Page 1 Read this manual carefully, it contains important safety information. 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. OW N E R’S M A N UA L 2024 FOREMAN 4X4...
Page 2 All illustrations are based on the TRX520FM2 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.
Page 3 2024 Honda TRX520FM1 4x4 TRX520FM2 4x4 EPS TRX520FE2 4×4 ES EPS FOURTRAX FOREMAN 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 4 Introduction Congratulations on choosing your Honda ATV. Introduction 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 5 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! Introduction...
Page 6 A Few Words About Safety Your safety, and the safety of others, is very important. And A Few Words About Safety 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.
Page 7 A Few Words About Safety These signal words mean: You WILL be KILLED or DANGER SERIOUSLY HURT if you don‘t follow instructions. You CAN be KILLED or SERIOUSLY WARNING HURT if you don’t follow instructions. You CAN be HURT if you don’t CAUTION follow instructions.
Page 8 Contents These pages give an overview of the contents of your owner’s Contents manual. The first page of each section lists the topics covered in that section. ATV Safety ..................1 Important safety information you should know, plus a look at the safety related labels on your ATV.
Page 9: Table Of Contents
What to do if you have a flat tire, your engine won’t start, etc. Technical Information ............245 ID numbers, technical specifications, and other technical facts. Consumer Information ............261 Information on warranties, emission controls, how to get Honda service manuals. Index ..................269 Quick Reference Handy facts about fuel, engine oil, tire sizes, and air pressures.
Page 10: Atv Safety
ATV Safety This section presents some of the most important information and ATV Safety 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 11 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 12 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 13 Don't drink or use and ride, and don't let your friends do it 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 14 Safety Labels Your ATV comes with a hang tag and several labels containing important safety information. Anyone who rides the vehicle should read and understand this information before riding. The labels should be considered permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your dealer for replacements.
Page 15 Safety Labels WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS ROADS OR ALCOHOL HELMET AND PROTECTIVE GEAR NEVER operate: without proper training or instruction at speeds too fast for your skills or the conditions on public roads - a collision can occur with another vehicle...
Page 16 Safety Labels Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. Cold tire pressure : Front : 4.4psi (30kPa) Rear : 4.4psi (30kPa) Maximum weight capacity : 551lbs. (250kg) WARNING Overloading this ATV or carrying cargo improperly can change handling, stability...
Page 17 Safety Labels DRIVELINE INFORMATION Driving in Front Differential Lock Mode changes the way your vehicle handles and turns. Use this mode only at low speed. See owner’s manual for more information. BRAKING INFORMATION With four-wheel drive, operating any brake control causes braking at both the front and rear wheels.
Page 18: Instruments & Controls
Instruments & Controls This section shows the location of all indicators and controls you Instruments & Controls 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 19 Instruments & Controls Controls & Features ..............35 Ignition Switch................. 35 4WD Switch ................36 Front Differential Lock and Speed Limiter Override (Differential Lock Switch and Start/Override Button) ........37 Start/Override Button............... 40 Engine Stop Switch..............41 Headlight Switch ..............42 Headlight Dimmer Switch ............
Page 20: Operation Component Locations
Operation Component Locations TRX520FM1/FM2 rear brake lever/ parking brake lever headlight switch P/R lever front brake lever 4WD switch ignition switch throttle lever engine stop switch differential lock switch start/override button headlight dimmer switch Instruments & Controls...
Page 21 Operation Component Locations TRX520FE2 parking brake lock lever rear brake lever/ headlight dimmer switch parking brake lever headlight switch reverse switch front brake lever 4WD switch ignition switch gearshift throttle lever switches differential lock switch start/override button engine stop switch Instruments &...
Page 22 Operation Component Locations front utility box front cargo rack rear cargo rack flag pole bracket rear brake pedal recoil starter (TRX520FM1/FE2 with recoil starter only) Instruments & Controls...
Page 23 Operation Component Locations accessory socket side utility box utility pocket shift lever trailer hitch (TRX520FM1/FM2) storage compartment Instruments & Controls...
Page 24: 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. (1) neutral indicator (5) high coolant temperature (2) reverse indicator indicator...
Page 25 Indicators & Displays Lamp Check Initial lamp check: The indicators come on for a few seconds and then go off when you turn the ignition switch to ON (q). TRX520FM2/FE2: The PS (Electric Power Steering) indicator comes back on and remains on until the engine is started after initial lamp check.
Page 26 Indicators & Displays Display Check When the ignition switch is turned on, the multi-function display (1) will temporarily show all the modes and digital segments and initial message. This is so you can make sure the liquid crystal display is functioning properly.
Page 27 Indicators & Displays Neutral indicator Lights when the transmission is in neutral. Lamp Check. Reverse indicator Lights when the transmission is in reverse. Lamp Check. Differential lock Lights when the front differential lock indicator mode is engaged. Should also light for a few seconds and go off when the ignition switch is turned on, and then come back on and remain on until the...
Page 28 Indicators & Displays Multi-function The display includes the following display functions. Display Check. 4WD indicator Shows when the 4WD drive mode is engaged. If the indicator blinks with the differential lock indicator when there is any abnormality in the front final gear system.
Page 29 Indicators & Displays Mode select Selects display in the lower parts of button multi-function display. Adjusts the digital clock (page 27). Changes the speed and mileage units (page 23). Resets the tripmeter to zero (0) (page 28). This button also used to reset the maintenance tripmeter and maintenance hour meter (page 34).
Page 30: Multi-Function Display
Indicators & Displays Multi-function Display The multi-function display (1) includes the following functions: 4WD indicator Odometer Gear position indicator Tripmeter Speedometer Coolant temperature gauge Maintenance minder indicator Hour meter Fuel gauge Maintenance tripmeter Digital clock Maintenance hour meter (1) multi-function display (5) lower part of the multi-function display (2) gear position indicator...
Page 31 Indicators & Displays Each time you press the mode select button, the mode will change as shown in the illustration. Fuel gauge (page 25) Digital clock (page 27) Odometer (page 28) Hour meter (page 31) Tripmeter (page 28) Maintenance tripmeter (page 32) Coolant temperature gauge (page 29)
Page 32: Speed And Mileage Unit Changing
Indicators & Displays Speed and Mileage Unit Changing The speedometer, odometer, tripmeter, and maintenance tripmeter show in either “MPH” and “MILE” or “KM/H” and “KM”. To change the speed and mileage units, press and hold the mode select button (1) for more than 5 seconds in the odometer mode (page 22) with the ATV stopped.
Page 33: Gear Position Indicator
Indicators & Displays Gear Position Indicator The gear position indicator (1) shows the gear position when the ignition switch is in the ON (q) position. The indicator displays: N for neutral, R for reverse, and 1 – 5 for the five forward gears.
Page 34: Fuel Gauge
Indicators & Displays Fuel Gauge The fuel gauge (1) shows the approximate fuel supply available with the fuel mark (2). The fuel tank capacity is: 3.88 US gal (14.7 ℓ) (1) fuel gauge (2) fuel mark Regardless of what mode the display is in, when the fuel level reaches 1st segment (3), the display will automatically switch to the fuel gauge display.
Page 35 Indicators & Displays (4) “E _ _ _ _ _ F” (5) “LO FUEL” When the fuel gauge shows “E _ _ _ _ _ F” (4) and “LO FUEL” (5) blinks 3 times alternately and the fuel mark blinks, you should refuel as soon as possible.
