7) air cleaner (4) screw (8) air cleaner body (5) air cleaner assembly (9) sub air cleaner (6) clamp (10) air cleaner joint (cont’d) Servicing Your Honda...
Page 134 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.
Page 135 Air Cleaner Dust Cover UNDER SEAT (1) dust cover (2) breather joint Do not push the dust cover ( ) too far into the breather joint ( ). If the dust cover is dirty, clean it. Servicing Your Honda...
Page 136 (3) air cleaner housing (2) clip Remove the drain tube ( ) by removing the clip ( ) under the air cleaner housing ( ). Drain the deposits. Reinstall the drain tube, securing it with the clip. Servicing Your Honda...
Page 137: Throttle
Loosen the lock nut ( ). Turn the adjuster to obtain the correct freeplay. Tighten the lock nut and reinstall the sleeve. After adjustment, check for smooth operation of the throttle lever from fully closed to fully open in all steering positions. Servicing Your Honda...
Page 138 If the cable is kinked or chafed, have it replaced. Check the cables for tension or stress in all steering positions. Lubricate the cables with a commercially available cable lubricant to prevent premature wear and corrosion. Servicing Your Honda...
Page 139: Carburetor Choke Cable & Knob
(1) choke cable (2) choke knob Check the condition of the choke cable ( ). Check the operation of the choke knob ( ). If the cable is damaged or kinked, have it replaced by your Honda dealer. Servicing Your Honda...
Page 140: Clutch System
Install the removed parts in reverse order of removal. If you cannot get proper adjustment, or the clutch does not work properly, the clutch friction discs may be worn. See your Honda dealer or refer to official Honda Service Manual (page...
Page 141: Reverse Lock System
After adjustment, tighten the lock nut securely. Return the dust cover. Other Checks Check the reverse assist lever and cable for loose connections or other damage. If the cable is worn or kinked, have it replaced by your Honda dealer. Servicing Your Honda...
Page 142: Engine Idle Speed
Engine Idle Speed The best way to assure proper carburetion is to see your Honda dealer for regularly scheduled servicing, including carburetor adjustment. Remember, idle speed adjustment is not a ‘‘cure-all’’ for other problems in your engine’s fuel-delivery system. Adjusting the idle will not compensate for a fault elsewhere.
Page 143: Spark Plug
Using a spark plug wrench provided in the tool kit, remove the spark plug. UNDER SEAT (1) screw (2) clip (3) resonance chamber (4) rubber cover (5) spark plug cap (cont’d) Servicing Your Honda...
Page 144 ( ) should not be eroded. If the electrodes and insulator tip appear unusually fouled or burned, we suggest that you contact your Honda dealer. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped.
Page 145 If a plug is too tight, the threads may be damaged. Reinstall the spark plug cap. Take care to avoid pinching any cables or wires. Install the remaining parts in the reverse order of removal. Servicing Your Honda...
Page 146: 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 Honda dealer. Servicing Your Honda...
Page 147: Spark Arrester
Allow the engine and muffler to cool. Remove the bolts ( ), the spark arrester ( ) and the gasket ( ) from the muffler ( ). REAR (1) bolts (3) gasket (2) spark arrester (4) muffler (cont’d) Servicing Your Honda...
Page 148 The spark arrester must be free of breaks and holes. Replace, if necessary. Check the gasket. Replace, if necessary. (5) spark arrester screen Install the spark arrester and gasket in the muffler, and tighten the bolts to the specified torque: 9 lbf·ft (12 N·m , 1.2 kgf·m) Servicing Your Honda...
Page 149: Brakes
Honda DOT 4 Brake Fluid The recommended brake fluid is Honda DOT 4 Brake Fluid, or any brake fluid of equal quality and performance. Use fresh brake fluid from a sealed container. Be sure to read the label before opening the sealed container.
Page 150 Do not add or replace brake fluid, except in an emergency. If you do add fluid, have your Honda dealer check the system as soon as possible. Brake f luid can damage plastic and painted surf aces. Handle with care.
Page 151 Other Inspections 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 Honda dealer. Servicing Your Honda...
Page 152 ). If the wear indicator aligns with the reference mark ( ), both pads must be replaced, see your Honda dealer for this replacement. Always inspect both pads in both the right and left front brake calipers. Servicing Your Honda...
