Honda FourTrax Foreman Rubicon TRX520FM6 2020 Owner's Manual

2020 OWNER’S MANUAL TRX520FM6 4x4 with Power Steering FOURTRAX FOREMAN RUBICON Read this manual carefully, it contains important safety information. Minimum recommended operator age: 16 Models sold in and used in California: The removal or modification of evaporative emission-related parts on this OHRV is illegal. Violators may be subject to civil and/or criminal penalties as provided under California and federal law. Part Number 20 TRX520FM6-31HR56500.book 1 ページ２０１９年４月２日火曜日午後４時８分 This manual should be considered a permanent part of the ATV and should remain with the ATV when it is resold. This publication includes the latest production information available before printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. This vehicle pictured in this owner’s manual may not match your actual vehicle. © Honda Motor Co., Ltd. 2019 20 TRX520FM6-31HR56500.book 2 ページ２０１９年４月２日火曜日午後４時８分 2020 Honda TRX520FM6 4×4 with Power Steering FOREMAN RUBICON 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 conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations, and operation on public streets, roads, or highways is illegal. The vehicle is equipped with a USDA qualified spark arrester. Obey local laws and regulations. It conforms to US EPA, California, and Environment Climate Change Canada emission regulations for ATVs. 20 TRX520FM6-31HR56500.book 3 ページ２０１９年４月２日火曜日午後４時８分 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. Before riding, take time to get acquainted with your ATV and how it works. To protect your investment, we urge you to take responsibility for keeping your ATV well maintained. Scheduled service is a must, of course. But it’s just as important to observe the break-in guidelines, and perform all pre-ride and other periodic checks detailed in this manual. We also recommend that you read this owner’s manual before you ride. It’s full of facts, instructions, safety information, and helpful tips. To make it easy to use, the manual contains a detailed list of topics at the beginning of each section and an index at the back of the book. As you read this manual, you will find information that is preceded by a NOTICE symbol. This information is intended to help you avoid damage to your Honda, other property, or the environment. Read the Warranties Booklet (page 245) thoroughly so you understand the coverages that protect your new Honda and are aware of your rights and responsibilities. Whenever you ride, tread lightly. By staying on established trails and riding only in approved areas, you help protect the environment and keep off-road riding areas open for the future. Introduction 20 TRX520FM6-31HR56500.book 4 ページ２０１９年４月２日火曜日午後４時８分 Introduction If you have any questions, or if you ever need special service or repairs, remember that your dealer knows your ATV best and is dedicated to your complete satisfaction. 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 20 TRX520FM6-31HR56500.book 5 ページ２０１９年４月２日火曜日午後４時８分 A Few Words About Safety Your safety, and the safety of others, is very important. And operating this ATV safely is an important responsibility. A Few Words About Safety To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others. Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining an ATV. You must use your own good judgment. You will find important safety information in a variety of forms, including: Safety Labels — on the ATV. Safety Messages — preceded by a safety alert symbol 2 and one of three signal words: DANGER, WARNING, or CAUTION. A Few Words About Safety 20 TRX520FM6-31HR56500.book 6 ページ２０１９年４月２日火曜日午後４時８分 A Few Words About Safety These signal words mean: 3 DANGER 3 WARNING 3 CAUTION You WILL be KILLED or SERIOUSLY HURT if you don‘t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. Safety Headings — such as Important Safety Reminders or Important Safety Precautions. Safety Section — such as ATV Safety. Instructions — how to use this ATV correctly and safely. This entire manual is filled with important safety information — please read it carefully. A Few Words About Safety 20 TRX520FM6-31HR56500.book 7 ページ２０１９年４月２日火曜日午後４時８分 Contents These pages give an overview of the contents of your owner’s manual. The first page of each section lists the topics covered in that section. Contents ATV Safety ..................................................................................1 Important safety information you should know, plus a look at the safety related labels on your ATV. Instruments & Controls ..............................................................9 The location and function of indicators and controls on your ATV and operating instructions for various controls and features. Before Riding ............................................................................57 The importance of wearing a helmet and other protective gear, how to make sure you and your ATV are ready to ride, and important information about loading. Basic Operation & Riding .........................................................73 How to start and stop the engine, shift gears, and brake. Also, riding precautions. Contents 20 TRX520FM6-31HR56500.book 8 ページ２０１９年４月２日火曜日午後４時８分 Contents Servicing Your Honda ............................................................107 Why your ATV needs regular maintenance, what you need to know before servicing your Honda, an owner maintenance schedule, and instructions for specific maintenance and adjustment items. Tips ..........................................................................................195 How to store and transport your ATV and how to be an environmentally responsible rider. Taking Care of the Unexpected.............................................205 What to do if you have a flat tire, your engine won’t start, etc. Technical Information ............................................................227 ID numbers, technical specifications, and other technical facts. Consumer Information ...........................................................243 Information on warranties, emission controls, how to get Honda service manuals. Index ........................................................................................250 Quick Reference Handy facts about fuel, engine oil, tire sizes, and air pressures. Contents 20 TRX520FM6-31HR56500.book 9 ページ２０１９年４月２日火曜日午後４時８分 20 TRX520FM6-31HR56500.book 1 ページ２０１９年４月２日火曜日午後４時８分 ATV Safety This section presents some of the most important information and recommendations to help you ride your ATV safely. Please take a few moments to read these pages. This section also includes information about the location of safety labels on your ATV. ATV Safety Important Safety Information........................................................ 2 Safety Labels ................................................................................ 5 ATV Safety 1 20 TRX520FM6-31HR56500.book 2 ページ２０１９年４月２日火曜日午後４時８分 Important Safety Information Your ATV can provide many years of service and pleasure if you take responsibility for your own safety and understand the challenges you can meet while riding. There is much that you can do to protect yourself when you ride. You’ll find many helpful recommendations throughout this manual. The following are a few that we consider to be most important. Follow the Age Recommendation The minimum recommended age for this ATV model is 16. Children under age 16 should never operate this vehicle. Refer to the age warnings provided in this manual and on the ATV. Always Wear a Helmet It’s a proven fact: helmets significantly reduce the number and severity of head injuries. So always wear an approved motorcycle helmet. We also recommend that you wear eye protection, sturdy boots, gloves, and other protective gear (page 58). Never Carry a Passenger Your ATV is designed for one person only. There are no handholds, footrests, or seat for a second person, so never carry a passenger. A passenger could interfere with your ability to move around to maintain your balance and control of the ATV. 2 ATV Safety 20 TRX520FM6-31HR56500.book 3 ページ２０１９年４月２日火曜日午後４時８分 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. Take Time to Learn & Practice Even if you have ridden other ATVs, take time to become familiar with how this ATV works and handles. Practice in a safe area until you build your skills and get accustomed to the ATV’s size and weight. Because many crashes involve inexperienced or untrained riders, we urge all riders to take a ATV operator course approved by the ATV Safety Institute (ASI). See page 60. Contact an authorized ATV dealer or call 1-800-887-2887 (USA only) to find out about the training courses nearest you. Be Alert for Off-road Hazards The terrain can present a variety of challenges when you ride offroad. Continually “read” the terrain for unexpected turns, drop-offs, rocks, ruts, and other hazards. Always keep your speed low enough to allow time to see and react to hazards. ATV Safety 3 20 TRX520FM6-31HR56500.book 4 ページ２０１９年４月２日火曜日午後４時８分 Important Safety Information Ride within Your Limits Pushing limits is another major cause of ATV crashes. Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good judgments and ride safely. Don’t Drink and Ride Alcohol and riding don’t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don’t drink and ride, and don’t let your friends drink and ride either. Keep Your Honda in Safe Condition It’s important to keep your ATV properly maintained and in safe riding condition. Having a breakdown can be difficult, especially if you are stranded off-road far from your base. To help avoid problems, inspect your ATV before every ride and perform all recommended maintenance. 4 ATV Safety 20 TRX520FM6-31HR56500.book 5 ページ２０１９年４月２日火曜日午後４時８分 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. ATV Safety 5 20 TRX520FM6-31HR56500.book 6 ページ Safety Labels WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY NEVER USE PASSENGERS WITH DRUGS OR ALCOHOL 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 with a passenger - passengers affect balance and steering and increase risk of losing control ALWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 6 ATV Safety ２０１９年４月２日火曜日午後４時８分 20 TRX520FM6-31HR56500.book 7 ページ２０１９年４月２日火曜日午後４時８分 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 : 573lbs. (260kg) WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum front cargo limit of : 99 lbs (45 kg). Refer to instructions in the Owner’s Manual. ATV Safety 7 20 TRX520FM6-31HR56500.book 8 ページ２０１９年４月２日火曜日午後４時８分 Safety Labels (For Canada) BRAKING INFORMATION With four-wheel drive, operating any brake control causes braking at both the front and rear wheels. For detailed braking information, refer to the Owner's Manual. 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. Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 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 OR ALCOHOL ROADS 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 with a passenger - passengers affect balance and steering and increase risk of losing control A LWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Towing an improperly loaded trailer can cause loss of control. Read towing instructions in owner's manual Tow weight limit : 1322lbs. (600kg) Tongue weight : WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum rear cargo limit (combined weight on the rear rack and in the storage area) of : 187 lbs (85 kg). Refer to instructions in the Owner’s Manual. 8 ATV Safety 30lbs. ( 14kg) 20 TRX520FM6-31HR56500.book 9 ページ２０１９年４月２日火曜日午後４時８分 Instruments & Controls This section shows the location of all indicators and controls you would normally use before or while riding your ATV. Instruments & Controls The items listed on this page are described in this section. Instructions for other components are presented in other sections of this manual where they will be most useful. Operation Component Locations ................................................ 11 Indicators & Displays ................................................................... 14 Multi-function Display.............................................................. 20 Speed and Mileage Unit Changing........................................... 22 4WD Indicator ......................................................................... 22 Gear Position Indicator............................................................. 23 Fuel Gauge .............................................................................. 24 Digital Clock ............................................................................ 26 Odometer................................................................................ 27 Tripmeter................................................................................. 27 Coolant Temperature Gauge ................................................... 28 Hour meter.............................................................................. 30 Maintenance Tripmeter/Maintenance Hour meter .................... 31 (cont’d) Instruments & Controls 9 20 TRX520FM6-31HR56500.book 10 ページ２０１９年４月２日火曜日午後４時８分 Instruments & Controls Controls & Features .................................................................... 34 Ignition Switch......................................................................... 34 4WD Switch ............................................................................ 35 Front Differential Lock and Speed Limiter Override (Differential Lock Switch and Start/Override Button) .................................. 36 Start/Override Button............................................................... 39 Engine Stop Switch.................................................................. 40 Headlight Switch ..................................................................... 41 Headlight Dimmer Switch ........................................................ 41 Recoil Starter (Canada only) ..................................................... 42 Throttle Lever .......................................................................... 43 Front Brake Lever..................................................................... 44 Rear Brake Lever/Parking Brake Lever ....................................... 44 Rear Brake Pedal...................................................................... 44 Parking Brake/Reverse Lever (P/R Lever) .................................... 45 Flag Pole Bracket ..................................................................... 47 Trailer Hitch ............................................................................. 48 Accessory Socket ..................................................................... 49 Side Utility Box......................................................................... 51 Front Utility Box ....................................................................... 52 Utility Pocket ........................................................................... 53 Storage Compartment ............................................................. 54 EPS (Electric Power Steering) .................................................... 55 10 Instruments & Controls 20 TRX520FM6-31HR56500.book 11 ページ２０１９年４月２日火曜日午後４時８分 Operation Component Locations rear brake lever/ parking brake lever headlight switch front brake lever P/R lever 4WD switch ignition switch throttle lever engine stop switch start/override button differential lock switch headlight dimmer switch Instruments & Controls 11 20 TRX520FM6-31HR56500.book 12 ページ２０１９年４月２日火曜日午後４時８分 Operation Component Locations rear cargo rack front utility box front cargo rack rear brake pedal recoil starter (Canada only) 12 Instruments & Controls 20 TRX520FM6-31HR56500.book 13 ページ２０１９年４月２日火曜日午後４時８分 Operation Component Locations accessory socket utility pocket side utility box flag pole bracket shift lever storage compartment trailer hitch Instruments & Controls 13 20 TRX520FM6-31HR56500.book 14 ページ２０１９年４月２日火曜日午後４時８分 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) (2) (3) (8) (1) neutral indicator (2) reverse indicator (3) differential lock indicator (4) PGM-FI indicator 14 Instruments & Controls (4) (7) (6) (5) (5) high coolant temperature indicator (6) PS (Electric Power Steering) indicator (7) multi-function display (8) mode select button 20 TRX520FM6-31HR56500.book 15 ページ２０１９年４月２日火曜日午後４時８分 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). The PS (Electric Power Steering) indicator comes back on and remains on until the engine is started after initial lamp check. The high coolant temperature indicator and PGM-FI indicator comes back on for a few seconds and then go off after initial lamp check. These indicators are identified in the table on page 17 with the words: Lamp Check. When applicable, the reverse or neutral indicators comes back on and remain on until you shift out of reverse or neutral after initial lamp check. When applicable, the differential lock indicator comes back on and remains on until you shift out of the front differential lock mode after initial lamp check. If one of these indicators does not come on when it should, have your dealer check for problems. Instruments & Controls 15 20 TRX520FM6-31HR56500.book 16 ページ２０１９年４月２日火曜日午後４時８分 Indicators & Displays Display Check When the ignition switch is turned on, the multi-function display (1) will temporarily show all the modes and digital segments and initial message. So you can make sure the liquid crystal display is functioning properly. The displays are identified in the table on page 18 with the words: Display Check. If any part of these displays does not come on when it should, have your dealer check for problems. (1) (1) multi-function display Meter Input Signal Failure If the neutral indicator, reverse indicator, differential lock indicator, PGM-FI indicator, high coolant temperature indicator stay on and the gear position indicator “–” and coolant temperature gauge “C – – – – – H” blink, have your dealer check for problems. 