Page 36: Digital Clock
Indicators & Displays Digital Clock The digital clock (1) shows time with the clock mark (2) when the ignition switch is ON (q). (1) digital clock (3) mode select button (2) clock mark To adjust the time, proceed as follows: 1.
Page 37: Odometer
Indicators & Displays Odometer The odometer (1) registers total distance traveled in mileage while the ignition switch is ON (q) with the “ODO” mark (2). The odometer locks at 999,999 when the readout exceeds 999,999. (1) odometer (2) “ODO” mark Tripmeter The tripmeter (1) shows mileage per trip since you last reset the tripmeter while the ignition switch is ON (q) with the “TRIP”...
Page 38: Coolant Temperature Gauge
Indicators & Displays Coolant Temperature Gauge The coolant temperature gauge (1) shows coolant temperature with the coolant temperature mark (2) while the ignition switch is ON (q). The normal operating temperature range is within the section between the 1st segment (3) and 4th segment (4). When coolant temperature is low, the coolant temperature gauge will display “Lo”...
Page 39 Indicators & Displays When the coolant is exceeds the specified temperature, the 5th segment (6) appears and the high coolant temperature indicator (7) lights. If this occurs, stop the engine and check the reserve tank coolant level. Read pages 234 – 235 and do not ride the ATV until the problem has been corrected.
Page 40: Hour Meter
Indicators & Displays Hour meter The hour meter (1) shows accumulated hours while the ignition switch is ON (q) with the hour meter mark (2). The hour meter provides accurate service period information for initial and regular maintenance. The hour meter locks at 99,999.9 when the readout exceeds 99,999.9.
Page 41: Maintenance Tripmeter/Maintenance Hour Meter
Indicators & Displays Maintenance Tripmeter/Maintenance Hour meter The maintenance tripmeter (1) shows mileage to maintenance while the ignition switch is ON (q) with the maintenance minder indicator (2). The maintenance hour meter (3) shows remaining time to maintenance while the ignition switch is ON (q) with the maintenance minder indicator.
Page 42 Indicators & Displays Maintenance Minder Indicators: Initial Maintenance 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.
Page 43 Indicators & Displays Reset the maintenance tripmeter/maintenance hour meter after maintenance. To reset the maintenance tripmeter/maintenance hour meter, proceed as follows: Press and hold the mode select button (5) and turn the ignition switch (6) to ON (q). The maintenance minder indicator will appear, then it will blink twice and the multi-function display will temporarily show all the modes and digital segments.
Page 44: Controls & Features
Controls & Features Ignition Switch The ignition switch (1) is used for starting and stopping the engine (page 84). Insert the key and turn it to the right for the ON (q) position. The ignition switch is also used to reset the maintenance tripmeter/ maintenance hour meter (page 34).
Page 45: 4Wd Switch
Controls & Features 4WD Switch Your ATV is equipped with a 4WD switch (1), which permits a choice between the “2WD” and “4WD” drive modes. Select a drive mode that’s suitable for your riding. Keep both hands on the handlebar while the machine is in motion and come to a complete stop before using the 4WD switch.
Page 46: Front Differential Lock And Speed Limiter Override (Differential Lock Switch And Start/Override Button)
Controls & Features Front Differential Lock and Speed Limiter Override (Differential Lock Switch and Start/Override Button) Your ATV is equipped with a front differential lock feature that includes a speed limiter and speed limiter override. This system is designed to provide maximum traction to help you escape from situations where the vehicle might otherwise become stuck, in the mud for example.
Page 47 Controls & Features To select the front differential lock mode: When the 4WD mode is engaged, reduce the speed of your ATV to below 10 mph (16 km/h) and slide the differential lock switch (1) over the 4WD switch. The differential lock indicator (2) will flash fast and the front differential locking process begins.
Page 48 Controls & Features To activate the speed limiter override mode: Push the start/override button (3) when the front differential lock mode is activated. LEFT HANDLEBAR TRX520FM1/FM2 TRX520FE2 (3) start/override button Front final gear system failure: The differential lock indicator and 4WD indicator (4) will both flash when there is any abnormality in the front final gear system.
Page 49: Start/Override Button
Controls & Features Start/Override Button LEFT HANDLEBAR TRX520FM1/FM2 TRX520FE2 (1) start/override button START or SPEED LIMITER OVERRIDE MODE The start/override button (1) is used for starting the engine and activating the speed limiter override mode. Pushing the button in starts the engine. See Starting Procedure, page 86.
Page 50: Engine Stop Switch
Controls & Features Engine Stop Switch LEFT HANDLEBAR TRX520FM1/FM2 TRX520FE2 (1) engine stop switch r OFF e RUN The engine stop switch (1) is used to stop the engine in an emergency. To operate, slide the switch to the OFF (r) position. The switch must be in the RUN (e) position to start the engine, and it should normally remain in the RUN (e) position even when the engine is OFF.
Page 51: Headlight Switch
Controls & Features Headlight Switch LEFT HANDLEBAR TRX520FM1/FM2 TRX520FE2 (1) headlight switch y ON t OFF (2) headlight dimmer switch u HI i LO The headlight switch (1) is used to turn the headlights and assist headlight ON (y) or OFF (t). To operate, turn the switch to ON (y) or OFF (t).
Page 52: Recoil Starter (Trx520Fm1/Fe2 With Recoil Starter Only)
Controls & Features Recoil Starter (TRX520FM1/FE2 with recoil starter only) RIGHT SIDE (1) recoil starter The recoil starter (1) is used to start the engine when the battery is low. See Using the Recoil Starter (TRX520FM1/FE2 with recoil starter only), page 90. Instruments &...
Page 53: 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 (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.
Page 54: Gearshift Switch (Trx520Fe2)
Controls & Features Gearshift Switch (TRX520FE2) These switches are used to select the next higher or lower gear in the transmission. To operate, press the upshift switch (1) to engage the next higher gear or press the downshift switch (2) to engage the next lower gear.
Page 55: Reverse Switch (Trx520Fe2)
Controls & Features Reverse Switch (TRX520FE2) LEFT HANDLEBAR (1) reverse switch The reverse switch (1) is used when shifting the transmission into reverse (R). To shift into reverse (R), see Riding in Reverse (TRX520FE2), page 98. Instruments & Controls...
Page 56: 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 100. Rear Brake Lever/Parking Brake Lever The rear brake lever/parking brake lever is used to slow or stop your ATV.
Page 57: Parking Brake/Reverse Lever (P/R Lever: Trx520Fm1/Fm2)
Controls & Features Parking Brake/Reverse Lever (P/R Lever: TRX520FM1/FM2) LEFT HANDLEBAR (1) P/R lever (2) rear brake lever/parking brake lever The P/R lever (1) on the rear brake lever/parking brake lever (2) is used to apply the parking brake or to shift the transmission into reverse.
Page 58 Controls & Features To apply the parking brake: Bring the vehicle to a complete stop and make sure the transmission is in neutral. Squeeze the rear brake lever/parking brake lever (1), then rotate the P/R lever (2) clockwise until it engages the slot on the rear brake lever/parking brake lever bracket.
Page 59: Parking Brake Lock Lever (Trx520Fe2)
Controls & Features Parking Brake Lock Lever (TRX520FE2) LEFT HANDLEBAR (1) parking brake lock lever (2) rear brake lever/parking brake lever The parking brake lock lever (1) on the rear brake lever/parking brake lever (2) is used to apply the parking brake. Instruments &...