Page 153 Measure the distance the rear brake pedal ( ) moves before the brake starts to take hold. Freeplay, measurement at the tip of the end of the pedal, should be: 9/16 13/16 in (15 20 mm) − − If necessary, adjust to the specified range. Servicing Your Honda...
Page 154 ( ). Adjust the freeplay of the rear brake pedal. Push the brake arm ( ), then check the clearance between the brake arm and the brake arm pin. (4) brake arm Servicing Your Honda...
Page 155 Measure the distance the rear brake lever/parking brake lever ( ) moves before the brake starts to take hold. Freeplay (measurement at the tip of the end of the brake lever) should be: 9/16 13/16 in (15 20 mm) − − If necessary, adjust to the specified range. Servicing Your Honda...
Page 156 ( ). Adjust the freeplay of the rear brake lever/parking brake lever. Push the brake arm ( ) then check the clearance between the brake arm and the brake arm pin. (4) brake arm Servicing Your Honda...
Page 157 Brakes Other Inspections Check that the rear brake lever and brake pedal assemblies are positioned properly and the securing bolts are tight. Make sure that the brake cables, brake arm, spring, and fasteners are in good condition. Servicing Your Honda...
Page 158 ( ). Replace the brake shoe if the arrow aligns with the reference mark ( ) on the brake panel upon full application of the brake. If replacement is necessary, see your Honda dealer. Servicing Your Honda...
Page 159 . Adjustment is done by turning the adjusting nut ( ). Turn the nut in direction ( ) if the switch operates too late and in direction ( ) if the switch operates too soon. RIGHT SIDE (1) rear brakelight switch (2) adjusting nut Servicing Your Honda...
Page 160 Make sure the engine is OFF and the parking brake is set. Remove the rear brake drain bolt ( ) from the bottom of the rear brake panel. If any water drains, the brake seals must be replaced by your Honda dealer as soon as possible. Servicing Your Honda...
Page 161: Tires
Always select your riding area with care. The following pages give detailed information on how and when to check your air pressure, how to inspect your tires for wear and damage, and our recommendations for tire repair and replacement. Servicing Your Honda...
Page 162 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. Servicing Your Honda...
Page 163 (25.0 kPa) (25.0 kPa) PRESSURE RECOMMENDED 3.6 psi 3.6 psi PRESSURE (25.0 kPa) (25.0 kPa) (TRX500FPM) FRONT REAR 4.4 psi 3.6 psi RECOMMENDED PRESSURE (30.0 kPa) (25.0 kPa) RECOMMENDED 4.4 psi 3.6 psi PRESSURE (30.0 kPa) (25.0 kPa) Servicing Your Honda...
Page 164 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. Servicing Your Honda...
Page 165 ( ). 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) Servicing Your Honda...
Page 166 If you choose to have a tire repaired, be sure the repair work is performed by a professional. If you have a tire professionally repaired at a non-Honda facility, we recommend that you have the work checked by your Honda dealer.
Page 167 When you replace a tire, remember: Have the tire replaced by your Honda dealer if possible. If you have a tire professionally replaced at a non-Honda facility, we recommended that you have the work checked by your Honda dealer. Servicing Your Honda...
Page 168: Engine Guard & Skid Plates
Maintenance Schedule. Have the engine guard and skid plates replaced if they are cracked or damaged. If the guard and plate bolts are loose, tighten them securely. Servicing Your Honda...
Page 169: Driveshaft Boots
Driveshaft Boots Refer to Saf ety Precautions on page FRONT (1) rubber driveshaft boots Check the rubber driveshaft boots ( ) for damage or leaking grease. If necessary, have your Honda dealer replace them. Servicing Your Honda...
Page 170: Electrical Battery
If you plan to store your ATV, see Battery Storage, page If your battery seems weak and/or is leaking electrolyte (causing slow starting or other electrical problems), see your Honda dealer. WARNING: Battery posts, terminals and related accessories contain lead and lead compounds.
Page 171 A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you. Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance. Servicing Your Honda...