16 Instruments & Controls 20 TRX520FM6-31HR56500.book 17 ページ２０１９年４月２日火曜日午後４時８分 Indicators & Displays 1 Neutral indicator 2 Reverse indicator 3 Differential lock indicator 4 PGM-FI indicator 5 High coolant temperature indicator Lights when the transmission is in neutral. Lamp Check. Lights when the transmission is in reverse. Lamp Check. Lights when the front differential lock mode is engaged. Should also light for a few seconds and go off when the ignition switch is turned on, and then come back on and remain on until the differential lock switch or the ignition switch is turned off. If the indicator blinks with the 4WD indicator, there is any abnormality in the differential system. See page 38. Lamp Check. Lights when there is any abnormality in the PGM-FI (Programmed Fuel Injection) system. Should also light for a few seconds and then go off when the ignition switch is turned on. If the indicator comes on at any other time, reduce speed and take your vehicle to your dealer as soon as possible. Lamp Check. Lights when coolant temperature is high enough to adversely affect the service life of the engine. If the high coolant temperature indicator comes on while you are riding, immediately bring the vehicle to a stop, turn the engine off and let it cool. See page 215. Lamp Check. (cont’d) Instruments & Controls 17 20 TRX520FM6-31HR56500.book 18 ページ２０１９年４月２日火曜日午後４時８分 Indicators & Displays 6 PS (Electric Power Steering) indicator 7 Multi-function display 4WD indicator Gear position indicator Maintenance minder indicator Speedometer Fuel gauge Digital clock Odometer Tripmeter Coolant temperature gauge Hour meter Maintenance tripmeter Maintenance hour meter Lights when there is an abnormality in the EPS (Electric Power Steering) system. See page 55. Lamp Check. The display includes the following functions. Display Check. Shows when the 4WD drive mode is engaged. If the indicator blinks with the differential lock indicator when there is any abnormality in the differential system. See page 38. Shows the gear position (page 23). Shows when specified maintenance interval is reached (page 32). Shows riding speed. Shows approximate fuel supply available (page 24). Shows the time (hours and minutes) (page 26). Shows accumulated mileage (page 27). Shows mileage per trip (page 27). Shows approximate coolant temperature (page 28). Shows hours and tenths of hours of engine operation (page 30). Inform when the mileage or operating hours on your ATV approaches and passes the interval specified on the maintenance schedule (page 31). 18 Instruments & Controls 20 TRX520FM6-31HR56500.book 19 ページ２０１９年４月２日火曜日午後４時８分 Indicators & Displays 8 Mode select button Selects display in the lower parts of multi-function display. Adjusts the digital clock (page 26). Changes the speed and mileage units (page 22). Resets the tripmeter to zero (0) (page 27). This button also used to reset the maintenance tripmeter and maintenance hour meter (page 33). Instruments & Controls 19 20 TRX520FM6-31HR56500.book 20 ページ２０１９年４月２日火曜日午後４時８分 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) (7) (2) (6) (3) (5) (4) (1) multi-function display (5) lower part of the multi-function display (2) gear position indicator (3) speedometer (6) 4WD indicator (7) mode select button (4) maintenance minder indicator The lower part of the multi-function display (5) shows the fuel gauge, digital clock, odometer, tripmeter, coolant temperature gauge, hour meter, maintenance tripmeter or maintenance hour meter. To change the lower part of the multi-function display, push the mode select button (7). 20 Instruments & Controls 20 TRX520FM6-31HR56500.book 21 ページ２０１９年４月２日火曜日午後４時８分 Indicators & Displays Each time you press the mode select button, mode will change as shown in the illustration. Fuel gauge (page 24) Digital clock (page 26) Odometer (page 27) Hour meter (page 30) Tripmeter (page 27) Coolant temperature gauge (page 28) When ATV is moving When ATV is not moving Maintenance tripmeter (page 31) Maintenance hour meter (page 31) If there is a fuel warning with your ATV, the display will automatically change to the fuel gauge. If you try to change the display back to ordinary display, it will automatically return to the fuel gauge. If there is a coolant temperature warning with your ATV, the display will automatically change to the coolant temperature gauge. If you try to change the display back to ordinary display, it will automatically return to the coolant temperature gauge. Instruments & Controls 21 20 TRX520FM6-31HR56500.book 22 ページ２０１９年４月２日火曜日午後４時８分 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 21) with the ATV stopped. (1) (1) mode select button 4WD Indicator The 4WD indicator (1) shows when the 4WD mode engages (page 35). (1) (1) 4WD indicator 22 Instruments & Controls 20 TRX520FM6-31HR56500.book 23 ページ２０１９年４月２日火曜日午後４時８分 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. “–” will be displayed on the gear position indicator when the transmission is not shifted into gear properly. Before riding, check that the gear position is properly displayed on the gear position indicator. If the gear position indicator shows “–” or blinks, turn the ignition switch to the OFF (w) position, and then turn it back to the ON (q) position again. If the gear position indicator shows “–”, rock the vehicle back and forth and make sure the gear position indicator is displayed properly and then if the gear position indicator still shows “–” or blinks, see your dealer. If the “–” on the gear position indicator is blinking, see your dealer. (1) (1) gear position indicator Instruments & Controls 23 20 TRX520FM6-31HR56500.book 24 ページ２０１９年４月２日火曜日午後４時８分 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) (2) (1) fuel gauge (1) (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. You should refuel as soon as possible. The amount of fuel remaining when the fuel gauge reaches the 1st segment is approximately: 1.82 US gal (6.9 ℓ) (3) (3) 1st segment 24 Instruments & Controls 20 TRX520FM6-31HR56500.book 25 ページ２０１９年４月２日火曜日午後４時８分 Indicators & Displays (4) (4) “E _ _ _ _ _ F” (5) (5) “LO FUEL” When the fuel gauge show “E _ _ _ _ _ F” (4) and “LO FUEL” (5) blink 3 times alternately and fuel mark blinks, you should refuel as soon as possible. The amount of fuel reserve is approximately: 1.29 US gal (4.9 ℓ) Fuel gauge failure: If the fuel gauge E – – – – – F (6) is blinking, the fuel gauge function failed. See your dealer. (6) (6) “E – – – – – F” Instruments & Controls 25 20 TRX520FM6-31HR56500.book 26 ページ２０１９年４月２日火曜日午後４時８分 Indicators & Displays Digital Clock The digital clock (1) shows time with the clock mark (2) when the ignition switch is ON (q). (3) (1) digital clock (2) clock mark (1) (2) (3) mode select button To adjust the time, proceed as follows: 1. Turn the ignition switch ON (q) and select the digital clock mode. 2. Press and hold the mode select button (3) until the display start blinking. 3. To advance the display 1 minute at a time, press and release the mode select button for 0.5 seconds. Press and hold the mode select button the display will begin advancing fast. Press and hold the button for: • 0.5 – 5.5 seconds: advance one minute at a time. • 5.5 – 10.5 seconds: advance five minutes at a time. • 10.5 seconds or more: advance ten minutes at a time. 4. Release the mode select button when the display reaches the desired time. 5. To end the adjustment, press and release the mode select button for less than 0.5 seconds or turn the ignition switch to OFF (w). After the battery is reconnected (page 187), check the clock. Readjust the clock if necessary. 26 Instruments & Controls 20 TRX520FM6-31HR56500.book 27 ページ２０１９年４月２日火曜日午後４時８分 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. (2) (1) odometer (1) (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” mark (2). The tripmeter returns to 0.0 when the readout exceeds 999.9. To reset the tripmeter to zero, press the mode select button (3) and hold it in for at least 2 seconds in the tripmeter mode. (2) (3) (1) tripmeter (2) “TRIP” mark (1) (3) mode select button Instruments & Controls 27 20 TRX520FM6-31HR56500.book 28 ページ２０１９年４月２日火曜日午後４時８分 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” (5). (2) (4) (1) (3) (1) coolant temperature gauge (2) coolant temperature mark (3) 1st segment 28 Instruments & Controls (5) (4) 4th segment (5) “Lo” 20 TRX520FM6-31HR56500.book 29 ページ２０１９年４月２日火曜日午後４時８分 Indicators & Displays When the coolant is over specified temperature, the 5th segment (6) appears and the high coolant temperature indicator (7) lights. If this occurs, stop the engine and check the reserve tank coolant level. Read pages 215 – 216 and do not ride the ATV until the problem has been corrected. NOTICE Continuing to ride with an overheated engine can cause serious engine damage. (7) (6) (6) 5th segment (7) high coolant temperature indicator If the “C – – – – – H” (8) blinks, the meter input signal fails. See your dealer. (8) (8) “C – – – – – H” Instruments & Controls 29 20 TRX520FM6-31HR56500.book 30 ページ２０１９年４月２日火曜日午後４時８分 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. (1) (1) hour meter 30 Instruments & Controls (2) (2) hour meter mark 20 TRX520FM6-31HR56500.book 31 ページ２０１９年４月２日火曜日午後４時８分 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. (1) (2) (1) maintenance tripmeter (2) maintenance minder indicator (3) (2) (3) maintenance hour meter The maintenance tripmeter decreases from 600 miles (1,000 km) after reset. The maintenance hour meter decreases from 100 hour after reset. Initial setting of the maintenance tripmeter is 100 miles (150 km). Initial setting of the maintenance hour meter is 20 hour. (cont’d) Instruments & Controls 31 20 TRX520FM6-31HR56500.book 32 ページ２０１９年４月２日火曜日午後４時８分 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. Regular Maintenance Interval 2 Appears 600 miles (1,000 km) or 100 operating hours after Regular Maintenance Interval 1 is performed and maintenance minder is reset, whichever comes first in the maintenance schedule. When the maintenance tripmeter or maintenance hour meter amounts to 0, the display of the maintenance minder indicator changes. When selected the maintenance tripmeter or maintenance hour meter, the maintenance minder indicator and lower part of the multi-function display (4) start blinking. When selected other mode, the maintenance minder indicator appears in the display. (4) (4) (4) lower part of the multi-function display 32 Instruments & Controls 20 TRX520FM6-31HR56500.book 33 ページ２０１９年４月２日火曜日午後４時８分 Indicators & Displays Reset the maintenance tripmeter/maintenance hour meter after maintenances. To reset the maintenance tripmeter/maintenance hour meter, proceed as follows: Press and hold the mode select button (5) and turn the ignition switch (6) to ON (q). The maintenance minder indicator will appear, then it will blinks twice, and the multi-function display will temporarily show all the modes and digital segments. The indicator message will disappear. Reset operation will be cancelled, if the mode select button is released before the indicator blinks twice. If the maintenance is done before the setting interval, be sure to reset the meters after the maintenance. (5) (6) (2) maintenance minder indicator (2) (5) mode select button (6) ignition switch Instruments & Controls 33 20 TRX520FM6-31HR56500.book 34 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features Ignition Switch The ignition switch (1) is used for starting and stopping the engine (page 80). Insert the key and turn it to the right for the ON (q) position. The ignition switch is also used to reset the maintenance tripmeter/ maintenance hour meter (page 33). Key Position ON (q) OFF (w) Function Electrical circuits on. No electrical circuits function. CENTER OF HANDLEBAR OFF ON (1) (1) ignition switch 34 Instruments & Controls q ON w OFF 20 TRX520FM6-31HR56500.book 35 ページ２０１９年４月２日火曜日午後４時８分 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 machine is in motion and come to a complete stop before using the 4WD switch. The 4WD switch is located above the throttle lever. To select the drive mode, with your ATV stopped, push the 4WD switch. To check your present drive mode, look at the 4WD indicator (2). 2WD mode: the 4WD indicator disappears when the 2WD mode engages. 4WD mode: the 4WD indicator appears when the 4WD mode engages. If the 4WD indicator does not appear when selecting the 4WD mode, accelerate your ATV slowly until the 4WD indicator appears. The 4WD indicator and differential lock indicator both flash together when there is any abnormality in the differential system. See Front Differential Lock and Speed Limiter Override (Differential Lock Switch and Start/Override Button), page 38. 2WD mode 2WD mode (2) 4WD mode (1) 4WD switch (1) 4WD mode (1) (2) 4WD indicator Instruments & Controls 35 20 TRX520FM6-31HR56500.book 36 ページ２０１９年４月２日火曜日午後４時８分 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 use of available traction to help you escape from situations where the vehicle might otherwise become stuck, in the mud for example. When the front differential lock mode is activated, the front differential gear is locked causing all four wheels to rotate at the same speed. Because locking all four wheels together changes the way the vehicle handles and increases the amount of room necessary to turn, a speed limiter restricts the speed to 20 mph (32 km/h). Pushing and holding the start/override button in this mode allows you to momentarily override the 20 mph (32 km/h) speed limiter, up to 40 mph (64 km/h), to help you free the vehicle in more severe conditions. You should only use this feature where maximum traction is required and only in low speeds. For normal riding, use 2WD and 4WD modes. 36 Instruments & Controls 20 TRX520FM6-31HR56500.book 37 ページ２０１９年４月２日火曜日午後４時８分 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. When the locking is complete, the differential lock indicator stays on. 4WD mode front differential lock mode (1) (in the locking process) (2) off fast flashing (speed above 10 mph (16 km/h). Locking process interrupted) slow flashing (1) differential lock switch (1) (completed locking) (2) (2) solid light (2) (2) differential lock indicator If the speed of your ATV is above 10 mph (16 km/h), the locking process will be interrupted and the differential lock indicator will slowly flash. If the differential lock indicator does not stay on when the front differential lock mode is selected, steer the handlebar either to the left or right all the way while your ATV is stopped. If the differential lock indicator is still flashing, move your ATV slowly while steering the handlebar all the way to right or left. Instruments & Controls 37 20 TRX520FM6-31HR56500.book 38 ページ２０１９年４月２日火曜日午後４時８分 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 (3) (3) start/override button Differential system failure: The differential lock indicator and 4WD indicator (4) will both flash when there is any abnormality in the differential system. If this occurs, the differential actuator will stop moving, and the differential system will be fixed in the current position, either 2WD mode, 4WD mode or front differential lock mode. If both the differential lock indicator and 4WD indicator flash, reduce speed and take your ATV to your dealer as soon as possible. (2) (4) (2) differential lock indicator 38 Instruments & Controls (4) 4WD indicator 20 TRX520FM6-31HR56500.book 39 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features Start/Override Button LEFT HANDLEBAR (1) (1) start/override button START or SPEED LIMITER OVERRIDE MODE The start/override button (1) is used for starting the engine and activate the speed limiter override mode. Pushing the button in starts the engine. See Starting Procedure, page 82. When the engine is not running and the start/override button is pushed, the starter motor will crank the engine. The starter motor will not operate if the engine stop switch is in the OFF (r) position when the start/override button is pushed. To activate the speed limiter override mode, see Front Differential Lock and Speed Limiter Override (Differential Lock Switch and Start/ Override Button), page 36. Instruments & Controls 39 20 TRX520FM6-31HR56500.book 40 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features e Engine Stop Switch r LEFT HANDLEBAR (1) (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. If your ATV is stopped with the ignition switch ON (q) and the engine stop switch OFF (r), the battery will discharge. Turn the ignition switch to OFF (w) to prevent battery discharge. 