Page 60 Controls & Features To apply the parking brake: Bring the vehicle to a complete stop and make sure the transmission is in neutral. Squeeze the rear brake lever/parking brake lever (1), then rotate the parking brake lock lever (2) clockwise until it engages the slot on the rear brake lever/parking brake lever bracket.
Page 61: Flag Pole Bracket
Controls & Features Flag Pole Bracket RIGHT REAR (1) flag pole bracket Flag poles are optional equipment available from your dealer. To mount a pole in the bracket (1), follow the instructions that come with the flag pole kit. Flag poles are required in some riding areas. Check local regulations before riding.
Page 62: Trailer Hitch
Controls & Features Trailer Hitch REAR (1) trailer hitch (2) ball The trailer hitch (1) is located on the rear axle housing. To use the hitch, you’ll need a proper size ball (2) as specified by the trailer manufacturer. To attach the ball and properly hook up a trailer, follow the trailer manufacturer’s instructions.
Page 63: Accessory Socket
Controls & Features Accessory Socket LEFT FRONT (1) accessory socket (3) accessory socket cap (2) assist headlight The accessory socket (1) is attached to the left side under the assist headlight (2). You can use the accessory socket to power a trouble light, spotlight, CB radio, or cell phone, etc.
Page 64 Controls & Features Be sure the engine is on and the headlights are turned off before using the accessory socket, otherwise you may drain the battery. The accessory socket’s rated capacity is DC 12 V, 120 Watts (10 A) or less. If you exceed this limit, you may blow a fuse. See If a Fuse Blows, page 236.
Page 65: Side Utility Box
Controls & Features Side Utility Box The side utility box (1) is located on the left side of the front fender. You may store small, lightweight items in the box. To open: Pull up the front of the side utility box cover (2). To close: Push down the front of the side utility box cover until it locks in place.
Page 66: Front Utility Box
Controls & Features Front Utility Box The front utility box (1) is located on the front center cover. You may store small, lightweight items in the box. To open: Pull up the front of the front utility box cover (2). To close: Push down the front of the front utility box cover until it locks in place.
Page 67: Utility Pocket
Controls & Features Utility Pocket The utility pocket (1) is located on the left side cover. You may store small, lightweight items in the pocket. NOTICE Do not store valuable items in the utility pocket. LEFT SIDE COVER (1) utility pocket Instruments &...
Page 68: Storage Compartment
Controls & Features Storage Compartment The storage compartment (1) is located below the rear cargo rack (2). To open the compartment, unhook the rubber strap (3). Be careful not to flood this area when washing your ATV. REAR (1) storage compartment (2) rear cargo rack (3) rubber strap Instruments &...
Page 69: Eps (Electric Power Steering) (Trx520Fm2/Fe2)
Controls & Features EPS (Electric Power Steering) (TRX520FM2/FE2) This ATV is equipped with an electronically controlled, electric- power-assisted steering system. While the engine is running, the EPS (Electric Power Steering) system provides power from the electric motor, which helps you to turn the ATV’s handlebar more easily.
Page 70: Before Riding
Before Riding Before each ride, you need to make sure you and your Honda are Before Riding 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 71: 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: •...
Page 72 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.
Page 73: 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 74: 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. WARNING WARNING A child using an ATV that is not recommended for their age could lose vehicle control while riding, resulting in severe injury or death.
Page 75: 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 76: Is Your Atv Ready To Ride
Is Your ATV Ready to Ride? Before each ride, it’s important to inspect your ATV and make sure any problem you find is corrected. A pre-ride inspection is a must, not only for safety, but because having a breakdown, or even a flat tire, can be a major inconvenience.
Page 77 Is Your ATV Ready to Ride? Fuel Check the level and add fuel (page 137) if needed. Also make sure the fuel fill cap is securely fastened. Check for leaks. Tires Use a gauge to check the air pressure. Adjust if needed.
Page 78 Is Your ATV Ready to Ride? Cable Check the cable housings for wear. Check the fittings for looseness. Replace or tighten as needed. Lights Make sure the headlights, brake light and taillight are working properly. If you are carrying cargo, also check the following: Loading Limits Make sure you do not exceed the load limits (page 72).
Page 79 Is Your ATV Ready to Ride? Headlight and Check for proper function (page 42). Headlight Dimmer Switch Engine Stop Switch Check for proper function (page 41). 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.
Page 80: 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 81: 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 82: 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: •...
Page 83: Accessories & Modifications
Accessories & Modifications Modifying your ATV or using non-Honda accessories can make your ATV unsafe. Before you consider making any modifications or adding an accessory, be sure to read the following information. WARNING WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed.
Page 84: 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...
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Page 86: Basic Operation & Riding
Basic Operation & Riding This section gives basic riding instructions, including how to start and Basic Operation & Riding 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 253).
Page 87 Basic Operation & Riding Braking..................100 Riding Your ATV............... 102 Making Turns ................ 102 Skidding or Sliding..............104 Riding Up Hills ............... 105 Riding Down Hills ..............109 Crossing or Turning on Hills or Slopes ........110 Riding Over Obstacles ............112 Riding Through Water ............
Page 88: Safe Riding Precautions
Safe Riding Precautions Before riding your ATV for the first time, please review the ATV Safety section beginning on page 1, and the Before Riding section beginning on page 61. Even if you have ridden other ATVs, take time to become familiar with how this ATV works and handles.
Page 89: 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 90: Control Speed
Safe Riding Precautions (1) footpeg Control Speed Riding at excessive speed increases the chance of a crash. In choosing a proper speed, you need to consider the capability of your vehicle, the terrain, visibility and other operating conditions, plus your own skills and experience. WARNING WARNING Operating this ATV at excessive speeds...
Page 91: 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.) WARNING WARNING...
Page 92: 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. WARNING WARNING Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction or vehicle control, which could result in a crash, including an...
Page 93: 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 94: Preparation
Starting & Stopping the Engine Preparation TRX520FM1/FM2 TRX520FE2 (1) ignition switch (3) engine stop switch (2) neutral indicator 1. Before starting, select a level surface and lock the parking brake (page 48). 2. Turn the ignition switch (1) to ON (q). Confirm the following: •...
Page 95: Starting Procedure
Starting & Stopping the Engine Starting Procedure This ATV is fuel-injected with an automatic choke. Follow the procedure indicated below. Any Air Temperature • Press the start/override button with the throttle completely closed. The engine will not start if the throttle is fully open (because the electronic control module cuts off the fuel supply).
Page 96: 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: 1. Leave the engine stop switch set to RUN (e). 2. Open the throttle fully. 3.
Page 97: Stalled Engine
Starting & Stopping the Engine Stalled Engine You can restart the engine while the vehicle is stopped by squeezing the front brake lever and pressing the start/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).
Page 98: 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 to OFF (w). The engine stop switch should normally remain in the RUN (e) position even when the engine is OFF.
Page 99: Using The Recoil Starter (Trx520Fm1/Fe2 With Recoil Starter Only)
Starting & Stopping the Engine Using the Recoil Starter (TRX520FM1/FE2 with recoil starter only) The recoil starter is used to start the engine when the battery is low. To operate the recoil starter: 1. Turn the ignition switch to ON and engine stop switch to RUN. 2.