Page 172 Release the rings and remove the rubber band ( ). − Disconnect the negative ( ) terminal lead ( ) from the battery ( ) ＋ first, then disconnect the positive ( ) terminal lead ( ). Remove the battery. Servicing Your Honda...
Page 173 Slow charge the battery (see following section) once every 30 days. Installation Reinstall in the reverse order of removal. ＋ Be sure to connect the positive ( ) terminal first, then the negative ( ) terminal. − Make sure all bolts and other fasteners are secure. Servicing Your Honda...
Page 174 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. Servicing Your Honda...
Page 175: Appearance Care
Appearance Care Frequent cleaning and polishing will keep your Honda looking newer longer. Frequent cleaning also identifies you as an owner who values his ATV. A clean ATV is also easier to inspect and service. General Recommendations Refer to Saf ety Precautions...
Page 176 As a precaution, ride your ATV at a slow speed and apply the brakes several times. This will help dry the brakes and restore normal braking performance. If the inside of the headlight lens appears clouded immediately after washing, it should clear after a few minutes of riding. Servicing Your Honda...
Page 177 Brake dust. necessary, rub with a sponge. Rinse and dry. Apply a spray cleaner/polish and wipe with a non-abrasive cloth. Dull, corroded chrome Apply a high quality chrome/ or aluminum. aluminum polish and wipe with a non-abrasive cloth. Servicing Your Honda...
Page 178 Apply the polish or wax according to the instructions on the container. If a surface on your ATV is chipped or scratched, your Honda dealer has touch-up paint to match your ATV’s color. Be sure to use your ATV’s color code (page ) when you buy touch-up paint.
Page 179: Tips
Tips Here’s helpful advice on how to prepare for an off-road adventure, how to transport and store your Honda, and how to be an environmentally responsible ATV owner. Preparing for a Ride ................172 What to Take to the Riding Area ..........
Page 180: Preparing For A Ride
Preparing for a Ride A safe and enjoyable ride begins with good planning and preparation. Always ride with at least one other person in case you have trouble, and let someone know where you’re going and when you expect to return. Before riding in an unfamiliar area, find out in advance if you need special permits, get maps so you can study the terrain, and talk to other riders who know the area.
Page 181: What To Take On The Trail
Preparing for a Ride What to Take on the Trail What you take with you during a ride depends on the kind of terrain, how long you expect to ride, how far you might go from your base camp or help, and how experienced you or your companions are in making repairs.
Page 182: Transporting Your Honda
Transporting Your Honda Do not tow your ATV behind a car or other vehicle. When you transport your ATV, we recommend that you carry the vehicle in its normal operating position (on all four wheels). Do not incline the vehicle upright on its rear end. This can damage the vehicle, and leaking gasoline could be a hazard.
Page 183 Transporting Your Honda Secure the vehicle with tie-down straps in the areas shown. Suitable tie-down straps are available from your Honda dealer. Ordinary rope is not recommended because it can stretch under load. Using tie-down straps in any other areas can damage your ATV.
Page 184: Storing Your Honda
For more information about storage, refer to the Honda Motorcycle Winter Storage Guide, available from your Honda 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.
Page 185: Preparation For Storage
Storing Your Honda Preparation for Storage Refer to Saf ety Precautions on page This procedure requires a means for draining and disposing of drained fuel (page Change the engine oil and filter (page Fill the fuel tank. Make sure the fuel fill cap is properly installed.
Page 186 Storing Your Honda To prevent rusting in the cylinder, perform the following: Remove the spark plug cap from the spark plug. Remove the spark plug. Do not connect the spark plug to the spark plug cap. − Pour a tablespoon (15 20 cc) of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth.
Page 187: Removal From Storage
(page If your ATV has been stored for more than two months − ask your Honda dealer to drain and replace the fuel. Charge the battery (page ) as required. Install the battery. Perform a pre-ride inspection (page ), then test-ride your ATV at low speeds.
Page 188: You & The Environment
You & the Environment Owning and riding an ATV can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport of off-road riding. Following are tips on how you can be an environmentally responsible ATV owner.
Page 189: Taking Care Of The Unexpected
Taking Care of the Unexpected With all the challenges you can encounter off-road, there’s a chance that sometime something may go wrong. This section gives practical advice to help you deal with a wide range of problems. Take time to read this section before you ride.