40 Instruments & Controls 20 TRX520FM6-31HR56500.book 41 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features y Headlight Switch LEFT HANDLEBAR t (1) (2) (1) headlight switch (2) headlight dimmer switch y ON t OFF u HI i LO The headlight switch (1) is used to turn the headlights and assist headlight ON (y) or OFF (t). The assist headlight turns on only when the dimmer switch (2) is in the HI (u) position. To operate, turn the switch to ON (y) or OFF (t). Headlight Dimmer Switch u i The headlight dimmer switch (2) is used to change between the high and low beams of the headlights and to activate the assist headlight. To operate, turn the switch to HI (u) for high beam of the headlights and activate the assist headlight, LO (i) for low beam of the headlights and deactivate the assist headlight. Instruments & Controls 41 20 TRX520FM6-31HR56500.book 42 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features Recoil Starter (Canada only) RIGHT SIDE (1) (1) recoil starter The recoil starter (1) is used to start the engine when the battery is low. See Using the Recoil Starter (Canada only), page 86. 42 Instruments & Controls 20 TRX520FM6-31HR56500.book 43 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features Throttle Lever RIGHT HANDLEBAR (A) (1) (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. Instruments & Controls 43 20 TRX520FM6-31HR56500.book 44 ページ２０１９年４月２日火曜日午後４時８分 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 91. Rear Brake Lever/Parking Brake Lever The rear brake lever/parking brake lever is used to slow or stop your ATV. To operate, pull the lever. For information on braking techniques, see page 91. Rear Brake Pedal The rear brake pedal is used to slow or stop your ATV. To operate, depress the pedal. For information on braking techniques, see page 91. 44 Instruments & Controls 20 TRX520FM6-31HR56500.book 45 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features Parking Brake/Reverse Lever (P/R Lever) LEFT HANDLEBAR (1) (2) (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. (cont’d) Instruments & Controls 45 20 TRX520FM6-31HR56500.book 46 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features To apply the parking brake: Bring the vehicle to a complete stop, then make sure the transmission is in neutral. Squeeze the rear brake lever /parking brake lever (1), then rotate the P/R lever (2) clockwise until it engages the slot on the rear brake lever/parking brake lever bracket. For more information on Parking, see page 106. (2) (1) (1) rear brake lever/parking brake lever (2) P/R lever To release the parking brake: Squeeze the rear brake lever/parking brake lever until the P/R lever is released from the slot on the rear brake lever/parking brake lever bracket. The brake light is activated by applying the parking brake. When using the parking brake, be sure to turn the ignition switch to OFF (w) to avoid discharging the battery. To shift the transmission into reverse: See Riding in Reverse, page 89. 46 Instruments & Controls 20 TRX520FM6-31HR56500.book 47 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features Flag Pole Bracket RIGHT REAR (1) flag pole bracket (1) 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. Instruments & Controls 47 20 TRX520FM6-31HR56500.book 48 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features Trailer Hitch REAR (2) (1) (1) trailer hitch (2) ball The trailer hitch (1) is located on the rear frame. To use the hitch, you’ll need a proper size ball (2) as specified by the trailer manufacturer. To attach the ball and properly hook up a trailer, follow the trailer manufacturer’s instructions. For load limits and operational guidelines, see page 67. 48 Instruments & Controls 20 TRX520FM6-31HR56500.book 49 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features Accessory Socket LEFT FRONT (2) (3) (1) (1) accessory socket (2) front center cover (3) accessory socket cap The accessory socket (1) is attached to the left side of the front center cover (2). You can use the accessory socket to power a trouble light, spotlight, CB radio, or cell phone, etc. NOTICE Do not plug in any heat-generating accessory, such as an automobile cigarette lighter, because it can damage the socket. To use the accessory socket, turn the ignition switch to ON (q), start the engine. Then turn the headlights OFF (t), and open the accessory socket cap (3). (cont’d) Instruments & Controls 49 20 TRX520FM6-31HR56500.book 50 ページ２０１９年４月２日火曜日午後４時８分 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 217. When you are done using an accessory, unplug it, and cover the socket with the cap. Be careful not to flood this accessory socket when washing your ATV. 50 Instruments & Controls 20 TRX520FM6-31HR56500.book 51 ページ２０１９年４月２日火曜日午後４時８分 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 utility box cover (2). To close: Push down the front of the utility box cover until it locks in place. Make sure that the stud (3) is locked securely in position by pulling up lightly on the front of the utility box cover. Do not store valuable items in the side utility box. Be careful not to flood this area when washing your ATV. LEFT FRONT FENDER (3) (2) (1) (1) side utility box (2) utility box cover (3) stud Instruments & Controls 51 20 TRX520FM6-31HR56500.book 52 ページ２０１９年４月２日火曜日午後４時８分 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 utility box cover (2). To close: Push down the front of the utility box cover until it locks in place. Make sure that the studs (3) are locked securely in position by pulling up lightly on the front of the utility box cover. Do not store valuable items in the front utility box. Be careful not to flood this area when washing your ATV. FRONT CENTER COVER (3) (2) (1) (1) front utility box (2) utility box cover 52 Instruments & Controls (3) studs 20 TRX520FM6-31HR56500.book 53 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features Utility Pocket The utility pocket (1) is located on the left side cover. You may store small, lightweight items in the pocket. Do not store valuable items in the utility pocket. LEFT SIDE COVER (1) (1) utility pocket Instruments & Controls 53 20 TRX520FM6-31HR56500.book 54 ページ２０１９年４月２日火曜日午後４時８分 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 (3) (2) (1) (1) storage compartment (2) rear cargo rack (3) rubber strap 54 Instruments & Controls 20 TRX520FM6-31HR56500.book 55 ページ２０１９年４月２日火曜日午後４時８分 Controls & Features EPS (Electric Power Steering) This ATV is equipped with an electronically controlled, electricpower-assisted steering system. While the engine is running, the EPS (Electric Power Steering) system provides power from the electric motor, which helps you to turn the ATV’s handlebar more easily. The EPS system on this ATV utilizes an overheat protection feature to prevent damage to system components. In certain extended, repetitive high-load situations the PS indicator will illuminate and the system will reduce or even disable power steering assist. The steering will perform as a normal non-EPS system during this brief period. If this occurs, safely stop the vehicle and allow the EPS system to cool down until the PS indicator goes off. After cooling down, steering will return to normal EPS operation. The PS indicator should light when the ignition switch is turned on and remain on until the engine is started. The PS indicator also lights when there is any abnormality in the EPS system. If this occurs, the electric power assist for turning will not be available, but the manual steering system will perform as usual. If the PS indicator lights at any time while riding, other than the temporary overheat condition described above, reduce speed and take your ATV to your dealer as soon as possible. Continuing to ride with a EPS system problem can damage system components. Do not modify your Electric Power Steering system. In case of a malfunction, take your ATV to your dealer. Instruments & Controls 55 20 TRX520FM6-31HR56500.book 56 ページ 56 Instruments & Controls ２０１９年４月２日火曜日午後４時８分 20 TRX520FM6-31HR56500.book 57 ページ２０１９年４月２日火曜日午後４時８分 Before Riding Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, what items you should check on your ATV, and adjustments to make for your comfort, convenience, or safety. This section also includes important information about loading. Before Riding Are You Ready to Ride? .............................................................. 58 Protective Apparel ................................................................... 58 Rider Training .......................................................................... 60 Age Recommendation ............................................................. 61 No Passengers ......................................................................... 61 No Alcohol or Drugs ................................................................ 62 Is Your ATV Ready to Ride? ........................................................ 63 Pre-ride Inspection ................................................................... 63 Load Limits & Guidelines............................................................. 67 Loading ................................................................................... 67 Load Limits .............................................................................. 68 Loading Guidelines .................................................................. 69 Accessories & Modifications........................................................ 70 Accessories .............................................................................. 70 Modifications........................................................................... 71 Before Riding 57 20 TRX520FM6-31HR56500.book 58 ページ２０１９年４月２日火曜日午後４時８分 Are You Ready to Ride? Before you ride your ATV for the first time, we urge you to: • Read this owner’s manual and the labels on your ATV carefully. • Make sure you understand all the safety messages. • Know how to operate all the controls. Before each ride, be sure: • You feel well and are in good physical and mental condition. • You are wearing an approved motorcycle helmet (with chin strap tightened securely), eye protection, and other protective clothing. • You don’t have any alcohol or drugs in your system. Protective Apparel For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket whenever you ride. Although complete protection is not possible, wearing proper gear can reduce the chance of injury when you ride. Following are suggestions to help you choose the proper gear. Helmet and Eye Protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. 58 Before Riding 20 TRX520FM6-31HR56500.book 59 ページ２０１９年４月２日火曜日午後４時８分 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. WARNING 3 WARNING Operating this ATV without wearing an approved motorcycle helmet, eye protection, and protective clothing could increase your chances of severe injury or death in the event of a crash. Always wear an approved motorcycle helmet that fits properly and wear eye protection (goggles or face shield), gloves, boots, longsleeved shirt or jacket and long pants. Additional Riding Gear In addition to a helmet and eye protection, we also recommend: • Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. • Off-road motorcycle gloves to help protect your hands. • Riding pants with knee and hip pads, a riding jersey with padded elbows, and a chest/shoulder protector. Before Riding 59 20 TRX520FM6-31HR56500.book 60 ページ２０１９年４月２日火曜日午後４時８分 Are You Ready to Ride? Rider Training Developing your riding skills is an on-going process. Even if you have ridden other ATVs, take time to become familiar with how this ATV works and handles. Practice riding the ATV in a safe area to build your skills. Do not ride in rough terrain until you get accustomed to the ATV’s controls, and feel comfortable with its size and weight. We urge all riders to take an ATV operator course approved by the ATV Safety Institute (ASI). For information about the ASI training course nearest you, call the national toll-free number; (800) 8872887 (USA only). Other riding tips can be found in the Tips & Practice Guide for the ATV Rider booklet that came with your ATV (USA only). WARNING 3 WARNING Operating this ATV without proper instruction could increase your risk of a crash which could lead to serious injury or death. Beginning and inexperienced operators should complete the certified training course offered by Honda. They should then regularly practice the skills learned in the course and the operating techniques described in the owner’s manual. 60 Before Riding 20 TRX520FM6-31HR56500.book 61 ページ２０１９年４月２日火曜日午後４時８分 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 3 WARNING A child using an ATV that is not recommended for their age could lose vehicle control while riding, resulting in severe injury or death. A child under 16 should never operate an ATV with engine size greater than 90cc. No Passengers This ATV is designed as an operator-only vehicle. The long seat is designed to allow the rider to change body position, not for carrying a passenger. Never let a passenger ride on the seat or on the front or rear cargo racks. WARNING 3 WARNING Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV and could cause a crash and you or your passenger could be injured or killed. Never carry a passenger on this ATV. Before Riding 61 20 TRX520FM6-31HR56500.book 62 ページ２０１９年４月２日火曜日午後４時８分 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. Consult your doctor to be sure it is safe to operate a vehicle after taking medication. WARNING 3 WARNING Operating this ATV after consuming alcohol or drugs can seriously affect your judgment, cause you to react more slowly, affect your balance and perception, and result in serious injury or death. Never consume alcohol or drugs before or while operating this ATV. 62 Before Riding 20 TRX520FM6-31HR56500.book 63 ページ２０１９年４月２日火曜日午後４時８分 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. If your ATV has overturned or been involved in a collision, do not ride the vehicle until it has been inspected by your dealer. There may be damage or other problems you cannot see. WARNING 3 WARNING Improperly maintaining this ATV or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed. Always perform a pre-ride inspection before every ride and correct any problems. Pre-ride Inspection Check the following items before you get on the ATV: Engine Oil Check the level and add oil if needed (page 132). Check for leaks. Radiator Coolant Check the coolant level and add coolant if needed (page 143). Check for leaks. (cont’d) Before Riding 63 20 TRX520FM6-31HR56500.book 64 ページ２０１９年４月２日火曜日午後４時８分 Is Your ATV Ready to Ride? Fuel Check the level and add fuel (page 127) if needed. Also make sure the fuel fill cap is securely fastened. Check for leaks. Tires Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damage or excessive wear (page 176). Drivetrain Boots Check for damage (pages 184). Guards Check for damage or looseness (pages 183). Nuts & Bolts Check the wheels to see that the axle nuts are tightened. Use a wrench to make sure all accessible nuts, bolts, and fasteners are tight. Underbody & Exhaust Check for, and remove, any dirt, vegetation System or other debris that could be a fire hazard or interfere with the proper operation of the vehicle. Air Cleaner Housing Drain Tube Check for deposits in the drain tube. If necessary, clean the tube (page 155) and check the air cleaner housing. Leaks, Loose Parts Walk around your ATV and look for anything that appears unusual, such as a leak or loose cable. 64 Before Riding 20 TRX520FM6-31HR56500.book 65 ページ２０１９年４月２日火曜日午後４時８分 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 68). Cargo Check that all cargo is secure. Check these items after you get on the ATV: Throttle Check the freeplay and adjust if needed. Press the throttle to make sure it moves smoothly without sticking, and snaps shut automatically when it is released, in all steering positions (page 156). Brakes Squeeze the front and rear brake levers and step on the rear brake pedal to check that the controls operate normally. Depress the rear brake pedal several times, then check for proper rear brake lever/parking brake lever freeplay (pages 173). Make sure there is no brake fluid leakage. Reverse Assist Lever Check the freeplay and adjust if needed (page 159). Make sure the lever operates smoothly without sticking. (cont’d) Before Riding 65 20 TRX520FM6-31HR56500.book 66 ページ２０１９年４月２日火曜日午後４時８分 Is Your ATV Ready to Ride? Headlight and Headlight Dimmer Switch Check for proper function (page 41). Engine Stop Switch Check for proper function (page 40). Steering Check that the wheels turn properly as you steer the handlebar. Move the handlebar right and left and check that there is no excessive backlash. Remember, be sure to take care of any problem you find, or have your dealer correct it before you ride. 66 Before Riding 20 TRX520FM6-31HR56500.book 67 ページ２０１９年４月２日火曜日午後４時８分 Load Limits & Guidelines Your Honda was designed as a rider-only ATV. It was not designed to carry a passenger. It can carry cargo on the cargo racks, however, carrying cargo anywhere else or carrying a passenger could interfere with your balance and control of the ATV. In addition, exceeding the weight limits or carrying an unbalanced load can seriously affect your ATV’s handling, braking and stability. Adding accessories or making modifications that change this ATV’s design and performance can also make it unsafe. Also, the weight of any accessories will reduce the maximum load the ATV can carry. More specific information on load limits, accessories, and modifications follows. Loading How much weight you put on your ATV, and how you load it, are important to your safety. If you decide to carry cargo, you should be aware of the following information. WARNING 3 WARNING Overloading, improper loading, or carrying a passenger can cause a crash and you can be seriously hurt or killed. Follow all load limits and other loading guidelines in this manual. Before Riding 67 20 TRX520FM6-31HR56500.book 68 ページ２０１９年４月２日火曜日午後４時８分 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. maximum weight capacity 573 lb (260 kg) (includes the weight of the rider, all cargo, and accessories.) front cargo rack weight limit rear cargo rack weight limit tow weight limit (Combined weight of the trailer and all cargo in the trailer) tongue weight (Weight on the trailer tongue) tongue and rear cargo weight (Combined weight on the trailer tongue and on the rear cargo rack) = 99 lb (45 kg) = 187 lb (85 kg) = 1322 lb (600 kg) = 30 lb (14 kg) recommended = 187 lb (85 kg) maximum Tongue weight can be measured with an ordinary bathroom scale. Place the scale under the tongue, using either a tongue jack or other support to keep the trailer level. The weight of added accessories will reduce the maximum cargo weight you can carry. 