Page 100: Shifting Gears
Shifting Gears Shifting Gears (TRX520FM1/FM2) 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 101 Shifting Gears 2. With the throttle closed, raise the shift lever one full stroke to shift into 1st (first) gear. 3. Release the rear brake lever/parking brake lever and increase engine speed by gradually opening the throttle. 4. When speed increases, release the throttle and shift to 2nd gear by raising the shift lever one full stroke.
Page 102: Shifting Gears (Trx520Fe2)
Shifting Gears Shifting Gears (TRX520FE2) UPSHIFTING SEQUENCE DOWNSHIFTING SEQUENCE (1) upshift switch (A) press (2) downshift switch Your ATV has five forward gears (1, 2, 3, 4, and 5). Two gearshift switches are located next to the left handlebar grip: Upshift ( ) and downshift ( ).
Page 103 Shifting Gears 2. With the throttle closed, press the upshift switch once to shift into 1st (first) gear. 3. Release the rear brake lever/parking brake lever and increase engine speed by gradually opening the throttle. 4. When speed increases, release the throttle and shift to 2nd gear by pressing the upshift switch once.
Page 104 Shifting Gears • Downshift to a lower gear before you feel the engine laboring (lugging) at low rpm. • Avoid downshifting to help slow your ATV when engine rpm is high. Downshifting when engine speed is near its allowable maximum may over-rev the engine and possibly cause damage. •...
Page 105: Riding In Reverse
Riding in Reverse Riding in Reverse (TRX520FM1/FM2) If you need to ride in reverse, make sure the area behind you is clear and only operate the ATV at low speed. WARNING WARNING Improperly operating in reverse could cause you to hit an obstacle or person behind you, resulting in serious injury.
Page 106 Riding in Reverse NOTICE Your ATV may be equipped with a reverse speed limiter, which helps the vehicle to maintain a safe speed while riding in reverse gear. 5. Make sure that the reverse indicator comes on and the gear position indicator shows “R”.
Page 107: Riding In Reverse (Trx520Fe2)
Riding in Reverse Riding in Reverse (TRX520FE2) If you need to ride in reverse, make sure the area behind you is clear and only operate the ATV at low speed. WARNING WARNING Improperly operating in reverse could cause you to hit an obstacle or person behind you, resulting in serious injury.
Page 108 Riding in Reverse NOTICE Your ATV may be equipped with a reverse speed limiter, which helps the vehicle to maintain a safe speed while riding in reverse gear. 4. Make sure that the reverse indicator comes on and the gear position indicator shows “R”.
Page 109: Braking
Braking Your ATV is equipped with disc brakes on both front wheels, which are hydraulically activated by operating the front brake lever. A single drum brake on the rear axle housing is mechanically activated by depressing the brake pedal or operating the 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 110 Braking When possible, reduce your speed or complete braking before entering a turn. Avoid braking or closing the throttle quickly while turning. Either action may cause one or more wheels to slip and reduce your control of your ATV. Your ability to brake in a turn and to brake hard in an emergency situation are important riding skills.
Page 111: 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. WARNING WARNING Turning improperly can make the ATV go out of control, causing a collision or overturn.
Page 112 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. Leaning into a turn is an important technique to master in riding an ATV.
Page 113: 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 114: 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. However, you must be able to decide which hills or hazards might cause the ATV to overturn.
Page 115 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 116 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. WARNING WARNING Stalling, rolling backwards or improperly...
Page 117 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 118: 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. WARNING WARNING Going down a hill improperly could cause loss of control or cause the ATV to overturn.
Page 119: 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 120 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 121: 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.
Page 122: 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. WARNING WARNING The ATV tires have some ability to float.
Page 123 Riding Your ATV 1. Choose a path where both banks have gradual slopes. 2. Proceed through the water at a slow, steady speed. 3. Watch out for submerged obstacles and slippery rocks. 4. Avoid getting the spark plug or air cleaner wet, as this would cause the engine to stop.
Page 124: Parking
Parking 1. Look for level parking area. Make sure the ground surface is firm. 2. After bringing your ATV to a stop, hold the brakes while you shift into neutral. 3. Set the parking brake. 4. Turn the ignition switch to OFF (w). If it is necessary to start the engine when your ATV in gear and is stopped on a grade, rock the vehicle back and forth to allow shifting the transmission into neutral.
Page 125: Servicing Your Honda
You’ll also find important safety precautions, information on fuels and oils, and tips for keeping your Honda looking good. For information about replacing fuses, see page 236. For information about the exhaust emission and noise requirements of the U.S.
Page 126 Servicing Your Honda Service Procedures Fluids & Filters Fuel ..................136 Engine Oil & Filter ..............139 Rear Final Gear Oil ..............148 Front Final Gear Oil..............151 Coolant ..................153 Air Cleaner ................161 Engine Throttle ..................167 Clutch System ................169 Reverse Inhibitor System ............
Page 127: The Importance Of Maintenance
Before You Service Your Honda The Importance of Maintenance A well-maintained ATV is essential for safe, economical, and trouble- free riding. It will also help reduce air pollution. Careful pre-ride inspections and good maintenance are especially important because your ATV is designed to be ridden over rough off-road terrain.
Page 128: 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 129: 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 130: Maintenance Schedule
Procedures for such items in this schedule are provided in an official Honda Service Manual available for purchase (page 262). If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it.
Page 131 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 (page 262). ** In the interest of safety, we recommend these items be serviced only by your dealer.
Page 132 RADIATOR COOLANT NOTE 3 COOLING SYSTEM NOTE 2 — * 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 (page 262). Servicing Your Honda...
Page 133 * 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 (page 262). ** In the interest of safety, we recommend these items be serviced only by your dealer.
Page 134: Maintenance Record
12 or 200 1,800 (3,000) or 18 or 300 2,400 (4,000) or 24 or 400 3,000 (5,000) or 30 or 500 3,600 (6,000) or 36 or 600 4,200 (7,000) or 42 or 700 4,800 (8,000) or 48 or 800 Servicing Your Honda...
Page 135: Maintenance Component Locations
Maintenance Component Service Preparations Locations TRX520FM1/FM2 front brake fluid reservoir P/R lever reverse front brake lever assist lever rear brake lever/ throttle lever parking brake lever Servicing Your Honda...
Page 136 Maintenance Component Locations TRX520FE2 front brake fluid reservoir parking brake lock lever front brake lever rear brake lever/ throttle lever parking brake lever Servicing Your Honda...
Page 137 Servicing Your Honda...
Page 138 (TRX520FE2) spark plug coolant reserve tank spark arrester engine oil fill cap/ rear brake panel dipstick engine oil drain bolt rear suspension spring pre-load adjuster rear final gear oil fill cap rear final gear oil drain bolt Servicing Your Honda...
Page 139: Tool Kit
(TRX520FE2) securely. An optional, larger tool kit may be available. Check with your dealer’s parts department. UNDER REAR FENDER COVER (1) tool kit (3) rubber band (2) gear change tool (TRX520FE2) Servicing Your Honda...
Page 140: Owner's Manual Storage
Be careful not to flood this area when washing your ATV. UNDER REAR FENDER COVER (1) owner’s manual (4) air pressure gauge (2) plastic document bag (5) 40 A spare fuse (3) rear fender cover (6) fuse puller (7) rubber band Servicing Your Honda...
Page 141: Seat Removal
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. Servicing Your Honda...
Page 142: Rear Fender Cover Removal
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. Servicing Your Honda...
Page 143: Tank Cover Assembly Removal
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. Servicing Your Honda...