Page 190: General Guidelines
Taking Care of the Unexpected General Guidelines Keeping your ATV well-maintained is the best way to reduce the possibility of having a problem while riding. However, problems can arise even with well-maintained machines. Remember to take along your owner’s manual, the tool kit that came with your ATV, and any other items (such as tire repair supplies and additional tools) that might help you solve a problem on your own.
Page 191 Taking Care of the Unexpected Should you ever have a problem while riding, please follow these guidelines: Always put personal safety first. Take time to assess the situation and your options before deciding what to do. If the problem is relatively minor and you have the tools, supplies, and skills to make a temporary repair, be sure to have permanent repairs made as soon as possible.
Page 192: If Your Engine Quits Or Won't Start
− performance the following information may help you. If you can’t correct the problem, see your Honda dealer. If your ATV won’t start, listen as you press the start button. If you don’t hear the starter motor turning, refer to the Starter motor doesn’t operate...
Page 193 If charging doesn’t help, see your Honda dealer. faulty starter motor If all possible causes are negative, the starter motor may be faulty. See your Honda dealer. SYMPTOM: Starter motor works, but the engine won’t start. POSSIBLE CAUSE WHAT TO DO out of fuel Fill the fuel tank.
Page 194 Check engine idle adjustment (page fast, stalls ). If the problem persists, see your Honda dealer. poor engine Ask your Honda dealer to modify the performance at carburetion with a high altitude jet. altitudes above Refer to High Altitude Carburetor...
Page 195: If You Have A Flat Tire
Follow the instructions provided with the repair kit to make a temporary repair. As soon as possible, have the tire permanently repaired by your Honda dealer. Any tire that cannot be repaired should be replaced. Whenever the ATV is to be operated far from service facilities or available transportation, we recommend that you carry a tire pump and a repair kit with the vehicle.
Page 196 If You Have a Flat Tire Riding your ATV with a temporary 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.
Page 197 If You Have a Flat Tire Emergency Wheel Removal/Installation Refer to Saf ety Precautions on page (1) wheel nuts (2) wheel rim Removal Park your ATV on a firm, level surface. Loosen − but do not remove − the wheel nuts ( ). Raise the front (or rear) wheels off the ground and place a support block under the vehicle.
Page 198 47 lbf·ft (64 N·m , 6.5 kgf·m) If a torque wrench was not used for installation, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capability.
Page 199: If The High Oil Temperature Indicator Lights
Start the engine, and check that the high oil temperature indicator goes off. If the indicator goes off − resume riding. If there is a leak − do not ride the ATV until the leak is repaired by Honda dealer. Taking Care of the Unexpected...
Page 200: If A Fuse Blows
If a Fuse Blows All of the electrical circuits on your ATV have fuses to protect them from damage caused by excess current flow (short circuit or overload). If something electrical on your ATV stops working, the first thing you should check for is a blown fuse ( ).
Page 201 If a Fuse Blows Main Fuse Access To prevent an accidental short circuit, turn the ignition switch OFF ) before checking or replacing the fuses. Remove the seat (page To access the main fuse ( ), remove the fuse box cover ( ). UNDER SEAT (2) main fuse (4) spare main fuse...
Page 202 If a Fuse Blows Circuit Fuse Access (5) circuit fuses (6) spare fuses To check or replace a circuit fuse ( ), pull the old fuse out of its retaining clips. If the fuse is blown, replace it with a spare fuse ( ) of the same rating. If you do not have a replacement fuse with the proper rating for the circuit, install one with a lower rating.
Page 203 Remove the seat (page To access the PS fuse ( ), remove the PS fuse box cover ( ). If the PS fuse is blown, see your Honda dealer for this service. Install the PS fuse box cover. Install the seat.
Page 204: If You Crash
Sometimes, crash damage is hidden or not immediately apparent. When you get home, thoroughly check your ATV and correct any problems you find. Also, be sure to have your Honda dealer check the frame and suspension after any serious crash.
Page 205: If You Lose Your Key
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 Honda dealer.
Page 206: If The Battery Is Low (Or Dead)
The greater amperage of an automobile battery when the car engine is running can damage your ATV’s electrical system. Bump starting is also not recommended. If you can’t charge the battery or it appears unable to hold a charge, contact your Honda dealer. Taking Care of the Unexpected...