68 Before Riding 20 TRX520FM6-31HR56500.book 69 ページ２０１９年４月２日火曜日午後４時８分 Load Limits & Guidelines Loading Guidelines Carrying cargo or pulling a trailer will affect how your ATV handles and greatly reduce its ability in accelerating, braking and making turns and other maneuvers. Be sure to observe the weight limits and follow these guidelines: • Check that the tires are properly inflated. • Do not place cargo anywhere on the ATV other than on the front and rear racks. Otherwise, operating stability may be adversely affected. • Never ride with a passenger on the front or rear cargo racks. The ATV is not designed to carry a passenger. • Use the trailer hitch to tow another vehicle or trailer. Do not tow by tying a rope or cable to the rear rack. • Load cargo on the rear rack as far forward as possible. Make sure cargo on the front rack does not interfere with handlebar movement. • Do not allow cargo to extend beyond the edges of either the front or rear racks. • Make sure all cargo is secured before riding. • Balance cargo weight evenly on both sides. • Never exceed the maximum weight limit. • When towing a trailer, take care to maintain balance and stability. Distribute cargo between the front and rear of the trailer to obtain the recommended tongue weight. • Allow extra room for starting, stopping and turning whenever you carry cargo or pull a trailer. • Avoid riding on steep slopes when carrying cargo or pulling a trailer. • Never cross a slope when towing a trailer. Before Riding 69 20 TRX520FM6-31HR56500.book 70 ページ２０１９年４月２日火曜日午後４時８分 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 3 WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner’s manual regarding accessories and modifications. Accessories We strongly recommend that you use only Honda Genuine Accessories that have been specifically designed and tested for your ATV. Because Honda cannot test all other accessories, you must be personally responsible for proper selection, installation, and use of non-Honda accessories. Check with your dealer for assistance and always follow these guidelines: • Make sure the accessory does not obscure any lights, reduce ground clearance, limit suspension travel or steering travel, or interfere with operating any controls. • Make sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls. • Do not add any electrical equipment that will exceed the vehicle’s electrical system capacity (page 233). A blown fuse can cause a loss of lights or engine power (page 217). 70 Before Riding 20 TRX520FM6-31HR56500.book 71 ページ２０１９年４月２日火曜日午後４時８分 Accessories & Modifications Modifications We strongly advise you not to remove any original equipment or modify your ATV in any way that would change its design or operation. Such changes could seriously impair your ATV’s handling, stability, and braking, making it unsafe to ride. We also advise you not to make any modifications or remove any equipment (such as the USDA qualified spark arrester or emission control system components) that would make your ATV illegal in your area. Removing or modifying your lights, exhaust system, emission control system, or other equipment can also make your ATV illegal. Before Riding 71 20 TRX520FM6-31HR56500.book 72 Before Riding 72 ページ２０１９年４月２日火曜日午後４時８分 20 TRX520FM6-31HR56500.book 73 ページ２０１９年４月２日火曜日午後４時８分 Basic Operation & Riding This section gives basic riding instructions, including how to start and stop your engine, and how to use the throttle and brakes. It also provides important information on riding with cargo. Basic Operation & Riding To protect your new engine and enjoy optimum performance and service life, refer to Break-in Guidelines (page 235). Safe Riding Precautions .............................................................. 75 Off-road Use Only.................................................................... 75 Keep Hands and Feet on Controls............................................ 76 Control Speed ......................................................................... 77 Use Care on Unfamiliar or Rough Terrain ................................. 78 Do Not Perform Stunts............................................................. 79 Starting & Stopping the Engine................................................... 80 Preparation.............................................................................. 81 Starting Procedure ................................................................... 82 Flooded Engine........................................................................ 83 Bank Angle Sensor Ignition Cut-off System .............................. 83 Stalled Engine.......................................................................... 84 How to Stop the Engine........................................................... 85 Using the Recoil Starter (Canada only) ..................................... 86 Shifting Gears............................................................................. 87 Riding in Reverse ........................................................................ 89 (cont’d) Basic Operation & Riding 73 20 TRX520FM6-31HR56500.book 74 ページ２０１９年４月２日火曜日午後４時８分 Basic Operation & Riding Braking....................................................................................... 91 Riding Your ATV ......................................................................... 93 Making Turns .......................................................................... 93 Skidding or Sliding................................................................... 95 Riding Up Hills ......................................................................... 96 Riding Down Hills .................................................................. 100 Crossing or Turning on Hills or Slopes .................................... 101 Riding Over Obstacles ............................................................ 103 Riding Through Water ........................................................... 104 Parking ..................................................................................... 106 74 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 75 ページ２０１９年４月２日火曜日午後４時８分 Safe Riding Precautions Before riding your ATV for the first time, please review the ATV Safety section beginning on page 1, and the Before Riding section beginning on page 57. Even if you have ridden other ATVs, take time to become familiar with how this ATV works and handles. Practice in a safe area until you build your skills and get accustomed to the ATV’s size and weight. Off-road Use Only Your ATV and its tires are designed and manufactured for off-road use only, not for pavement. Riding on pavement can affect handling and control. You should not ride your ATV on pavement. WARNING 3 WARNING Operating this ATV on paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. Never operate the ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. When riding off-road, also remember to always obey local off-road riding laws and regulations. Obtain permission to ride on private property. Avoid posted areas and obey “no trespassing” signs. (cont’d) Basic Operation & Riding 75 20 TRX520FM6-31HR56500.book 76 ページ２０１９年４月２日火曜日午後４時８分 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. WARNING 3 WARNING Operating this ATV on public streets, roads or highways could cause you to collide with another vehicle. Never operate this ATV on any public street, road or highway, even a dirt or gravel one. Keep Hands and Feet on Controls Always keep both hands on the handlebars and both feet on the footpegs when riding your ATV. This is important to maintain your balance and to control the vehicle. Removing even one hand from the handlebars or one foot from the footpegs can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. WARNING 3 WARNING Removing hands from handlebars or feet from footpegs during operation can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. Always keep both hands on the handlebars and both feet on the footpegs of your ATV during operation. 76 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 77 ページ２０１９年４月２日火曜日午後４時８分 Safe Riding Precautions 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 3 WARNING Operating this ATV at excessive speeds increases your chances of losing control of the ATV, which can result in a crash. Always go at a speed that is proper for your vehicle, the terrain, visibility and other operating conditions, and your experience. Basic Operation & Riding 77 20 TRX520FM6-31HR56500.book 78 ページ２０１９年４月２日火曜日午後４時８分 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 3 WARNING Failure to use extra care when operating this ATV on unfamiliar terrain could result in the ATV overturning or going out of control. Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. 78 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 79 ページ２０１９年４月２日火曜日午後４時８分 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 3 WARNING Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction or vehicle control, which could result in a crash, including an overturn. Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. Do Not Perform Stunts You should always operate your ATV in a safe and reasonable manner. When riding, always keep all four wheels on the ground. WARNING 3 WARNING Attempting wheelies, jumps, and other stunts increases the chance of a crash, including an overturn. Never attempt stunts, such as wheelies or jumps. Don’t try to show off. Basic Operation & Riding 79 20 TRX520FM6-31HR56500.book 80 ページ２０１９年４月２日火曜日午後４時８分 Starting & Stopping the Engine Always follow the proper starting procedure described below. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your ATV’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death. WARNING 3 WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause a rapid build-up of toxic carbon monoxide gas. Breathing this colourless, odorless gas can quickly cause unconsciousness and lead to death. Only run your vehicle's engine when it is located in a well ventilated area outdoors. 80 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 81 ページ２０１９年４月２日火曜日午後４時８分 Starting & Stopping the Engine Preparation (2) (1) (3) (1) ignition switch (2) neutral indicator (3) engine stop switch 1. Before starting, make sure the vehicle is on a level surface and lock the parking brake (page 45). 2. Turn the ignition switch (1) to ON (q). Confirm the following: • The transmission is in neutral, the neutral indicator (2) is ON and the gear position indicator shows “N”. • The engine stop switch (3) is set to RUN (e). Basic Operation & Riding 81 20 TRX520FM6-31HR56500.book 82 ページ２０１９年４月２日火曜日午後４時８分 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). Snapping the throttle or fast idling for more than 5 minutes may cause exhaust pipe and muffler discolorations. 82 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 83 ページ２０１９年４月２日火曜日午後４時８分 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. (USA) Press the start/override button for 5 seconds. (Canada) Press the start/override button for 5 seconds (or operate the recoil starter several times). 4. Follow the normal starting procedure. 5. If the engine starts, then open the throttle slightly if idling is unstable. If the engine does not start, wait 10 seconds, then follow steps 1 – 4 again. If the engine still won’t start, refer to If Your Engine Quits or Won’t Start, page 208. Bank Angle Sensor Ignition Cut-off System Your vehicle’s banking (lean angle) sensor system is designed to automatically stop the engine if the vehicle is overturned. Before restarting the engine, you must turn the ignition switch to the OFF (w) position and then back to ON (q). The engine will not restart until you perform this procedure. Basic Operation & Riding 83 20 TRX520FM6-31HR56500.book 84 ページ２０１９年４月２日火曜日午後４時８分 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). Once you have started the engine, release the front brake lever, then apply throttle gradually. 84 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 85 ページ２０１９年４月２日火曜日午後４時８分 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. If your ATV is stopped with the engine stop switch OFF (r) and the ignition switch ON (q), the battery will discharge. Emergency Engine Stop To stop the engine in an emergency, use the engine stop switch. To operate, slide the switch to either OFF (r) position. Basic Operation & Riding 85 20 TRX520FM6-31HR56500.book 86 ページ２０１９年４月２日火曜日午後４時８分 Starting & Stopping the Engine Using the Recoil Starter (Canada 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. Check that the transmission is in neutral. 3. Grasp the starter grip (1) firmly, then pull it out slowly approximately 4 in (100 mm). 4. Pull the grip up briskly and fully. 5. After the engine starts, allow the starter grip to return slowly. Pull the recoil starter grip straight out so that the cord does not touch the side cover. Repeated contact with the side cover can damage the starter cord. If the starter grip does not return smoothly (because of dirt in the assembly), see your dealer. RIGHT SIDE (1) (1) starter grip 86 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 87 ページ２０１９年４月２日火曜日午後４時８分 Shifting Gears UPSHIFTING SEQUENCE DOWNSHIFTING SEQUENCE Your ATV has five forward gears: 1, 2, 3, 4, and 5. The shift lever is located near the left footpeg. One full stroke of the shift lever shifts the transmission to the next higher or lower gear in the shifting sequence. The shift lever automatically returns to the horizontal position when released. To upshift to a higher gear, put the toe of your boot under the shift lever and raise it one full stroke. To downshift, step on the shift lever and depress it one full stroke. To select reverse, see Riding in Reverse, page 89. After starting the engine and letting it warm up, follow this procedure: 1. With the transmission in neutral, release the parking brake, but continue squeezing the rear brake lever/parking brake lever. Basic Operation & Riding 87 20 TRX520FM6-31HR56500.book 88 ページ２０１９年４月２日火曜日午後４時８分 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. 5. Repeat this sequence to progressively upshift to 3rd, 4th and 5th (top) gear. 6. To downshift, reverse this sequence. Remember to close the throttle each time you shift to the next lower gear. Learning when to shift gears comes with experience. Keep the following tips in mind: • As a general rule, shift while moving in a straight line. • Close the throttle (release) completely before shifting. Improper shifting may damage the engine, transmission, and drivetrain. • Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high. Learn the relationship between engine sound and the normal shifting points. • Downshift to a lower gear before you feel the engine laboring (lugging) at low rpm. • Avoid downshifting to help slow your ATV when engine rpm is high. Downshifting when engine speed is near its allowable maximum may over-rev the engine and possibly cause damage. • To prevent transmission damage, do not coast or tow the ATV for long distances with the engine off. Recommended Shift Points Ride in the highest gear that lets the engine run and accelerate smoothly. This will give you good fuel economy and effective emissions control. 88 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 89 ページ２０１９年４月２日火曜日午後４時８分 Riding in Reverse If you need to ride in reverse, make sure the area behind you is clear and only operate the ATV at low speed. WARNING 3 WARNING Improperly operating in reverse could cause you to hit an obstacle or person behind you, resulting in serious injury. Make sure there are no obstacles or people behind you before selecting reverse gear. When it is safe to proceed, go slowly. 1. Bring the vehicle to a complete stop, then make sure the transmission is in neutral. 2. Be sure there are no obstacles or people in the way. 3. Fully rotate the P/R lever (1) counterclockwise to engage the P/R lever with the reverse assist lever (2). 