Page 144: Clip Removal
1. Pull 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. Servicing Your Honda...
Page 145: Fuel
86 (or higher) Use only unleaded fuel in your Honda. If you ride your Honda in a country where leaded fuel might be available, take precautions to use only unleaded fuel. Your engine is designed to use any unleaded gasoline that has a pump octane number of 86 or higher.
Page 146 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. Refueling Procedure Refer to Safety Precautions on page 120. (1) fuel fill cap (2) bottom of the filler neck (cont’d) Servicing Your Honda...
Page 147 After refueling, turn the fuel fill cap clockwise securely. (California type) After refueling, turn the fuel fill cap clockwise until it clicks. If you replace the fuel fill cap, use a Honda Genuine replacement part or equivalent. NOTICE Gasoline can damage the camouflage coating.
Page 148: Engine Oil & Filter
Change the engine oil as specified in the maintenance schedule on page 123. When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule. Servicing Your Honda...
Page 149 SAE 10W-30 JASO T 903 standard suggested oil Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil. Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving or resource conserving on the circular API service label.
Page 150 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) oil code (2) oil classification Servicing Your Honda...
Page 151 3. Stop the engine and wait 2 – 3 minutes. 4. Remove the oil check/fill door (1) by disengaging the studs (2) from the grommets and releasing the tabs (3) from the slits. LEFT SIDE (1) oil check/fill door (3) tabs (2) studs Servicing Your Honda...
Page 152 8. Reinstall the oil fill cap/dipstick. 9. Install the oil check/fill door. NOTICE Running the engine with an improper oil level can cause serious engine damage. LEFT SIDE (4) oil fill cap/dipstick (5) upper level mark (6) lower level mark Servicing Your Honda...
Page 153 Changing Engine Oil & Filter Refer to Safety Precautions on page 120. Your ATV’s oil filter has very specific performance requirements. Use a new Honda Genuine oil filter specified for your model or a filter of equal quality. NOTICE Using the wrong oil filter may result in leaks or engine damage.
Page 154 Engine Oil & Filter 2. Place an oil drain pan under the crankcase and remove the engine oil drain bolt (1) and sealing washer (2). UNDER ENGINE (2) sealing washer (1) engine oil drain bolt Servicing Your Honda...
Page 155 (8) facing out, away from the engine. You will see the “OUT-SIDE (TOWARDS FILTER COVER)” mark (9) on the filter body, near the seal. Use only the Honda Genuine oil filter or a filter of equivalent quality specified for your model.
Page 156 If necessary, add more oil but do not overfill. 6. Check that there are no oil leaks. 7. Install the oil check/fill door. If a torque wrench is not used for installation, see your dealer as soon as possible to verify proper assembly. Servicing Your Honda...
Page 157: Rear Final Gear Oil
(weight) SAE 80W-90 suggested oil Honda shaft drive oil or equivalent Changing Oil Refer to Safety Precautions on page 120. Change the oil with the rear final gear at normal operating temperature to assure complete and rapid draining.
Page 158 3. Remove the oil fill cap (2), O-ring (3), drain bolt and sealing washer (4). 4. After the oil has completely drained, reinstall the drain bolt with a new sealing washer and tighten it to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) (cont’d) Servicing Your Honda...
Page 159 9. Install the oil level check bolt with a new sealing washer and tighten it to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) REAR (5) oil level check bolt (7) oil level check hole (6) sealing washer Servicing Your Honda...
Page 160: Front Final Gear Oil
(weight) SAE 80W-90 suggested oil Honda shaft drive oil or equivalent Changing Oil Refer to Safety Precautions on page 120. Change the oil with the front final gear at normal operating temperature to assure complete and rapid draining.
Page 161 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) FRONT (1) oil drain bolt (4) sealing washer (2) oil fill cap (5) oil fill inspection hole (3) O-ring Servicing Your Honda...
Page 162: Coolant
Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion. Coolant Recommendation Use Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. Check the antifreeze container label.
Page 163 (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. Servicing Your Honda...
Page 164 5. Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark. FRONT (4) radiator cap lid (6) grommet (5) stud (7) reserve tank cap 6. After adding coolant, reinstall the reserve tank cap. 7. Install the radiator cap lid. Servicing Your Honda...
Page 165 Refer to Safety Precautions on page 120. Coolant should be replaced by your dealer, unless you have the proper tools and service data, and are mechanically qualified. Refer to the official Honda Service Manual (page 262). WARNING WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you.
Page 166 20% of the radiator surface. Clean the radiator core after riding the ATV in mud. The right, left and center radiator grill covers must be removed to clean the radiator core. Servicing Your Honda...
Page 167 2. Remove the reserve tank (1) by removing the bolt (2) and clips (3) (page 135). 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 (3) clips (2) bolt (4) hoses Servicing Your Honda...
Page 168 B, tab C, hook A, hook B and hose (12), then remove the center radiator grill cover (13). RIGHT FRONT (TRX520FM1) (11) (12) (13) (10) (6) (11) right radiator grill cover (13) center radiator grill cover (12) hose (cont’d) Servicing Your Honda...
Page 169 9. Wash the radiator core (14) and radiator grill covers. NOTICE Do not apply pressured water directly to the radiator core. The pressured water can damage the radiator core. 10. Install the removed parts in reverse order of removal. Servicing Your Honda...
Page 170: Air Cleaner
Your dealer can help you determine the correct service interval for your riding conditions. Your ATV’s air cleaner has very specific performance requirements. Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality. NOTICE Using the wrong air cleaner may result in premature engine wear.
Page 171 Air Cleaner Cleaning 1. Remove the seat (page 132). UNDER SEAT (1) retainer clips (2) air cleaner housing cover 2. Unlatch the retainer clips (1). 3. Remove the air cleaner housing cover (2). Servicing Your Honda...
Page 172 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.
Page 173 • 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) tab Servicing Your Honda...
Page 174 Air Cleaner Dust Cover UNDER SEAT (1) dust cover (2) breather joint Do not push the dust cover (1) too far into the breather joint (2). If the dust cover is dirty, clean it. Servicing Your Honda...
Page 175 (3) air cleaner housing (2) clip 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. Servicing Your Honda...
Page 176: Throttle
3. Turn the adjuster to obtain the correct freeplay. 4. Tighten the lock nut and reinstall the sleeve. 5. After adjustment, check for smooth operation of the throttle lever from fully closed to fully open in all steering positions. Servicing Your Honda...
Page 177 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. Servicing Your Honda...
Page 178: Clutch System
If you cannot get proper adjustment, or the clutch does not work properly, the clutch friction discs may be worn. See your dealer or refer to official Honda Service Manual (page 262). Servicing Your Honda...
Page 179: Reverse Inhibitor System
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. Servicing Your Honda...
Page 180: Spark Plug
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. LEFT SIDE (1) spark plug cap (cont’d) Servicing Your Honda...
Page 181 The gap should be: 0.039 – 0.043 in (1.00 – 1.10 mm) 0.039 – 0.043 in (1.00 – 1.10 mm) (2) center electrode (4) spark plug gap (3) side electrode Servicing Your Honda...
Page 182 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. Servicing Your Honda...
Page 183: 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. Servicing Your Honda...
Page 184: Spark Arrester
3. Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel. 4. Stop the engine and allow the exhaust pipe to cool. 5. Reinstall the bolt securely. Servicing Your Honda...