Page 207: If A Component Fails
If a Component Fails The brake levers or pedal, control cables, and other components can be damaged as you ride in dense brush or over rocky terrain. Making a trailside repair depends on how serious the damage is and what tools and supplies you have with you.
Page 208 Taking Care of the Unexpected...
Page 209: Technical Information
Technical Information This section contains dimensions, capacities, and other technical data, plus information on government requirements and how to break-in your ATV. Vehicle Identification ................ Specifications ..................Break-in Guidelines ................High Altitude Carburetor Adjustment ..........Emission Control Systems ..............Catalytic Converter ................
Page 210: Vehicle Identification
Vehicle Identification Serial Numbers The VIN, engine serial number, and key number may be required when ordering replacement parts. You may record these numbers in the Quick Reference section at the rear of this manual. The VIN ( ) is stamped on the front of the frame. FRONT (1) VIN The engine number ( ) is stamped on the lower side of the rear...
Page 211 Vehicle Identification Color Label & Code The color label ( ) is attached on the front of the frame. The color code is helpful when ordering replacement parts. You may record the color and code in the Quick Reference section at the rear of this manual.
Page 212: Specifications
API service label, SAE 10W-30, JASO T 903 standard MA, Pro Honda GN4 4-stroke oil (USA & Canada) or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil Technical Information...
Page 213 Specifications Capacities operator only passenger capacity maximum weight 485 lbs (220 kg) capacity rider, all cargo and accessories Engine Specifications displacement 29.0 cu-in (475 cm ) bore & stroke 3.62 × 2.81 in (92.0 × 71.5 mm) compression ratio 8.3 : 1 spark plug BKR5E-11 (NGK) (standard)
Page 214 Specifications Chassis & Suspension ° caster trail 0.1 in (3 mm) tire size, front AT25 × 8-12 ★★ DUNLOP KT181 tire size, rear AT25 × 10-12 ★★ DUNLOP KT185 TRX500FM tire pressure, front & 3.6 psi (25.0 kPa) rear (cold) TRX500FPM tire pressure, front &...
Page 215 Specifications Fuses 30 A main other 15 A × 2, 10 A × PS (Electric Power 40 A Steering) fuse (TRX500FPM only) Torque Specification engine oil drain bolt 18 lbf·ft (25 N·m , 2.5 kgf·m) engine oil filter cover 7 lbf·ft (10 N·m , 1.0 kgf·m) bolts differential oil drain 9 lbf·ft (12 N·m , 1.2 kgf·m)
Page 216: Break-In Guidelines
Break-in Guidelines Help assure your ATV’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts, rapid acceleration, and constant rpm operation. Technical Information...
Page 217: High Altitude Carburetor Adjustment
High Altitude Carburetor Adjustment At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.
Page 218: Emission Control Systems
Emission Control Systems Exhaust Emission Requirements The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Environment Canada (EC) require that your ATV comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions provided.
Page 219 Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. Exhaust Emission Control System The exhaust emission control system is composed of an oxidation catalyst and appropriate carburetor settings.
Page 220 Problems That May Affect ATV Exhaust Emissions If you are aware of any of the following symptoms, have the vehicle inspected and repaired by your Honda ATV dealer. Symptoms: Hard starting or stalling after starting Rough idle...
Page 221 Emission Control Systems Noise Emission Control System TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: State laws prohibit, or Canadian provincial laws may prohibit, the following acts or the causing thereof: ( ) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
Page 222: Catalytic Converter
The catalytic converter acts on HC and CO. A replacement unit must be an original Honda part or its equivalent. The catalytic converter must operate at a high temperature for the chemical reactions to take place. It can set fire to any combustible materials that come near it.
Page 223: Oxygenated Fuels
Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.
Page 224 Oxygenated Fuels 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.
Page 225: Consumer Information
This section contains information on your warranty and how to get an official Honda service manual. Authorized Manuals ................Warranty Coverage ................Warranty Service ................Contacting Honda ................Your Honda Dealer ................The Honda Rider’s Club (USA only) ..........Consumer Information...