4. While continuing to hold the P/R lever, squeeze the rear brake lever/parking brake lever (3), then depress the shift lever once to shift into “R” (reverse) gear. 5. Make sure that the reverse indicator comes on and the gear position indicator shows “R”. LEFT HANDLEBAR (1) (2) (3) (1) P/R lever (2) reverse assist lever (3) rear brake lever/parking brake lever Basic Operation & Riding 89 20 TRX520FM6-31HR56500.book 90 ページ２０１９年４月２日火曜日午後４時８分 Riding in Reverse NOTICE Your ATV may be equipped with a reverse speed limiter, which helps the vehicle to maintain a safe speed while riding in reverse gear. 6. Release the rear brake lever/parking brake lever. 7. Open the throttle gradually and ride slowly. Do not open the throttle suddenly or make abrupt turns. 8. To stop, close the throttle and gradually apply both the front and rear brakes. Do not abruptly apply the rear brake by alone. 9. To shift out of reverse and into neutral, raise the shift lever one stroke to shift into “N” (neutral) gear. (the neutral indicator is on and the gear position indicator shows “N”) WARNING 3 WARNING Applying only the rear brake abruptly when operating in reverse gear could cause the front wheels to lift off the ground and the ATV could overturn backwards. Carefully apply both the front and rear brakes when stopping in reverse gear. 90 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 91 ページ２０１９年４月２日火曜日午後４時８分 Braking Your ATV is equipped with disc brakes on both front wheels which are hydraulically activated by operating the right brake lever. The single disc brake of the rear drivetrain is hydraulically activated by pressing down on the brake pedal and mechanically activated by 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. So operating any brake control in the 4WD mode will cause braking at both the front and rear wheels. As a general rule, the front braking system provides about 70 percent of total stopping power. For full braking effectiveness, use both the pedal and lever simultaneously. Using both braking systems will stop your ATV faster with greater stability. To slow or stop, apply the brake lever and brake pedal smoothly, while downshifting to match your speed. Gradually increase braking as you feel the brakes slowing your speed. The increase in engine compression from downshifting will help slow your ATV. Applying the brakes too hard may cause the wheels to lock and slide, reducing control of your ATV. If this happens, release the brake controls, steer straight ahead until you regain control, then reapply the brakes more gently. Basic Operation & Riding 91 20 TRX520FM6-31HR56500.book 92 ページ２０１９年４月２日火曜日午後４時８分 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. When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduce their effectiveness. Riding with your foot resting on the brake pedal or your hands on the brake levers may overheat the brakes, reducing effectiveness. For information on how to apply the brakes in various riding situations, see the following section, Riding Your ATV. 92 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 93 ページ２０１９年４月２日火曜日午後４時８分 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 3 WARNING Turning improperly can make the ATV go out of control, causing a collision or overturn. • Always follow proper procedures for turning as described in this owner’s manual. • Practice turning at low speeds before attempting to turn at faster speeds. • Do not turn at excessive speeds. Remember that steering the handlebar in the front differential lock mode will cause steering to be heavy and increase turning radius. Basic Operation & Riding 93 20 TRX520FM6-31HR56500.book 94 ページ２０１９年４月２日火曜日午後４時８分 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. To make a sharp turn at low speed: It helps to shift your body slightly forward on the seat, and lean inside, as you steer the handlebar. Shifting weight forward allows the rear wheels to turn easier, and it also improves front-wheel steering. To make a turn from a full stop: Apply the throttle gradually when you turn and start at the same time. Remember to shift your body forward to make sharp low-speed turns and whenever you turn while accelerating from a full stop. 94 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 95 ページ２０１９年４月２日火曜日午後４時８分 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. To avoid skidding on slippery terrain, keep your speed low and ride with caution. WARNING 3 WARNING Skidding or sliding improperly may cause you to lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. Learn to safely control skidding by practicing at low speeds and on level, smooth terrain. If your ATV skids sideways during a turn, steer in the direction of the skid. Avoid hard braking or accelerating until you have regained directional control. Remember that steering the handlebar in the front differential lock mode will cause steering to be heavy and increase turning radius. (cont’d) Basic Operation & Riding 95 20 TRX520FM6-31HR56500.book 96 ページ２０１９年４月２日火曜日午後４時８分 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. Avoid excessively steep hills. WARNING 3 WARNING Operating on excessively steep hills can cause the vehicle to overturn more easily than operating on level surfaces or small hills. Never operate the ATV on hills too steep for the ATV or for your abilities. When climbing hills, you must shift weight toward the front wheels to help keep them on the ground. To do this, shift your body slightly forward on the seat and lean forward. For greater weight shift, move your body farther forward and lean forward. WARNING 3 WARNING Climbing hills improperly could cause loss of control or cause the ATV to overturn. Always follow proper procedures for climbing hills as described in this owner’s manual. 96 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 97 ページ２０１９年４月２日火曜日午後４時８分 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. Maintain a steady speed as you ascend the hill. • Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backward. • Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. Basic Operation & Riding 97 20 TRX520FM6-31HR56500.book 98 ページ２０１９年４月２日火曜日午後４時８分 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 3 WARNING Stalling, rolling backwards or improperly dismounting while climbing a hill could result in the ATV overturning. Always follow proper procedures for climbing a hill as described in this owner’s manual. What to do if the ATV stalls or rolls backwards when climbing a hill: If you are about to lose all forward speed: 1. Using the front and rear brakes together, bring the ATV to a stop with the vehicle pointed straight uphill. 2. Get off the ATV while you continue holding the brakes. 3. Shift into neutral, set the parking brake and turn the engine off. 4. Then assess the situation. If the ATV starts rolling backwards before you begin braking: 1. Keep your weight uphill. 2. Carefully apply the front brakes first, then carefully apply the rear brake. Do not apply either brake abruptly if you are rolling backwards, or the vehicle may overturn. If the ATV continues sliding backwards: After you’ve applied the brakes, get off and away from the vehicle. Remember that operating any brake control in the 4WD mode will cause braking at both the front and rear wheels. 98 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 99 ページ２０１９年４月２日火曜日午後４時８分 Riding Your ATV What to do after the ATV has stalled or rolled backwards: If the hill is too steep or too slippery, or if you have any doubt whether you can safely walk the ATV back down the hill, leave the vehicle where it is and get help. If possible, block the wheels so the vehicle doesn’t roll backwards. If the hill is not too steep and you have good footing, you may be able to walk the ATV back down the hill. Make sure your intended path is clear in case you lose control of the ATV. Be sure your legs are clear of the wheels. Body position for backing down a hill. 1. Stand with your body facing downhill, beside the vehicle so you can reach the rear brake lever/parking brake lever with your right hand. 2. Be sure your legs are clear of the wheels. Check your footing. 3. Slowly and carefully back the ATV down the hill using the rear brake lever/parking brake lever to control speed. 4. If you lose control of the ATV, for your safety, get away from the vehicle. (cont’d) Basic Operation & Riding 99 20 TRX520FM6-31HR56500.book 100 ページ２０１９年４月２日火曜日午後４時８分 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 3 WARNING Going down a hill improperly could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this owner’s manual. On downhills, shift your weight back. As you approach a downhill, stop and survey the terrain below. Never ride past the limit of your visibility. Never go down a hill at high speed. 100 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 101 ページ２０１９年４月２日火曜日午後４時８分 Riding Your ATV When you’ve selected a safe downhill path, shift into a lower gear, shift your weight back with your arms extended and braced against the handlebar, then go down slowly with the throttle closed. Use mainly the rear brake to control speed. Avoid using either the front brake or rear brake hard or abruptly when riding down hills. Remember that operating any brake control in the 4WD mode will cause braking at both the front and rear wheels. Remember, braking effectiveness is reduced on any hill with a loose surface. Crossing or Turning on Hills or Slopes Riding on hills or slopes is different from riding on level terrain. Be careful when riding on any hill. Make sure that you practice on gentle, smooth slopes before attempting to ride on steeper or more difficult terrain. WARNING 3 WARNING Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn. Always follow proper procedures for crossing or turning on slopes as described in this owner’s manual. Avoid crossing steep hills if possible. Remember that steering the handlebar in the front differential lock mode will cause steering to be heavy and increase turning radius. Basic Operation & Riding 101 20 TRX520FM6-31HR56500.book 102 ページ２０１９年４月２日火曜日午後４時８分 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. • On a slippery or loose surface, you may also need to steer slightly uphill to maintain a straight course across the slope. • Avoid crossing hills that are excessively steep, slippery or rough. Shift weight uphill when crossing slopes. Making Turns on Slopes • Compared to riding on level ground, you may need to shift more weight and lean more when making turns on slopes. • Do not make turns on any slopes until you have first mastered the techniques for making turns on level terrain. 102 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 103 ページ２０１９年４月２日火曜日午後４時８分 Riding Your ATV Riding Over Obstacles Before operating in a new area, check for obstacles. Watch out for bumps, rain ruts, potholes and other obstacles in the terrain. When you approach any obstacle, reduce your speed and be prepared to stop. Never try to ride over large obstacles, such as large rocks or fallen logs. WARNING 3 WARNING Improperly operating over obstacles could cause loss of control or a collision and could cause the ATV to overturn. When you go over obstacles, always follow proper procedures as described in this owner’s manual. (cont’d) Basic Operation & Riding 103 20 TRX520FM6-31HR56500.book 104 ページ２０１９年４月２日火曜日午後４時８分 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 3 WARNING The ATV tires have some ability to float. Operating this ATV through deep or fastflowing water may cause a loss of traction and loss of control, which could lead to a crash. Never operate this ATV in fast-flowing water or in water deeper than that specified in this owner’s manual. NOTICE Water entering the muffler may damage the oxygen sensor and result in emissions control system malfunction. Have your ATV dealer inspect the oxygen sensor immediately after water enters the muffler. 104 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 105 ページ２０１９年４月２日火曜日午後４時８分 Riding Your ATV 1. Choose a path where both banks have gradual slopes. 2. Proceed through the water at a slow, steady speed. 3. Watch out for submerged obstacles and slippery rocks. 4. Avoid getting the spark plug or air cleaner wet, as this would cause the engine to stop. 5. After leaving the water, always test both the front and rear brakes. • Riding through water can make the brakes less effective than normal, and may reduce stopping ability. • If necessary, apply the brakes repeatedly until they dry out and operate normally. Basic Operation & Riding 105 20 TRX520FM6-31HR56500.book 106 ページ２０１９年４月２日火曜日午後４時８分 Parking 1. Look for level parking area. Make sure the ground surface is firm. 2. After bringing your ATV to a stop, hold the brakes while you shift into neutral. 3. Set the parking brake (page 46). 4. Turn the ignition switch 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. The brake light is activated by applying the parking brake. When using the parking brake, be sure to turn the ignition switch to OFF (w) to avoid discharging the battery. Parking on a Steep Incline or a Loose or Slippery Surface If you must park your ATV on a steep incline or loose or slippery surface, use the following procedure: 1. While holding the brakes, set the parking brake. 2. Turn the ignition switch to OFF (w) and release the brakes. 3. If the ATV begins to move, either while sitting on it or after you dismount, find a better parking location. 4. If rocks or other objects are available, you can block the wheels as shown for additional security. 106 Basic Operation & Riding 20 TRX520FM6-31HR56500.book 107 ページ２０１９年４月２日火曜日午後４時８分 Servicing Your Honda To help keep your ATV in good shape, this section includes a Maintenance Schedule for required service and step-by-step instructions for specific maintenance tasks. You’ll also find important safety precautions, information on fuels and oils, and tips for keeping your Honda looking good. Servicing Your Honda For information about replacing fuses, see page 217. For information about the exhaust emission and noise requirements of the U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Environment Climate Change Canada (ECCC), see page 236. USA only Maintenance, replacement or repair of the emission control devices and systems may be performed by any ATV repair establishment or individual using parts that are “certified” to EPA standards. Before You Service Your Honda The Importance of Maintenance ............................................... 109 Maintenance Safety.................................................................. 110 Important Safety Precautions ................................................. 111 Maintenance Schedule ............................................................. 112 Maintenance Record................................................................. 116 Service Preparations Maintenance Component Locations ......................................... 117 Tool Kit .................................................................................... 120 Owner’s Manual Storage .......................................................... 121 Seat Removal............................................................................ 122 Rear Fender Cover Removal ...................................................... 123 Tank Cover Assembly Removal ................................................. 124 Clip Removal ............................................................................ 125 (cont’d) Servicing Your Honda 107 20 TRX520FM6-31HR56500.book 108 ページ２０１９年４月２日火曜日午後４時８分 Servicing Your Honda Service Procedures Fluids & Filters Fuel .......................................................................................... 126 Engine Oil & Filter ..................................................................... 129 Rear Final Gear Oil .................................................................... 138 Front Final Gear Oil................................................................... 140 Coolant .................................................................................... 142 Air Cleaner ............................................................................... 150 Engine Throttle .................................................................................... 156 Clutch System .......................................................................... 158 Reverse Inhibitor System ........................................................... 159 Spark Plug ................................................................................ 160 Valves....................................................................................... 163 Spark Arrester .......................................................................... 164 Chassis Suspension ............................................................................... 165 Brakes ...................................................................................... 168 Tires ......................................................................................... 176 Guards ..................................................................................... 183 Drivetrain Boots ........................................................................ 184 Electrical Battery ..................................................................................... 