Page 185: Suspension
Do not attempt to disassemble, service, or dispose of the damper; see your dealer. The instructions found in this owner’s manual are limited to adjustments of the shock assembly only. Servicing Your Honda...
Page 186 Refer to Safety Precautions on page 120. FRONT REAR (1) spring pre-load adjuster (2) pin spanner The spring pre-load adjuster (1) has 5 positions for different load or riding conditions. Use the pin spanner (2) to adjust the shock spring pre-load. Servicing Your Honda...
Page 187 Make sure that both front shock absorbers are adjusted to the same position. Always adjust the shock absorber position in sequence (1-2-3-4-5 or 5-4-3-2-1). Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber. Servicing Your Honda...
Page 188: 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 189 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. Servicing Your Honda...
Page 190 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 dealer. Servicing Your Honda...
Page 191 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. Servicing Your Honda...
Page 192 Measure the distance the rear brake pedal (1) moves before the brake starts to take hold. Freeplay, measurement at the tip of the end of the pedal, should be: 9/16 – 13/16 in (15 – 20 mm) If necessary, adjust to the specified range. Servicing Your Honda...
Page 193 (3). 2. Adjust the freeplay of the rear brake pedal. Push the brake arm (4), then check the clearance between the brake arm and the brake arm pin. (4) brake arm Servicing Your Honda...
Page 194 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 195 (3). 2. Adjust the freeplay of the rear brake lever/parking brake lever. Push the brake arm (4) then check the clearance between the brake arm and the brake arm pin. (4) brake arm Servicing Your Honda...
Page 196 (1) on the brake arm (2). 2. Replace the brake shoe if the arrow aligns with the reference mark (3) on the brake panel upon full application of the brake. If replacement is necessary, see your dealer. Servicing Your Honda...
Page 197 (2). Turn the nut in direction (A) if the switch operates too late and in direction (B) if the switch operates too soon. RIGHT REAR (1) rear brake light switch (2) adjusting nut Servicing Your Honda...
Page 198 If any water drains, the brake seals must be replaced by your dealer as soon as possible. 3. Install the rear brake drain bolt with a new sealing washer and tighten it to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) Servicing Your Honda...
Page 199: 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 200 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 201 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 4.4 psi (30 kPa) 4.4 psi (30 kPa) PRESSURE Servicing Your Honda...
Page 202 • 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 203 (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) Servicing Your Honda...
Page 204 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 dealer.
Page 205 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. Servicing Your Honda...
Page 206: Guards
Maintenance Schedule. Have the engine guard and skid plate replaced if they are cracked or damaged. If the guard and plate bolts are loose, tighten them securely. Servicing Your Honda...
Page 207 (1) front boot guards (2) front driveshaft guards Check the front boot guards (1) and front driveshaft guards (2) for cracks, damage or looseness. Tighten any loose fasteners. Replace the front boot guards and front driveshaft guards as required. Servicing Your Honda...
Page 208: Drivetrain Boots
Refer to Safety Precautions on page 120. (1) propeller shaft boots (2) yoke joint boot Check the propeller shaft boots (1) and yoke joint boot (2) for cuts, damage or leaking grease. If necessary, have your dealer replace them. Servicing Your Honda...
Page 209 Drivetrain Boots Front Driveshaft Boots Refer to Safety Precautions on page 120. FRONT (1) driveshaft boots Check the driveshaft boots (1) for cuts, damage or leaking grease. If necessary, have your dealer replace them. Servicing Your Honda...
Page 210: Battery
If you plan to store your ATV, see Battery Storage, page 202. If your battery seems weak and/or is leaking electrolyte (causing slow starting or other electrical problems), see your dealer. WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. Wash your hands after handling. Servicing Your Honda...
Page 211 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 212 4. Release the rings and remove the rubber band (1). 5. Disconnect the negative (–) terminal lead (2) from the battery (3) first, then disconnect the positive (+) terminal lead (4). 6. Remove the battery taking care not to drop the terminal nuts (5). (cont’d) Servicing Your Honda...
Page 213 4. Make sure all bolts and other fasteners are secure. 5. Install the removed parts in reverse order of removal. (6) battery rubber After the battery is reconnected, check the clock. Readjust the clock if necessary (page 27). Servicing Your Honda...
Page 214 We recommend using a charger (1) designed specifically for your Honda, which can be purchased from your dealer. These units can be left connected for long periods without risking damage to the battery. However, do not intentionally leave the charger connected longer than the time period recommended in the charger’s...
Page 215: 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 their ATV. A clean ATV is also easier to inspect and service. General Recommendations Refer to Safety Precautions on page 120.
Page 216 Any condensation inside the headlight should dissipate after a few minutes of running the engine with the headlight(s) on. However, if you see a large amount of water or ice accumulated inside the lens(es), have your vehicle inspected by your dealer. Servicing Your Honda...
Page 217 If 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 218 Dry with chamois or a soft towel. If necessary, remove heat stains by using a commercially available fine texture compound. Then, rinse by the same manner as removing mud or dust. Servicing Your Honda...
Page 219 This page intentionally left blank. Servicing Your Honda...
Page 220: Tips
Tips Here’s helpful advice on how to prepare for an off-road adventure, Tips how to transport and store your Honda, and how to be an environmentally responsible ATV owner. Preparing for a Ride..............212 What to Take to the Riding Area..........212 What to Take on the Trail ............
Page 221: 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 222: 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 223: 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 224 Transporting Your Honda 2. Secure the vehicle with tie-down straps in the areas shown. • Suitable tie-down straps are available from your dealer. • Ordinary rope is not recommended because it can stretch under load. • Using tie-down straps in any other areas can damage your ATV.
Page 225: Storing Your Honda
That way, needed repairs won’t be forgotten and it will be easier to get your ATV running again. For more information about storage, refer to the Honda Winter Storage Guide, available from your dealer (USA only). We suggest you perform the following procedures to keep your ATV in top condition.
Page 226: Preparation For Storage
Storing Your Honda Preparation for Storage Refer to Safety Precautions on page 120. 1. Change the engine oil and filter (page 144). 2. Make sure the cooling system is filled with a 50/50% antifreeze solution (page 153). 3. Fill the fuel tank. Make sure the fuel fill cap is properly installed.
Page 227 Storing Your Honda 5. Remove the battery and charge it fully. Store it in an area protected from freezing temperatures and direct sunlight. Slow charge the battery (page 205) once a month. WARNING WARNING The battery gives off explosive hydrogen gas during normal operation.
Page 228: Removal From Storage
Storing Your Honda Removal from Storage Refer to Safety Precautions on page 120. 1. Uncover and clean your ATV. 2. If your ATV has been stored for more than four months — change the engine oil (page 144). 3. If your ATV has been stored for more than two months — ask your dealer to drain and replace the fuel.
Page 229: 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 230: Taking Care Of The Unexpected
Taking Care of the Unexpected With all the challenges you can encounter off-road, there’s a chance Taking Care of the Unexpected 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 231: 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 232 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 233: If Your Engine Quits Or Won't Start
If Your Engine Quits or Won’t Start Proper operation and maintenance can prevent starting and engine performance problems. In many cases, the cause of the problem may be a simple operational oversight. If you have a problem starting the engine — or experience poor engine performance —...
Page 234 If Your Engine Quits or Won’t Start SYMPTOM: Starter motor doesn’t operate. POSSIBLE CAUSE WHAT TO DO ignition switch OFF Turn the ignition switch ON. engine stop switch OFF Slide the engine stop switch to RUN. transmission not in Shift into neutral or squeeze neutral the front brake lever.