Page 226: Authorized Manuals
Helm, Inc. (USA only, Canada: See your Honda dealer to order authorized manuals.) Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles, motor scooters and ATVs.
Page 227 Mail to Helm, Inc. at the address shown on the back of this order form (USA only). Canada: See your Honda dealer to order authorized manuals. Publication Item Description Qty.
Page 228 NOTE: Dealers and Companies please provide dealer or company name, and also the name of the person to whose attention the shipment should be sent. Customer Name Attention Street address/P. O. BOX Apartment Number City State Zip Code Daytime Telephone Number Check or money order enclosed payable to Helm Inc.
Page 229: Warranty Coverage
There are responsibilities, restrictions, and exclusions which apply to these warranties. Please read the Warranties Booklet given to you by your Honda dealer at the time of purchase. Be sure to keep your Honda owner’s card with your Warranties Booklet (USA only).
Page 230: Warranty Service
If you have questions about warranty coverage or the nature of the repair, it is best to talk to the Service Manager of your Honda dealer. Sometimes, in spite of the best intentions of all concerned, a misunderstanding may occur.
Page 231: Contacting Honda
That’s why it’s important to work to resolve any differences at the dealership level. If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address (USA only): Motorcycle Division, American Honda Motor Co., Inc., P.O.
Page 232: Your Honda Dealer
Your Honda Dealer Once you purchase your new Honda, get familiar with the organization of your Honda dealer so you can utilize the full range of services available. The service department is there to perform regular maintenance and unexpected repairs. It has the latest available service information from Honda.
Page 233: The Honda Rider's Club (Usa Only)
The Honda Rider’s Club (USA only) You may be eligible for a Honda Rider’s Club of America (HRCA) membership with the purchase of your new Honda. You can log on to the HRCA Clubhouse website for details at www.hrca.honda.com. Consumer Information...
Page 234: Table Of Contents
Table of Contents The following presents the contents of each section of your owner’s manual. ATV SAFETY ..................Important Safety Information ............... Safety Labels ..................INSTRUMENTS & CONTROLS ............Operation Component Locations ............Indicators & Displays ................Multi-function Display ..............Gear Position Indicator ..............
Page 235 Table of Contents Controls & Features ................Fuel Valve ..................Choke Knob ..................Ignition Switch .................. 2WD/4WD Select Switch ..............Start Button ..................Engine Stop Switch ................Headlight Switch ................Headlight Dimmer Switch ..............Starting Primer Knob ................ Recoil Starter ..................
Page 236 Table of Contents BEFORE RIDING (cont’d) Load Limits & Guidelines ..............Loading ..................... Load Limits ..................Loading Guidelines ................Accessories & Modifications ..............Accessories ..................Modifications ..................BASIC OPERATION & RIDING ............ . 59 Safe Riding Precautions ................ Off-road Use Only ................
Page 237 Table of Contents Parking ....................SERVICING YOUR HONDA ............91 Bef ore You Service Your Honda The Importance of Maintenance ............Maintenance Safety ................Important Safety Precautions ............Maintenance Schedule ................Maintenance Record ................Service Preparations Maintenance Component Locations ..........
Page 238 ....................171 Preparing for a Ride ................What to Take to the Riding Area ..........What to Take on the Trail ............. Transporting Your Honda ..............Storing Your Honda ................Preparation for Storage ..............Removal from Storage ..............You & the Environment ..............
Page 239 . 217 Authorized Manuals ................Warranty Coverage ................Warranty Service ................Contacting Honda ................Your Honda Dealer ................The Honda Rider’s Club (USA only) ..........TABLE OF CONTENTS ..............226 INDEX ....................232 QUICK REFERENCE Table of Contents...
Page 240: Index
................128 air pressure, gauge ....................104 tire ....................154 altitude, high ..................209 American Honda, contacting .............. . 223 apparel, protective ................. 46 appearance care .................. . 167 authorized manuals ................218 battery ....................
Page 241 Index rear brake lever ................. . 36 rear brake lever freeplay ..............147 rear brake pedal ................. 36 rear brake pedal freeplay ..............145 shoe wear ..................150 braking ....................76 break-in guidelines ................206 button, adjust ..................