185 Appearance Care...................................................................... 190 108 Servicing Your Honda 20 TRX520FM6-31HR56500.book 109 ページ２０１９年４月２日火曜日午後４時８分 Before You Service Your Honda The Importance of Maintenance A well-maintained ATV is essential for safe, economical, and troublefree riding. It will also help reduce air pollution. Careful pre-ride inspections and good maintenance are especially important because your ATV is designed to be ridden over rough off-road terrain. To help you properly care for your ATV, this section of the manual provides a Maintenance Schedule. The service intervals in this schedule are based on average riding conditions. WARNING 3 WARNING Improperly maintaining this ATV or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair. If your ATV overturns or is involved in a crash, be sure your dealer inspects all major parts, even if you are able to make some repairs. Servicing Your Honda 109 20 TRX520FM6-31HR56500.book 110 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Safety This section includes instructions on how to perform some important maintenance tasks. If you have basic mechanical skills, you can perform many of these tasks with the tools provided with your ATV. Other tasks that are more difficult and require special tools are best performed by professionals. Removing the wheels should normally be handled only by a Honda technician or other qualified mechanic. Instructions are included in this manual only to assist in emergency service. Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. WARNING 3 WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner’s manual. 110 Servicing Your Honda 20 TRX520FM6-31HR56500.book 111 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Safety Important Safety Precautions • Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine. Burns from hot ATV parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. • Read the instructions before you begin, and make sure you have the tools and skills required. • To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only non-flammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts. Remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new Honda Genuine Parts or other equivalents for repair and replacement. If you have the tools and skills required for additional maintenance jobs, you can purchase an official Honda Service Manual (page 244). Servicing Your Honda 111 20 TRX520FM6-31HR56500.book 112 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Schedule The required Maintenance Schedule that follows specifies how often you should have your ATV serviced, and what things need attention. It is essential to have your ATV serviced as scheduled to maintain safe, dependable performance and proper emission control. The service intervals in this Maintenance Schedule are based on average riding conditions. Some items will need more frequent service if you ride in unusually wet or dusty areas or at full throttle. Consult your dealer for recommendations applicable to your individual needs and use. Some items in the Maintenance Schedule can be performed with basic mechanical skills and hand tools. Procedures for these items are provided in this manual. Other items involve more extensive procedures and may require special training, tools, and equipment. We recommend that you have your dealer perform these tasks unless you have advanced mechanical skills and the required tools and equipment. Procedures for such items in this schedule are provided in an official Honda Service Manual available for purchase (page 244). If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your ATV best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only Honda Genuine Parts or their equivalents for repair or replacement to ensure the best quality and reliability. 112 Servicing Your Honda 20 TRX520FM6-31HR56500.book 113 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Schedule Perform the pre-ride inspection (page 63) and owner maintenance on this section at each scheduled maintenance period. Each item on the maintenance schedule requires some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools. Consult your dealer. 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 244). ** In the interest of safety, we recommend these items be serviced only by your dealer. * Summary of Maintenance Schedule Notes & Procedures: NOTES: 1. Service more frequently when riding in dusty areas, sand or snow. 2. Service more frequently after riding in very wet or muddy conditions. 3. Replace every 2 years. Replacement requires mechanical skill. 4. California type only Servicing Your Honda 113 20 TRX520FM6-31HR56500.book 114 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Schedule Maintenance Procedures: I: inspect and clean, adjust, lubricate, or replace, if necessary C: clean A: adjust L: lubricate R: replace FREQUENCY ITEMS * FUEL LINE * THROTTLE OPERATION AIR CLEANER AIR CLEANER HOUSING DRAIN TUBE SPARK PLUG * VALVE CLEARANCE ENGINE OIL WHICHEVER COMES FIRST NOTE NOTE 1 NOTE 2 ENGINE OIL FILTER * * * ENGINE IDLE SPEED NOTE 4 EVAPORATIVE EMISSION CONTROL SYSTEM (For AC type) RADIATOR COOLANT NOTE 3 COOLING SYSTEM NOTE 2 mi km MONTH HOURS INITIAL REGULAR MAINT. MAINT. INTERVAL 100 150 1 20 600 1000 6 100 C I 1200 2000 12 200 I I C I Refer to page — 156 150 155 I I I I I INITIAL= 100 mi (150 km), 20 operating hours or 1 month: R REGULAR= Every 600 mi (1,000 km), 100 operating hours or 12 months: R I I I I: EVERY 2 YEARS 160 163 129 I I 142 — I I 134 — — * 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 244). 114 Servicing Your Honda 20 TRX520FM6-31HR56500.book 115 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Schedule FREQUENCY ITEMS * * * * * * * * ** ** ** ** WHICHEVER COMES FIRST NOTE DRIVETRAIN BOOTS FRONT/REAR FINAL GEAR OIL BRAKE FLUID BRAKE PADS WEAR BRAKE LIGHT SWITCH BRAKE SYSTEM REVERSE INHIBITOR SYSTEM GUARDS CLUTCH SYSTEM SUSPENSION SPARK ARRESTER NUTS, BOLTS, FASTENERS WHEELS/TIRES TIE-ROD AND JOINT BOOTS STEERING SHAFT HOLDER BEARINGS STEERING SYSTEM mi km MONTH HOURS INITIAL REGULAR MAINT. MAINT. INTERVAL 100 150 1 20 NOTE 3 NOTE 1, 2 I I I I I I I 600 1000 6 100 I (R: EVERY 2 YEARS) I I I I I I I C I I 1200 2000 12 200 I I Refer to page I I I I I 184 138, 140 168 171 175 168 159 I I I C I I I 183 158 165 164 — 176 — I — I — * 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 244). ** In the interest of safety, we recommend these items be serviced only by your dealer. Servicing Your Honda 115 20 TRX520FM6-31HR56500.book 116 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Record Keeping an accurate maintenance record will help ensure that your ATV is properly maintained. Retain detailed receipts to verify the maintenance was performed. If the ATV is sold, these receipts should be transferred with the ATV to the new owner. Make sure whoever performs the maintenance completes this record. All scheduled maintenance, including the 100 mile (150 km) or 1 month or 20 hours initial maintenance, is considered a normal owner operating cost and will be charged for by your dealer. Use the space under Notes to record anything you want to remind yourself about or mention to your dealer. Miles (km) or ODO or months or hours HOUR 100 (150) or 1 or 20 600 (1,000) or 6 or 100 1,200 (2,000) or 12 or 200 1,800 (3,000) or 18 or 300 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 800 116 Servicing Your Honda Date Performed By: Notes 20 TRX520FM6-31HR56500.book Service Preparations P/R lever 117 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Component Locations reverse assist lever front brake fluid reservoir front brake lever rear brake lever/ parking brake lever throttle lever Servicing Your Honda 117 20 TRX520FM6-31HR56500.book 118 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Component Locations battery fuse box main fuse 1 main fuse 2 EPS fuse front suspension spring pre-load adjusters coolant reserve tank rear brake fluid reservoir fuel fill cap rear brake light switch rear brake pedal rear brake caliper engine oil filter front brake calipers rear brake lever/parking front final gear oil fill cap front final gear oil drain bolt brake lever adjuster rear final gear oil fill cap rear final gear oil drain bolt 118 Servicing Your Honda 20 TRX520FM6-31HR56500.book 119 ページ２０１９年４月２日火曜日午後４時８分 Maintenance Component Locations clutch adjuster air cleaner spark plug owner’s manual air pressure gauge 40 A spare fuse fuse puller seat latch coolant reserve tank spark arrester engine oil fill cap/ dipstick engine oil drain bolt air cleaner housing drain tube tool kit rear suspension spring pre-load adjusters Servicing Your Honda 119 20 TRX520FM6-31HR56500.book 120 ページ２０１９年４月２日火曜日午後４時８分 Tool Kit The tool kit (1) is stored in the storage compartment (page 54). After using the tools, be sure to use the rubber band (2) to fasten the tool kit securely. An optional, larger tool kit may be available. Check with your dealer’s parts department. REAR (2) (1) (1) tool kit 120 Servicing Your Honda (2) rubber band 20 TRX520FM6-31HR56500.book 121 ページ２０１９年４月２日火曜日午後４時８分 Owner’s Manual Storage Your ATV provides storage for the owner’s manual so you’ll have it with you for easy reference. Store your owner’s manual (1) in the plastic document bag (2) underside of the rear fender cover (3). The owner’s manual, air pressure gauge (4), 40 A spare fuse (5) and fuse puller (6) should be stored in the plastic document bag and fastened with the rubber band (7). To remove the rear fender cover, see page 123. Be careful not to flood this area when washing your ATV. REAR FENDER COVER UNDERSIDE (7) (6) (1) (2) (3) (5) (1) owner’s manual (2) plastic document bag (3) rear fender cover (4) air pressure gauge (4) (5) 40 A spare fuse (6) fuse puller (7) rubber band Servicing Your Honda 121 20 TRX520FM6-31HR56500.book 122 ページ２０１９年４月２日火曜日午後４時８分 Seat Removal Refer to Safety Precautions on page 111. The seat must be removed for the engine oil filter, air cleaner, spark plug, battery and fuse maintenance and to remove the rear fender cover and tank cover assembly, to access the owner’s manual, air pressure gauge, 40 A spare fuse and fuse puller. (3) (6) (2) (4) (5) (1) seat latch (2) seat (3) front prongs (4) tank cover (7) (5) hooks (6) studs (7) grommets (1) Removal 1. Pull the seat latch (1) at the rear of the seat. 2. Slide the seat (2) back and lift it. Installation 1. Insert the front prongs (3) into the backside of the tank cover (4) and hooks (5) on the frame, and press the studs (6) into the grommets (7). 2. Press down on the seat until locks. 122 Servicing Your Honda 20 TRX520FM6-31HR56500.book 123 ページ２０１９年４月２日火曜日午後４時８分 Rear Fender Cover Removal Refer to Safety Precautions on page 111. The rear fender cover must be removed for the battery and fuse maintenance and to access the owner’s manual, air pressure gauge, 40 A spare fuse and fuse puller. (4) (5) (2) (1) (3) (1) rubber strap (2) studs (3) grommets (4) rear fender cover (5) tabs Removal 1. Remove the seat (page 122). 2. Unhook the rubber strap (1). 3. Firmly pull the studs (2) from the grommets (3). 4. Slide the rear fender cover (4) forward to disengage the tabs (5). 5. Remove the rear fender cover. Installation Install the rear fender cover in the reverse order of removal. Servicing Your Honda 123 20 TRX520FM6-31HR56500.book 124 ページ２０１９年４月２日火曜日午後４時８分 Tank Cover Assembly Removal Refer to Safety Precautions on page 111. The tank cover assembly must be removed for the engine oil filter and spark plug maintenance. (1) (2) (1) (3) (3) (1) right studs (2) tank cover assembly (3) right tabs Removal 1. Remove the seat (page 122). 2. Carefully remove the right studs (1) and left studs from the grommets. 3. Remove the tank cover assembly (2) by releasing the right tabs (3) and left tabs from the slits. Installation Install the tank cover assembly in the reverse order of removal. 124 Servicing Your Honda 20 TRX520FM6-31HR56500.book 125 ページ２０１９年４月２日火曜日午後４時８分 Clip Removal Removal 1. Pull up the center pin to release the lock. 2. Pull out the clip of the hole. 1. 2. Installation 1. Insert the clip into the hole. 2. Press down the center pin securely to lock the clip. 1. 2. Servicing Your Honda 125 20 TRX520FM6-31HR56500.book 126 ページ２０１９年４月２日火曜日午後４時８分 Service&Procedures Fluids Filters Fuel Refer to Safety Precautions on page 111. Fuel Recommendation type pump octane number unleaded 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. Gasoline pumps at service stations normally display the pump octane number. For information on the use of oxygenated fuels, see page 240. Use of lower octane gasoline can cause persistent “pinging” or “spark knock” (a loud rapping noise) which, if severe, can lead to engine damage. Light pinging experienced while operating under a heavy load, such as climbing a hill, is no cause for concern. If pinging or spark knock occurs at a steady engine speed under normal load, change brands of gasoline. If pinging or spark knock persists, consult your dealer. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt, dust, or water in the fuel tank. 126 Servicing Your Honda 20 TRX520FM6-31HR56500.book 127 ページ２０１９年４月２日火曜日午後４時８分 Fuel Fuel Capacity Fuel tank capacity, including reserve: 3.88 US gal (14.7 ℓ) Reserve capacity: 1.29 US gal (4.9 ℓ) When there is only one segment left in the fuel gauge (page 24), fuel will be low and you should refuel as soon as possible. Refueling Procedure Refer to Safety Precautions on page 111. (2) (1) (1) fuel fill cap (2) lower edge of filler neck (cont’d) Servicing Your Honda 127 20 TRX520FM6-31HR56500.book 128 ページ２０１９年４月２日火曜日午後４時８分 Fuel 1. To open the fuel fill cap (1), turn it counterclockwise. 2. Add fuel until the level reaches the lower edge of the filler neck (2). Avoid over filling the tank. There should be no fuel in the filler neck. WARNING 3 WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. 3. (Except California type) 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. Do not allow spilled gasoline to pool on camouflage colored bodywork. Also, do not allow gasoline soaked rags to be placed on camouflage bodywork. 128 Servicing Your Honda 20 TRX520FM6-31HR56500.book 129 ページ２０１９年４月２日火曜日午後４時８分 Engine Oil & Filter Engine oil quality is a major factor that affects both the performance and the service life of the engine. Using the proper oil (page 130) and filter, and regularly checking, adding, and changing oil will help extend your engine’s life. Even the best oil wears out. Changing oil helps get rid of dirt and deposits in the engine. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the engine and transmission. Change the engine oil as specified in the maintenance schedule on page 114. When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule. Servicing Your Honda 129 20 TRX520FM6-31HR56500.book 130 ページ２０１９年４月２日火曜日午後４時８分 Engine Oil & Filter Oil Recommendation API classification viscosity (weight) JASO T 903 standard suggested oil* * SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label SAE 10W-30 MA 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. • Your ATV does not need oil additives. Use the recommended oil. • Do not use oils with graphite or molybdenum additives. They may adversely affect clutch operation. • Do not use API SH or higher oils displaying a circular API “energy conserving” or “resource conserving” service label on the container. They may affect lubrication and clutch performance. NOT RECOMMENDED RECOMMENDED • Do not use non-detergent, vegetable, or castor based racing oils. 130 Servicing Your Honda 20 TRX520FM6-31HR56500.book 131 ページ２０１９年４月２日火曜日午後４時８分 Engine Oil & Filter Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range. JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification. (1) (2) (1) oil code (2) oil classification Servicing Your Honda 131 20 TRX520FM6-31HR56500.book 132 ページ２０１９年４月２日火曜日午後４時８分 Engine Oil & Filter Checking & Adding Oil Refer to Safety Precautions on page 111. Check the engine oil level each day before operating your ATV and add if needed. The oil fill cap/dipstick is located at the front left crankcase. Before riding your ATV, check the engine oil level. 1. Park your ATV on a firm, level surface. 2. Start the engine in a well-ventilated area and let it idle for 3 – 5 minutes. If the air temperature is below 10°C (50°F), let the engine idle for an additional 5 minutes (a total of 10 minutes). 3. Stop the engine and wait 2 – 3 minutes. 4. Remove the oil check/fill door (1) by disengaging the stud (2) from the grommet and releasing the tabs (3) from the slits. LEFT SIDE (2) (1) (3) (1) oil check/fill door (2) stud 132 Servicing Your Honda (3) tabs 20 TRX520FM6-31HR56500.book 133 ページ２０１９年４月２日火曜日午後４時８分 Engine Oil & Filter 5. Remove the oil fill cap/dipstick (4) from the front crankcase and wipe it clean. 6. Insert the oil fill cap/dipstick without screwing it in, then remove the oil fill cap/dipstick and check the oil level. The oil level should be between the upper level mark (5) and the lower level mark (6) on the oil fill cap/dipstick. 7. If the oil level is near or below the lower level mark, then add the specified oil into the fill cap hole, up to the upper level mark on the oil fill cap/dipstick. Do not overfill. 8. Reinstall the oil fill cap/dipstick. 