Page 235 If Your Engine Quits or Won’t Start SYMPTOM: Engine starts, but runs poorly. POSSIBLE CAUSE WHAT TO DO high coolant Check the coolant temperature temperature gauge and high coolant temperature indicator. If the High Coolant Refer to Temperature Indicator Lights page 234.
Page 236: If The Shift Switches Do Not Function (Trx520Fe2)
If the Shift Switches Do Not Function (TRX520FE2) If one or both shift switches do not function, see the following instructions. If proper function cannot be restored, see your dealer. When the engine is running: 1. Stop the ATV. 2. Turn the ignition switch to the OFF (w) position. 3.
Page 237: Emergency Gear Selection & Operation (Trx520Fe2)
Emergency Gear Selection & Operation (TRX520FE2) If the shift switches do not operate, use the following procedure to manually select a gear so you may drive the vehicle to a location where it can be loaded and transported to your dealer. 1.
Page 238 Emergency Gear Selection & Operation (TRX520FE2) How to Shift Gears Manually: (1) gear change tool (A) downshift (counterclockwise) (B) upshift (clockwise) • With the ATV unoccupied, align the hexagonal hole of the gear change tool (1) with the hexagonal end of the secondary spindle which is located on the front crankcase next to the front propeller shaft.
Page 239: If You Have A Flat Tire
If You Have a Flat Tire How you handle a flat tire on the trail depends on how serious the tire damage is, and what tools and supplies you have with you. If you have a slow leak or a minor puncture, use the plug method to make a temporary repair.
Page 240 If You Have a Flat Tire If you are unable to repair a flat tire on the trail, you will need to send for help. We strongly recommend that you do not try to ride with a flat tire. The ATV will be hard to handle, and if the tire comes off the rim, it may lock up the wheel and cause you to crash.
Page 241 If You Have a Flat Tire Emergency Wheel Removal/Installation Refer to Safety Precautions on page 120. (1) wheel nuts (2) wheel rim Removal 1. Park your ATV on a firm, level surface. 2. Loosen — but do not remove — the wheel nuts (1). 3.
Page 242 If You Have a Flat Tire Installation 1. Position the wheel. 2. Position the wheel nuts so that the tapered sides face the wheel rim (2). 3. Hand-tighten the wheel nuts on the wheel, then lower the ATV to the ground before tightening the nuts in a crisscross (rather than circular) pattern to the specified torque: 47 lbf·ft (64 N·m, 6.5 kgf·m) If a torque wrench was not used for installation, see your dealer as...
Page 243: If The High Coolant Temperature Indicator Lights
If the High Coolant Temperature Indicator Lights Normally, the high coolant temperature indicator will only light momentarily when you turn the ignition to ON (q). High coolant temperature may be caused by restriction of air flow to the radiator (such as mud caked on the radiator), extended idling, an oil leak, a coolant leak, a low oil level, a low coolant level, or extended operation under adverse conditions.
Page 244 If the High Coolant Temperature Indicator Lights • If the reserve tank is low or empty, don’t ride without adding coolant (page 154). After adding coolant, turn the engine on and check the coolant temperature gauge and high coolant temperature indicator. If the indicator doesn’t turn off, do not ride.
Page 245: 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 (1).
Page 246 If a Fuse Blows Main Fuses Access 1. To prevent an accidental short circuit, turn the ignition switch to OFF (w) before checking or replacing the fuses. 2. Remove the seat (page 132). 3. Remove the rear fender cover (page 133). 4.
Page 247 If a Fuse Blows 7. Pull the main fuse 2 out with the fuse puller on the underside of the rear fender cover (page 131). If the main fuse 2 is blown, install the spare fuse (6). 8. Install the fuse cover. Circuit Fuses Access TRX520FM1/FM2 TRX520FE2...
Page 248 If a Fuse Blows EPS (Electric Power Steering) Fuse Access (TRX520FM2/FE2) 1. Turn the ignition switch to OFF (w) before checking the fuse. 2. Remove the seat (page 132). 3. Remove the rear fender cover (page 133). 4. To access the EPS fuse (1), remove the fuse cover (2). If the EPS fuse is blown, see your dealer for this service.
Page 249 If a Fuse Blows If you do not have a spare fuse and you cannot ride the ATV without fixing the problem, take a fuse of the same rating or a lower rating from one of the other circuits that you can do without temporarily. If you replace a blown fuse with a spare fuse that has a lower rating, replace the fuse with the correct rating as soon as you can.
Page 250: If You Crash
If You Crash Personal safety is your first priority after a crash. If you or anyone else has been injured, take time to assess the severity of the injuries and whether it is safe to continue riding. If you cannot ride safely, send someone for help.
Page 251: If You Lose Your Key
If you lose your key and aren’t carrying a duplicate, either get your spare or have one made. If you don’t know your key number, call the dealer where you purchased your Honda ATV. They may have it listed in their records. If they don’t, transport your ATV to them or the nearest dealer.
Page 252: If The Battery Is Low (Or Dead)
If the Battery Is Low (or Dead) Jump starting is not recommended, especially if you use an automobile battery. The greater amperage of an automobile battery when the car engine is running can damage your ATV’s electrical system. Bump starting is also not recommended. If you can’t charge the battery or it appears unable to hold a charge, contact your dealer.
Page 253: 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 254: Technical Information
Technical Information This section contains dimensions, capacities, and other technical Technical Information data, plus information on government requirements and how to break-in your ATV. Vehicle Identification ..............246 Specifications ................248 Break-in Guidelines..............253 Emission Control Systems ............254 Oxygenated Fuels ..............258 Technical Information...
Page 255: Vehicle Identification
Vehicle Identification Serial Numbers The VIN and engine serial 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 (1) is stamped on the front of the frame. Remove the radiator cap lid (page 155).
Page 256 Vehicle Identification Color Label & Code The color label (1) is attached on the left side of the frame. The color code is helpful when ordering replacement parts. You may record the color code in the Quick Reference section at the rear of this manual.
Page 257: 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, or an equivalent motorcycle oil Technical Information...
Page 258 Specifications Fuel & Lubricants (cont’d) cooling system Pro Honda HP Coolant or an recommendation equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines cooling system 1.7 US qt (1.6 ℓ) capacity Capacities...
Page 259 Specifications Power Transmission primary reduction 2.103 secondary reduction 1.875 final reduction front 3.231 rear 3.154 transmission ratio 4.230 2.388 1.608 1.178 0.848 reverse 5.743 final drive shaft Chassis & Suspension caster 2° trail 0.2 in (5 mm) tire size, front AT25 ×...
Page 260 Specifications Electrical battery GYZ16H 12 V – 16 Ah (10HR) generator 0.481 kW/5,000 rpm Lights headlight 12 V 35/35 W × 2 assist headlight 12 V 50 W brake/tail light neutral indicator reverse indicator high coolant temperature indicator PGM-FI indicator differential lock indicator PS (Electric Power...
Page 261 Specifications Torque Specification engine oil drain 18 lbf·ft (25 N·m, 2.5 kgf·m) bolt engine oil filter 7 lbf·ft (10 N·m, 1.0 kgf·m) cover bolts rear final gear oil 9 lbf·ft (12 N·m, 1.2 kgf·m) drain bolt rear final gear oil 9 lbf·ft (12 N·m, 1.2 kgf·m) fill cap rear final gear oil...