Page 242 Index compartment, owner’s manual ................105 storage compartment ................ . 43 tool kit .................... . 104 component fails .................. . 199 consumer information ................ . 217 controls & features ................27 crash, if you ..................196 crossing or turning on hills or slopes ............
Page 243 Index electric power steering (PS) ..............44 emission control systems ..............210 engine, flooded ....................69 guard ....................160 idle speed ..................134 number ................... . 202 ....................110 pinging ................... . 107 starting ....................
Page 244 Index fuel, fill cap .................... . 108 gauge ....................26 high altitude fuel mixture adjustment ..........209 oxygenated ..................215 recommendation ................107 refueling ..................108 reserve fuel supply ................108 tank capacity .................. .
Page 245 ............. 86 riding down hills ................85 riding up hills ..................81 stopping on hills ................83 Honda, contacting ..................223 dealer ....................224 Rider’s Club ..................225 service manual ................
Page 246 Index key, lost ....................197 number ................... . 197 kit, tool ....................104 labels, safety ................... lamp check ................... . 15 limit, weight ..................55 load limits ....................55 loading guidelines ................. 56 lubrication, differential oil ................
Page 247 Index manual, service ..................218 maximum weight limit ................55 minute select button ..............14, 17, 25 modifications ..................58 multi-function display ................18 neutral indicator ................14, 16 noise emission control system .............
Page 248 . 133 assist lever ..................133 gear, shifting into ................74 indicator ..................14, 16 riding in .................... . 74 selector knob ..................35 rider training ..................48 Rider’s Club, Honda ................225 Index...
Page 249 Index riding, basic operations ................. 59 clothing ....................46 over obstacles ..................88 precautions ..................61 preparing for .................. . 172 safety ....................safety precautions ................61 through water ..................89 safety, important precautions ...............
Page 250 Index shifting gears ..................72 skid plates ................... . 160 skidding or sliding ................. 80 spark arrester ..................139 spark knock ..................107 spark plug ................... . 135 specifications ..................204 speedometer ..................18 stalled engine ..................
Page 251 Index throttle, cable ..................129, 130 lever .................. . 34, 129, 130 tires, air pressure ..................154 flat ....................187 replacing ..................159 repairing ..................158 tread conditions ............... 156, 157 tool kit ....................
Page 252 Index valve, fuel ....................27 valve clearance ..................138 vehicle identification no. (VIN) ............202 warning labels ..................warranty, coverage ..................221 extended ..................221 service .................... . 222 washing your ATV ................168 water, draining from brakes ..............
Page 253: Quick Reference
Quick Reference The following is a brief, but important collection of information you need to know about your Honda. You’ll also find space to record important notes. How To Avoid Costly Repairs The engine of your Honda can be the most expensive component to repair.
Page 254 Quick Reference Engine No. Ignition Key No. Color Label Owner’s Name Address City/State Phone Dealer’s Name Address City/State Phone Service Mgr. Quick Reference...
Page 255 API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label, SAE 10W-30, JASO T 903 standard MA, Pro Honda GN4 4-stroke oil or equivalent 485 lbs (220 kg) Maximum Weight Capacity rider, all cargo and accessories...
Page 256 Quick Reference Front: AT25 × 8-12 ★★ DUNLOP KT181 Tires Rear: AT25 × 10-12 ★★ DUNLOP KT185 (TRX500FM) Tire Pressure (cold) Front: 3.6 psi (25.0 kPa) Rear: 3.6 psi (25.0 kPa) (TRX500FPM) Front: 4.4 psi (30.0 kPa) Rear: 3.6 psi (25.0 kPa) Spark Plugs standard: BKR5E-11 (NGK)
Page 257 Quick Reference These symbols are used in Controls & Features section: SYMBOL COMPONENT SEE PAGE choke knob − ignition switch − ignition switch 2WD/4WD select switch − 4WD indicator lights when the 4WD mode START button − engine stop switch −...

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Honda FOURTRAX FOREMAN 4X4 TRX500FM 2009 Owner's Manual

Instruments & Controls

Before Riding

Basic Operation & Riding

Servicing Your Honda

Tips

Taking Care of the Unexpected

Consumer Information

Table of Contents

Quick Links

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