9. Install the oil check/fill door. NOTICE Running the engine with an improper oil level can cause serious engine damage. LEFT SIDE (4) (5) (6) (4) oil fill cap/dipstick (5) upper level mark (6) lower level mark Servicing Your Honda 133 20 TRX520FM6-31HR56500.book 134 ページ２０１９年４月２日火曜日午後４時８分 Engine Oil & Filter Changing Engine Oil & Filter Refer to Safety Precautions on page 111. Your ATV’s oil filter has very specific performance requirements. Use a new Honda Genuine oil filter specified for your model or a filter of equal quality. NOTICE Using the wrong oil filter may result in leaks or engine damage. This procedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid (page 204). If you do not have the skills or the tools, see your dealer. Change the oil with the engine warm to assure complete and rapid draining. Drain the Engine Oil: 1. With the ATV on level ground, remove the oil check/fill door (page 132) and the oil fill cap/dipstick from the front crankcase. 134 Servicing Your Honda 20 TRX520FM6-31HR56500.book 135 ページ２０１９年４月２日火曜日午後４時８分 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) (1) (1) engine oil drain bolt (2) sealing washer (cont’d) Servicing Your Honda 135 20 TRX520FM6-31HR56500.book 136 ページ２０１９年４月２日火曜日午後４時８分 Engine Oil & Filter Install a New Engine Oil Filter: Place shop towels under the oil filter cover because oil will flow out. 1. Remove the seat (page 122) and tank cover assembly (page 124). 2. Remove the oil filter cover (3) and O-rings (4) by removing the bolts (5). Let the remaining oil drain out. Discard the oil filter (6) in an approved manner (page 204). 3. Apply engine oil to new O-rings and install them to the oil filter cover and crankcase cover. 4. Reposition the spring (7) to the crankcase cover and install a new oil filter with the rubber seal (8) facing out, away from the engine. You will see the “OUT-SIDE (TOWARDS FILTER COVER)” mark (9) on the filter body, near the seal. Use only the Honda Genuine oil filter or a filter of equivalent quality specified for your model. Using the wrong Honda filter or a non-Honda filter which is not of equivalent quality may cause engine damage. NOTICE Improper installation of the oil filter can cause serious engine damage. RIGHT SIDE (4) (5) (7) (6) (8) (9) (3) (3) oil filter cover (4) O-rings (5) bolts (6) oil filter 136 Servicing Your Honda (7) spring (8) rubber seal (9) “OUT-SIDE” mark 20 TRX520FM6-31HR56500.book 137 ページ２０１９年４月２日火曜日午後４時８分 Engine Oil & Filter 5. Reinstall the oil filter cover, making sure the bolts are tightened to the specified torque: 7 lbf·ft (10 N·m, 1.0 kgf·m) 6. Pour the drained oil into a suitable container and dispose of it in an approved manner (page 204). NOTICE Improper disposal of drained fluids is harmful to the environment. 7. Install the tank cover assembly and seat. Add Engine Oil: 1. Reinstall the oil drain bolt with the new sealing washer and tighten it to the specified torque: 18 lbf·ft (25 N·m, 2.5 kgf·m) 2. Fill the crankcase with the recommended grade oil approximately: 3.2 US qt (3.0 ℓ) 3. Reinstall the oil fill cap/dipstick. 4. Start the engine and let it idle for 3 – 5 minutes. 5. Stop the engine, wait 2 – 3 minutes and check the oil level. Make sure the oil is between the upper and lower level marks on the oil fill cap/dipstick. If necessary, add more oil but do not overfill. 6. Check that there are no oil leaks. 7. Install the oil check/fill door. If a torque wrench is not used for installation, see your dealer as soon as possible to verify proper assembly. Servicing Your Honda 137 20 TRX520FM6-31HR56500.book 138 ページ２０１９年４月２日火曜日午後４時８分 Rear Final Gear Oil Oil Recommendation type viscosity (weight) suggested oil hypoid gear oil SAE 80W-90 Honda shaft drive oil or equivalent Changing Oil Refer to Safety Precautions on page 111. Change the oil with the rear final gear at normal operating temperature to assure complete and rapid draining. 138 Servicing Your Honda 20 TRX520FM6-31HR56500.book 139 ページ２０１９年４月２日火曜日午後４時８分 Rear Final Gear Oil 1. Park your ATV on a firm, level surface. 2. Place an oil drain pan under the oil drain bolt (1). 3. Remove the oil fill cap (2), O-ring (3), drain bolt and sealing washer (4). 4. After the oil has completely drained, reinstall the drain bolt with a new sealing washer and tighten it to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) 5. Pour the drained oil into a suitable container and dispose of it in an approved manner (page 204). NOTICE Improper disposal of drained fluids is harmful to the environment. 6. Fill the rear final gear case with the recommended oil. 4.2 US oz (125 cm3) Make sure the oil level is at the lower edge of the oil fill inspection hole (5). 7. Coat a new O-ring with grease and install it into the fill cap groove and tighten it to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) REAR (5) (2) (4) (3) (1) (1) oil drain bolt (2) oil fill cap (3) O-ring (4) sealing washer (5) oil fill inspection hole Servicing Your Honda 139 20 TRX520FM6-31HR56500.book 140 ページ２０１９年４月２日火曜日午後４時８分 Front Final Gear Oil Oil Recommendation type viscosity (weight) suggested oil hypoid gear oil SAE 80W-90 Honda shaft drive oil or equivalent Changing Oil Refer to Safety Precautions on page 111. Change the oil with the front final gear at normal operating temperature to assure complete and rapid draining. 140 Servicing Your Honda 20 TRX520FM6-31HR56500.book 141 ページ２０１９年４月２日火曜日午後４時８分 Front Final Gear Oil 1. Park your ATV on a firm, level surface. 2. Place an oil drain pan under the oil drain bolt (1). 3. Remove the oil fill cap (2), O-ring (3), drain bolt and sealing washer (4). 4. After the oil has completely drained, reinstall the drain bolt with a new sealing washer and tighten it to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) 5. Pour the drained oil into a suitable container and dispose of it in an approved manner (page 204). NOTICE Improper disposal of drained fluids is harmful to the environment. 6. Fill the front final gear case with the recommended oil. 11.0 US oz (325 cm3) Make sure the oil level is at the lower edge of the oil fill inspection hole (5). 7. Coat a new O-ring with grease and install it into the fill cap groove and tighten it to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) FRONT (5) (2) (4) (1) (3) (1) oil drain bolt (2) oil fill cap (3) O-ring (4) sealing washer (5) oil fill inspection hole Servicing Your Honda 141 20 TRX520FM6-31HR56500.book 142 ページ２０１９年４月２日火曜日午後４時８分 Coolant Your ATV’s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head. Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion. 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. Use only distilled water as a part of the coolant solution. Water that is high in mineral content or salt may be harmful to the aluminum engine. NOTICE Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. The factory provides a 50/50 solution of antifreeze and water in this ATV. This coolant solution is recommended for most operating temperatures and provides good corrosion protection. Decreasing the concentration of antifreeze to less than 40% will not provide proper corrosion protection. 142 Servicing Your Honda 20 TRX520FM6-31HR56500.book 143 ページ２０１９年４月２日火曜日午後４時８分 Coolant Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance. Higher concentrations of antifreeze (up to 60%) should only be used to provide additional protection against freezing. Check the cooling system frequently during freezing weather. Checking & Adding Coolant Refer to Safety Precautions on page 111. Check the engine coolant level each day before operating your ATV and add if needed. LEFT FRONT (2) (3) (1) (1) reserve tank (2) UPPER level mark (3) LOWER level mark 1. Make sure the vehicle is on level ground. 2. With the engine at normal operating temperature, check the coolant level in the reserve tank (1). It should be between the UPPER (2) and LOWER (3) level marks. If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your dealer for repair. (cont’d) Servicing Your Honda 143 20 TRX520FM6-31HR56500.book 144 ページ２０１９年４月２日火曜日午後４時８分 Coolant 3. Remove the radiator cap lid (4) by disengaging the stud (5) from the grommet (6). 4. Remove the reserve tank cap (7). Always add coolant to the reserve tank. Do not attempt to add coolant by removing the radiator cap. 5. Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark. FRONT (4) (7) (5) (6) (4) radiator cap lid (5) stud (6) grommet (7) reserve tank cap 6. After adding coolant, reinstall the reserve tank cap. 7. Install the radiator cap lid. 144 Servicing Your Honda 20 TRX520FM6-31HR56500.book 145 ページ２０１９年４月２日火曜日午後４時８分 Coolant Coolant Replacement Refer to Safety Precautions on page 111. Coolant should be replaced by your dealer, unless you have the proper tools and service data, and are mechanically qualified. Refer to the official Honda Service Manual (page 244). WARNING 3 WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. To properly dispose of drained coolant, refer to You & the Environment, page 204. NOTICE Improper disposal of drained fluids is harmful to the environment. Servicing Your Honda 145 20 TRX520FM6-31HR56500.book 146 ページ２０１９年４月２日火曜日午後４時８分 Coolant Radiator Core Refer to Safety Precautions on page 111. Check the air passages for clogging or damage. Remove insects, mud, or any obstruction with low water pressure. Have the radiator checked by your dealer if the air flow is restricted over more than 20% of the radiator surface. Clean the radiator core after riding the ATV in mud. The left and center radiator grill covers must be removed to clean the radiator core. 146 Servicing Your Honda 20 TRX520FM6-31HR56500.book 147 ページ２０１９年４月２日火曜日午後４時８分 Coolant To clean the radiator core and radiator grill plate: 1. Remove the radiator cap lid (page 144). 2. Remove the reserve tank (1) by removing the bolt (2) and clips (3) (page 125). 3. Release the hoses (4) from the guides. 4. Hold the reserve tank being careful not to spill the coolant. LEFT FRONT (2) (1) (3) (3) (4) (1) reserve tank (2) bolt (3) clips (4) hoses (cont’d) Servicing Your Honda 147 20 TRX520FM6-31HR56500.book 148 ページ２０１９年４月２日火曜日午後４時８分 Coolant 5. Remove the clips. 6. Remove the left radiator grill cover (5) by releasing the tab A (6), tab B (7), tab C (8), hook A (9) and hook B (10). LEFT FRONT (3) (9) (8) (5) (7) (6) (10) (7) tab B (3) clips (5) left radiator grill cover (8) tab C (6) tab A (9) hook A 148 Servicing Your Honda (10) hook B 20 TRX520FM6-31HR56500.book 149 ページ２０１９年４月２日火曜日午後４時８分 Coolant 7. Remove the center radiator grill cover by releasing the tab A, tab B, hook A and hook B. FRONT (9) (12) (11) (6) (7) (10) (6) tab A (7) tab B (9) hook A (10) hook B (11) center radiator grill cover (12) radiator core 8. Wash the radiator core (12) and radiator grill covers. NOTICE Do not apply pressured water directly to the radiator core. The pressured water can damage the radiator core. 9. Install the removed parts in reverse order of removal. Servicing Your Honda 149 20 TRX520FM6-31HR56500.book 150 ページ２０１９年４月２日火曜日午後４時８分 Air Cleaner Refer to Safety Precautions on page 111. Proper air cleaner maintenance is very important for off-road vehicles. A dirty, water-soaked, worn-out, or defective air cleaner will allow dirt, dust, mud, and other impurities to pass into the engine. Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your dealer can help you determine the correct service interval for your riding conditions. Your ATV’s air cleaner has very specific performance requirements. Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality. NOTICE Using the wrong air cleaner may result in premature engine wear. Proper air cleaner maintenance can prevent premature engine wear or damage, expensive repairs, low engine power, poor gas mileage, and spark plug fouling. NOTICE Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear. 150 Servicing Your Honda 20 TRX520FM6-31HR56500.book 151 ページ２０１９年４月２日火曜日午後４時８分 Air Cleaner Cleaning 1. Remove the seat (page 122). UNDER SEAT (1) (2) (1) spring hooks (2) retainer clips (3) (2) (3) air cleaner housing cover 2. Unlatch the spring hooks (1) and retainer clips (2). 3. Remove the air cleaner housing cover (3). (cont’d) Servicing Your Honda 151 20 TRX520FM6-31HR56500.book 152 ページ２０１９年４月２日火曜日午後４時８分 Air Cleaner 4. Loosen the screw (4) and remove the air cleaner assembly (5) from the air cleaner housing. 5. Remove the clamp (6). 6. Remove the air cleaner (7) from the air cleaner body (8). 7. Gently wash the air cleaner in clean, non-flammable (high flash point) solvent such as kerosene — not gasoline. After cleaning, gently squeeze out the remaining solvent. Avoid twisting or wringing the air cleaner. This can tear the foam. 8. Inspect for tears or cracks in the foam or seams of the air cleaner. Replace the air cleaner if it is damaged. 9. Allow the air cleaner to dry thoroughly before applying oil. A wet air cleaner will not fully absorb the oil. 10. Pour clean Pro Honda Foam Filter Oil or an equivalent (Canada: Honda Foam Filter Oil or an equivalent) over the entire surface of the air cleaner. Use both hands to evenly spread the oil into the air cleaner. Gently squeeze out any excess oil. (To keep your hands dry, place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner.) UNDER SEAT (4) (8) (5) (6) (7) (4) screw (5) air cleaner assembly (6) clamp 152 Servicing Your Honda (7) air cleaner (8) air cleaner body 20 TRX520FM6-31HR56500.book 153 ページ２０１９年４月２日火曜日午後４時８分 Air Cleaner 11. Install the air cleaner on the air cleaner body. 12. Install the clamp. 13. Insert the air cleaner assembly into the air cleaner housing. 14. Fasten the screw. 15. Reassemble by reversing the disassembly sequence. • Install the air cleaner housing cover with the FRONT mark (9) facing forward and fit the cut out of the tab (10) at the end of the air cleaner. UNDER SEAT (9) (9) FRONT mark (10) tab (10) (10) Servicing Your Honda 153 20 TRX520FM6-31HR56500.book 154 ページ２０１９年４月２日火曜日午後４時８分 Air Cleaner Dust Cover UNDER SEAT (1) (2) (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. 154 Servicing Your Honda 20 TRX520FM6-31HR56500.book 155 ページ２０１９年４月２日火曜日午後４時８分 Air Cleaner Air Cleaner Housing Drain Tube The air cleaner housing drain tube should be serviced in accordance with the Maintenance Schedule. (Riding through water may require more frequent inspection.) If deposits can be seen in the drain tube, the tube must be cleaned before starting the vehicle. REAR (3) (1) drain tube (2) clip (1) (2) (3) air cleaner housing 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 155 20 TRX520FM6-31HR56500.book 156 ページ２０１９年４月２日火曜日午後４時８分 Engine Throttle Throttle Freeplay Refer to Safety Precautions on page 111. RIGHT HANDLEBAR (2) (4) (B) 1/8 – 5/16 in (3 – 8 mm) (A) (3) (1) throttle lever (2) rubber sleeve (3) throttle cable adjuster (1) (4) lock nut (A) decrease freeplay (B) increase freeplay Inspection Check freeplay at the throttle lever (1). Freeplay: 1/8 – 5/16 in (3 – 8 mm) Adjustment 1. Slide the rubber sleeve (2) back to expose the throttle cable adjuster (3). 2. Loosen the lock nut (4). 3. Turn the adjuster to obtain the correct freeplay. 4. Tighten the lock nut and reinstall the sleeve. 5. After adjustment, check for smooth operation of the throttle lever from fully closed to fully open in all steering positions. 156 Servicing Your Honda 20 TRX520FM6-31HR56500.book 157 ページ２０１９年４月２日火曜日午後４時８分 Throttle Throttle Inspection Refer to Safety Precautions on page 111. 1. Check that the throttle assembly is positioned properly and the securing bolts are tight. 2. Check for smooth operation of the throttle lever from fully open to fully closed in all steering positions. If there is a problem, see your dealer. 3. Inspect the condition of the throttle cable from the throttle lever down to the throttle body. If the cable is kinked or chafed, have it replaced. 4. Check the throttle cable for tension or stress in all steering positions. 5. Lubricate the throttle cable with a commercially available cable lubricant to prevent premature wear and corrosion. Servicing Your Honda 157 20 TRX520FM6-31HR56500.book 158 ページ２０１９年４月２日火曜日午後４時８分 Clutch System Your ATV’s shift-activated, wet, multiplate clutch is part of the primary drive system. Proper adjustment allows a smooth, gradual engagement when shifting gears. Clutch Adjustment Refer to Safety Precautions on page 111. LEFT FRONT (2) (1) (1) lock nut (2) clutch adjuster 1. Make sure the engine is cool. 2. Make sure the ignition switch is OFF (w). 3. Loosen the lock nut (1). 4. Turn the clutch adjuster (2) counterclockwise until you feel slight resistance. 5. Turn the adjuster 1/4 turn clockwise, then tighten the lock nut to hold the adjuster in this position. 6. After adjustment, start the engine and test ride your ATV to be sure the clutch is operating properly. If you cannot get proper adjustment, or the clutch does not work properly, the clutch friction discs may be worn. See your dealer or refer to official Honda Service Manual (page 244). 158 Servicing Your Honda 20 TRX520FM6-31HR56500.book 159 ページ２０１９年４月２日火曜日午後４時８分 Reverse Inhibitor System Reverse Inhibitor System Adjustment Refer to Safety Precautions on page 111. LEFT HANDLEBAR (1) (4) (5) (3) 1/16 – 3/16 in (2 – 4 mm) (1) dust cover (2) reverse assist lever (3) rubber sleeve (2) (4) lock nut (5) adjusting nut 1. Turn over the dust cover (1). 2. Check the reverse assist lever (2) freeplay, measured at the reverse assist lever end near the cable: 1/16 – 3/16 in (2 – 4 mm) 3. To adjust, slide the rubber sleeve (3), loosen the lock nut (4) and turn the adjusting nut (5) to obtain the correct freeplay. After adjustment, tighten the lock nut securely. 