Page 262: 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 263: Emission Control Systems
Emission Control Systems Exhaust Emission Requirements The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Environment Climate Change Canada (ECCC) require that your ATV comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions provided.
Page 264 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 includes a PGM-FI system and oxygen sensor.
Page 265 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 else, according to applicable law, you must inform the new owner/operator in writing that the vehicle is to be used for competition only.
Page 266 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: (1) 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...
Page 267: 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.
Page 268 Oxygenated Fuels Do not use gasoline containing METHANOL (methyl alcohol). 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 269 This page intentionally left blank. Technical Information...
Page 270: Consumer Information
Consumer Information This section contains information on your warranty and how to get Consumer Information an official Honda service manual. Authorized Manuals ..............262 Warranty Coverage ..............263 Warranty Service ..............264 Contacting Honda ..............265 Your Honda Dealer ..............267 Reporting Safety Defects (Canada only) ........
Page 271: Authorized Manuals
Authorized Manuals The Service Manual used by your authorized dealer is available from your Honda dealer or Helm, Inc. (USA only, Canada: See your dealer to order authorized manuals.) Also available but not necessary to service your model is the Honda...
Page 272: 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.
Page 273: Warranty Service
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.
Page 274: Contacting Honda
Contacting Honda Your owner’s manual was written to cover most of the questions you might ask about your Honda. Any questions not answered in the owner’s manual can be answered by your dealer. If your dealer doesn’t have the answer right away, they will get it for you.
Page 275 Contacting Honda 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.com Please include the following information in your letter: • name, address, and telephone number • product model, year, and VIN •...
Page 276: 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 277: Reporting Safety Defects (Canada Only)
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform Honda Canada Inc. and you may also inform Transport Canada. If Transport Canada receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may lead to a recall and remedy campaign.
Page 278: Index
................165 filter ..................161 housing drain tube ..............166 air pressure, gauge ..................131 tire ..................191 American Honda, contacting ............265 apparel, protective ..............62 appearance care ...............206 authorized manuals ..............262 bank angle sensor ignition cut-off system ........87 battery ..................201 brake light switch adjustment ...........188 brakes, cables ..................187...
Page 279 Index braking ..................100 break-in guidelines ..............253 button, mode select ..............15, 20, 21 start/override ................40 capacity, fuel ................137 care, appearance ..............206 cargo, loading and operational guidelines ..........73 weight limit ................72 cleaning, appearance care ............206 climbing hills ................105 clip ...................135 clutch system ................169 color label ................247 compartment, owner’s manual ..............131...
Page 280 Index display check ................17 display, multi-function ..............21 drivetrain boots ................199 emission control systems ............254 engine, flooded ...................87 guards ...................197 number .................246 oil ..................139 pinging ..................136 starting ..................84 stop switch ................41 stopping ..................89 won’t start ................224 environment ................220 EPS (Electric Power Steering) ............60 exhaust system, cleaning ..................68 purging .................175...
Page 281 ............42 headlight switch .................42 high coolant temperature indicator .......15, 18, 234 hills, crossing or turning on slopes ..........110 riding down hills ..............109 riding up hills .................105 stopping on hills ..............107 Honda service manual ..............262 Honda, contacting ................265 dealer ..................267 Index...
Page 282 Index hour meter .................31 identification, vehicle ..............246 ignition switch ................35 indicators, 4WD indicator .............19, 21, 36 differential lock indicator ..........15, 18, 37 gear position indicator ............19, 24 high coolant temperature indicator ......15, 18, 234 maintenance minder indicator ...........21, 32 neutral indicator ..............15, 18 PGM-FI indicator ..............15, 18 PS (Electric Power Steering) indicator .........15, 18 reverse indicator ..............15, 18...
Page 283 Index maintenance, component locations .............126 hour meter ................32 importance ................118 minder indicator ..............21, 32 precautions ................120 record ...................125 safety ..................119 schedule ................121 tripmeter .................32 manual, service .................262 maximum weight limit ..............72 modifications ................75 multi-function display ..............21 neutral indicator ..............15, 18 noise emission control system ...........257 numbers, serial .................246 obstacles, riding over ..............112...
Page 284 Index parking ..................115 passengers, no carrying ..............65 pavement, no riding on ..............79 pinging, engine ................136 plug, spark ................171 pre-ride inspection ..............67 problems, unexpected ..............222 propeller shaft boots & yoke joint boot ........199 protective apparel ...............62 rear fender cover removal ............133 rear final gear oil ..............148 recoil starter (TRX520FM1/FE2 with recoil starter only) ..43, 90 removal,...
Page 285 Index riding, basic operation ................77 clothing ...................62 over obstacles ................112 precautions ................79 preparing for .................212 safety ..................2 safety precautions ..............79 through water ...............113 safety, important precautions ............120 labels ..................5 riding precautions ..............79 schedule, maintenance .............121 seat removal ................132 serial numbers ................246 service, customer ................265 manuals ................262...
Page 286 Index stalling on a hill ................107 start/override button ..............40 starting, engine ..................84 troubleshooting ..............224 stop switch, engine ..............41 stopping engine .................89 storage, ATV ..................216 owner’s manual ..............131 suspension, adjustment ................176 spring pre-load ..............177 switch, 4WD ..................36 differential lock ...............37 downshift ................45, 93 engine stop ................41 headlight .................42 headlight dimmer ..............42...
Page 287 Index tires, air pressure ................191 flat ..................230 repairing ................195 replacing ................196 tread conditions ............193, 194 tool kit ..................130 trailer hitch .................53 trailer towing, operational guidelines .............73 weight limits ................72 training, rider ................64 transporting your ATV ..............214 tripmeter ..................28 trouble, unexpected ..............221 troubleshooting, starting ............224 turning, on hills or slopes ..............110...
Page 288 Index warning labels ................5 warranty, coverage ................263 extended ................263 service ...................264 washing your ATV ..............207 water, draining from brakes .............189 riding through ...............113 weight limit ................72 wheel removal ................232 Index...
Page 289: Quick Reference
Quick Reference The following is a brief, but important collection of information you Quick Reference 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 290 Quick Reference Engine No. Color Label Owner’s Name Address City/State Phone Dealer’s Name Address City/State Phone Service Mgr. Quick Reference...
Page 291 Capacity 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: 3.1 US qt (2.9 ℓ) after draining & oil filter change: 3.2 US qt (3.0 ℓ)
Page 292 4.4 psi (30 kPa) Spark Plugs standard: 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 other: 20 A ×...
Page 293 Quick Reference These symbols are used in Controls & Features section: SYMBOL COMPONENT SEE PAGE ON — ignition switch OFF — ignition switch 4WD switch differential lock switch differential lock indicator — lights when the front differential lock mode engages start/override button RUN —...
Page 294 California Proposition 65 Warning WARNING: Operating, servicing and maintaining a passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
Page 295 - pavement may seriously affect handling and control LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 31HR4700 © 2022 Honda Motor Co., Ltd. 00X31-HR4-7000 Printed in the U.S.A. All Rights Reserved...

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Honda FOURTRAX FOREMAN 4X4 2024 Owner's Manual

Table of Contents

Instruments & Controls

Before Riding

Basic Operation & Riding

Servicing Your Honda

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Taking Care of the Unexpected

Technical Information

Quick Links

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