4. Return the dust cover and rubber sleeve. Other Checks Check the reverse assist lever and cable for loose connections or other damage. If the cable is worn or kinked, have it replaced by your dealer. Servicing Your Honda 159 20 TRX520FM6-31HR56500.book 160 ページ２０１９年４月２日火曜日午後４時８分 Spark Plug Spark Plug Recommendation standard spark plug BKR5E-11 (NGK) or K16PR-U11 (DENSO) Use only the recommended type of spark plug in the recommended heat range. NOTICE Using spark plugs with an improper heat range can cause engine damage. Spark Plug Inspection & Replacement Refer to Safety Precautions on page 111. 1. Remove the seat (page 122) and tank cover assembly (page 124). 2. Clean any dirt from around the spark plug base. 3. Disconnect the spark plug cap (1). Take care to avoid damaging the spark plug wire when disconnecting the cap. 4. Using a spark plug wrench provided in the tool kit, remove the spark plug. LEFT SIDE (1) (1) spark plug cap 160 Servicing Your Honda 20 TRX520FM6-31HR56500.book 161 ページ２０１９年４月２日火曜日午後４時８分 Spark Plug 5. Inspect the electrodes and center porcelain for deposits, corrosion, or carbon fouling. If the corrosion or deposits are heavy, replace the plug. Clean a carbon or wet-fouled plug with a plug cleaner, if available, or a wire brush. Inspect the spark plug electrodes for wear. The center electrode (2) should have a flat tip and sharp edges, and the side electrode (3) should not be eroded. If the electrodes and insulator tip appear unusually fouled or burned, we suggest that you contact your dealer. 6. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. 7. Using a wire-type feeler gauge, check the spark plug gap (4). If adjustment is necessary, bend the side electrode carefully. The gap should be: 0.039 – 0.043 in (1.00 – 1.10 mm) (4) (3) 0.039 – 0.043 in (1.00 – 1.10 mm) (2) (2) center electrode (3) side electrode (4) spark plug gap (cont’d) Servicing Your Honda 161 20 TRX520FM6-31HR56500.book 162 ページ２０１９年４月２日火曜日午後４時８分 Spark Plug 8. With the plug washer attached, thread the spark plug in by hand to prevent cross-threading. 9. Tighten the spark plug: • If the old plug is good: 1/8 turn after it seats. • If installing a new plug, tighten it twice to prevent loosening: a) First, tighten the plug: NGK: 3/4 turn after it seats. DENSO: 1/2 turn after it seats. b) Then loosen the plug. c) Next, tighten the plug again: 1/8 turn after it seats. NOTICE An improperly tightened spark plug can damage the engine. If a plug is too loose, the piston may be damaged. If a plug is too tight, the threads may be damaged. 10. Connect the spark plug cap. Take care to avoid pinching any cables or wires. 11. Install the remaining parts in the reverse order of removal. 162 Servicing Your Honda 20 TRX520FM6-31HR56500.book 163 ページ２０１９年４月２日火曜日午後４時８分 Valves Valve Inspection Refer to Safety Precautions on page 111. Valve clearance should be: intake: 0.006 ± 0.001 in (0.15 ± 0.02 mm) exhaust: 0.009 ± 0.001 in (0.23 ± 0.02 mm) Excessive clearance will cause noise. Insufficient clearance will cause loss of power and possibly damage the valves. For those who are mechanically proficient and have the proper tools, instructions on adjusting valve clearances are given in the official Honda Service Manual. Otherwise, the valves should be adjusted by your dealer. Servicing Your Honda 163 20 TRX520FM6-31HR56500.book 164 ページ２０１９年４月２日火曜日午後４時８分 Spark Arrester Refer to Safety Precautions on page 111. The spark arrester must be serviced every 100 operating hours to maintain its efficiency. Regular servicing prevents carbon build up (which can diminish engine performance) and also complies with USDA regulations for regular maintenance to assure proper function. The spark arrester prevents random sparks from the combustion process in your engine from reaching the environment. The use of safety glasses is recommended for this procedure. Because of the possible fire hazard, check that there are no combustible materials in the area before purging the spark arrester. REAR (1) bolt (1) 1. Select a well-ventilated area free of combustible materials and make sure the exhaust pipe is cool. 2. Remove the bolt (1). 3. Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel. 4. Stop the engine and allow the exhaust pipe to cool. 5. Reinstall the bolt securely. 164 Servicing Your Honda 20 TRX520FM6-31HR56500.book 165 ページ２０１９年４月２日火曜日午後４時８分 Chassis Suspension Your front and rear suspension systems use springs and hydraulic damping devices that suspend your weight and most of the weight of your ATV. The oil damper systems hydraulically control the natural compression and rebound of the suspension springs so that traction and comfort are maintained as the wheels ride over rough terrain. The spring pre-loads for your front and rear suspension systems adjust the amount of force required to begin compression of the spring. Consider adjusting your suspensions pre-load whenever you change your normal load, by adding or subtracting cargo, accessories, or when riding conditions change. The way you ride your ATV and the type of ride you want to experience can also influence your suspension needs. Lower spring pre-load provides a softer ride and is usually preferred for light loads and smooth terrain. Higher spring pre-load provides a firmer ride and is recommended for heavy loads and rough terrain. Suspension Adjustment Using a pin spanner, which is available from your dealer, the suspensions can be adjusted for rider weight and riding conditions by changing the spring pre-load. Do not attempt to disassemble, service, or dispose of the damper; see your dealer. The instructions found in this owner’s manual are limited to adjustments of the shock assembly only. Servicing Your Honda 165 20 TRX520FM6-31HR56500.book 166 ページ２０１９年４月２日火曜日午後４時８分 Suspension Suspension Spring Pre-Load Refer to Safety Precautions on page 111. FRONT REAR (1) (1) 12 3 4 5 1 2 3 4 5 (2) (2) (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. 166 Servicing Your Honda 20 TRX520FM6-31HR56500.book 167 ページ２０１９年４月２日火曜日午後４時８分 Suspension Position 1: for a light load and smooth terrain. Position 2: standard position. Positions 3 to 5: for when the ATV is more heavily loaded. (Also increase spring pre-load for stiffer suspension.) Make sure that both 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 167 20 TRX520FM6-31HR56500.book 168 ページ２０１９年４月２日火曜日午後４時８分 Brakes The hydraulic disc brakes (front) and a single hydraulic/mechanical disc brake (rear) on your ATV dissipate the heat generated by the friction of the brake pads on the disc as the wheels are slowed. As the brake pads wear, the brake fluid level will drop. A leak in the system will also cause the level to drop. There are no adjustments to perform, but fluid level and pad wear must be inspected periodically. The system must be inspected frequently to ensure there are no fluid leaks. If the brake lever or brake pedal freeplay does not feel within the normal range while riding, check the brake pads for wear (page 171). Worn pads should be replaced. If the pads are not worn beyond the recommended limit, there is probably air in the brake system. See your dealer to have the air bled from the system. Brake Fluid Recommendation brake fluid 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. An opened container may be contaminated or may have absorbed moisture from the air. 168 Servicing Your Honda 20 TRX520FM6-31HR56500.book 169 ページ２０１９年４月２日火曜日午後４時８分 Brakes Fluid Level Inspection Refer to Safety Precautions on page 111. If your inspection indicates a low fluid level, have your dealer add the recommended fluid. Do not add or replace brake fluid, except in an emergency. If you do add fluid, have your dealer check the system as soon as possible. NOTICE Brake fluid can damage plastic and painted surfaces. Handle with care. Wipe up spills immediately. Avoid brake fluid contact with skin or eyes. If it comes in contact with your eyes, wash them out with clean water and immediately call a doctor. If it comes in contact with your skin, wash with clean water and, if necessary, call a doctor. Front Brake Fluid Level RIGHT HANDLEBAR (1) LOWER level mark (1) (cont’d) Servicing Your Honda 169 20 TRX520FM6-31HR56500.book 170 ページ２０１９年４月２日火曜日午後４時８分 Brakes With the ATV on a level surface, check the fluid level. It should be above the LOWER level mark (1). If the level is at or below the LOWER level mark, check the brake pads for wear (page 171). Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. Rear Brake Fluid Level RIGHT SIDE (2) (3) (2) UPPER level mark (3) LOWER level mark With the ATV on a level surface, check the fluid level. It should be between the UPPER (2) and LOWER (3) level mark. If the level is at or below the LOWER level mark, check the brake pads for wear (page 171). Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. 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. 170 Servicing Your Honda 20 TRX520FM6-31HR56500.book 171 ページ２０１９年４月２日火曜日午後４時８分 Brakes Brake Pad Wear Refer to Safety Precautions on page 111. Brake pad wear will depend upon the severity of usage and riding conditions. The pads will wear faster in wet or muddy conditions. Inspect the pads visually during all regular service intervals to determine the pad wear. RIGHT FRONT (Left side similar) (1) (1) (2) (2) (1) wear indicator (2) edge of reference mark 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. (cont’d) Servicing Your Honda 171 20 TRX520FM6-31HR56500.book 172 ページ２０１９年４月２日火曜日午後４時８分 Brakes RIGHT REAR (4) (3) (3) wear indicator (4) reference mark Check the wear indicator. If the wear indicator (3) aligns with the reference mark (4), replace both pads as a set, see your dealer for this service. 172 Servicing Your Honda 20 TRX520FM6-31HR56500.book 173 ページ２０１９年４月２日火曜日午後４時８分 Brakes Rear Brake Lever Freeplay LEFT HANDLEBAR (1) 1 – 1 3/16 in (25 – 30 mm) (1) rear brake lever/parking brake lever Inspection 1. Press down on the rear brake pedal several times. 2. Measure the distance the rear brake lever/parking brake lever (1) moves before the brake starts to take hold. Freeplay (measurement at the tip of the end of the brake lever) should be: 1 – 1 3/16 in (25 – 30 mm) 3. If necessary, adjust to the specified range. (cont’d) Servicing Your Honda 173 20 TRX520FM6-31HR56500.book 174 ページ２０１９年４月２日火曜日午後４時８分 Brakes Adjustment RIGHT REAR (3) (B) (A) (2) (2) brake lever adjusting nut (3) brake arm pin (A) increase freeplay (B) decrease freeplay Adjust the freeplay of the rear brake lever/parking brake lever with the front wheels pointed straight ahead. Turn the brake lever adjusting nut (2), located on the brake operating rod at the brake caliper. Make sure the cutout on the adjusting nut is properly seated on the brake arm pin (3). Other Inspections • Check that the brake lever and brake pedal assemblies are positioned properly and the securing bolts are tight. • Make sure that the brake cable, brake arm, spring, P/R lever, and fasteners are in good condition. 174 Servicing Your Honda 20 TRX520FM6-31HR56500.book 175 ページ２０１９年４月２日火曜日午後４時８分 Brakes Brake Light Switch Adjustment Refer to Safety Precautions on page 111. Rear Brake Only: Check the operation of the rear brake light switch (1) at the right side behind the engine from time to time. Adjustment is done by turning the adjusting nut (2). Hold the rear brake light switch and turn the nut in direction (A) if the switch operates too late and in direction (B) if the switch operates too soon. RIGHT REAR (2) (A) (B) (1) (1) rear brake light switch (2) adjusting nut Servicing Your Honda 175 20 TRX520FM6-31HR56500.book 176 ページ２０１９年４月２日火曜日午後４時８分 Tires To safely operate your ATV, your tires must be the proper type and size, in good condition with adequate tread, and correctly inflated. WARNING 3 WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner’s manual regarding tire inflation and maintenance. This ATV is equipped with low pressure tubeless tires. Although the tires are designed specifically for off-road use, they are not immune to punctures. Always select your riding area with care. The following pages give detailed information on how and when to check your air pressure, how to inspect your tires for wear and damage, and our recommendations for tire repair and replacement. 176 Servicing Your Honda 20 TRX520FM6-31HR56500.book 177 ページ２０１９年４月２日火曜日午後４時８分 Tires Air Pressure Refer to Safety Precautions on page 111. Properly inflated tires provide the best combination of handling, tread life, and riding comfort. Generally, underinflated tires wear unevenly, adversely affect handling, and are more likely to fail from being overheated. Overinflated tires make your ATV ride 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. (cont’d) Servicing Your Honda 177 20 TRX520FM6-31HR56500.book 178 ページ２０１９年４月２日火曜日午後４時８分 Tires Always check air pressure when your tires are “cold.” If you check air pressure when your tires are “warm” — even if your ATV has only been ridden for a few miles — the readings will be higher. If you let air out of warm tires to match the recommended cold tire pressures, the tires will be underinflated. Be sure to check tire pressure at the riding site, since changes in altitude can affect air pressure. The recommended “cold” tire pressures are: FRONT RECOMMENDED PRESSURE 4.4 psi (30 kPa) 178 Servicing Your Honda REAR 4.4 psi (30 kPa) 20 TRX520FM6-31HR56500.book 179 ページ２０１９年４月２日火曜日午後４時８分 Tires A manually operated tire pump should be used rather than the high pressure system found in service stations. This will minimize the possibility of tire damage from overinflation. If you use a high pressure system at a service station, add air in small amounts and check the pressure increase frequently to prevent possible tire damage from overinflation. WARNING 3 WARNING Operating this ATV with improper tires, or with uneven tire pressure may cause loss of control, and you could be seriously injured or killed. • Always use the size and type tires specified in this owner’s manual for this vehicle. • Always maintain proper tire pressure as described in this owner’s manual. Inspection Refer to Safety Precautions on page 111. Whenever you check the tire pressures, you should also look for: • Bumps or bulges in the side of the tire or the tread. Replace any tire that has a bump or bulge. • Cuts, slits, or cracks in the tires. Replace the tire if you can see fabric or cord. • Nails or other foreign objects embedded in the side of the tire or tread. • Excessive tread wear. (cont’d) Servicing Your Honda 179 20 TRX520FM6-31HR56500.book 180 ページ２０１９年４月２日火曜日午後４時８分 Tires Also, if you hit a pothole or other hard object while riding, stop as soon as you safely can and carefully inspect the tires for damage. Tread Wear (2) NEW (1) (3) 3/16 in (4 mm) Replace (1) groove depth (2) wear indicator (3) wear indicator location mark To check the condition of a tire tread, measure the groove depth (1) in the center of the tire, or check the wear indicator (2). For best performance, you should replace a tire before the tread depth at the center reaches the following limits: front rear 180 Servicing Your Honda 3/16 in (4 mm) 3/16 in (4 mm) 20 TRX520FM6-31HR56500.book 181 ページ２０１９年４月２日火曜日午後４時８分 Tires Tire Repair Refer to Safety Precautions on page 111. A tire that is repaired, either temporarily or permanently, will have lower speed and performance limits than a new or undamaged tire. A temporary repair can sometimes be made in an emergency situation. However, since a temporary repair may not hold, you must ride very slowly, preferably without any cargo, and have the tire replaced or permanently repaired as soon as possible. (For more information on temporary repairs, see If You Have a Flat Tire, page 211.) A permanent repair, such as an internal plug patch, can be made if a tire has only a small puncture in the tread area. However you may not be able to safely carry as much weight. If you choose to have a tire repaired, be sure the repair work is performed by a professional. If you have a tire professionally repaired at a non-Honda facility, we recommend that you have the work checked by your dealer. Servicing Your Honda 181 20 TRX520FM6-31HR56500.book 182 ページ２０１９年４月２日火曜日午後４時８分 Tires Tire Replacement Refer to Safety Precautions on page 111. The tires that came on your ATV were designed to match the performance capabilities of your ATV and provide the best combination of handling, braking, and comfort. It is best to replace all four tires, however if that is not possible, you must replace the tires in pairs (front or rear) with tires of the same size and type as the originals. Never replace just one tire. WARNING 3 WARNING Installing improper tires on your ATV can affect handling and stability. This can cause a crash in which you can be seriously hurt or killed. Always use the size and type of tires recommended in this owner’s manual. The recommended tires for your ATV are: front rear AT25 × 8-1211 AT25 × 10-1211 MAXXIS MU25 MAXXIS MU26 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. 182 Servicing Your Honda 20 TRX520FM6-31HR56500.book 183 ページ２０１９年４月２日火曜日午後４時８分 Guards Refer to Safety Precautions on page 111. (1) (3) (4) (1) engine guard (2) skid plate (2) (5) (3) front boot guards (4) front driveshaft guards (5) rear driveshaft guards The engine guard (1) protects the engine crankcase. The skid plate (2) protects the frame. The front boot guards (3) protect the rubber driveshaft boots, and the front driveshaft guards (4) protect the front driveshafts. The rear driveshaft guards (5) protect the rubber driveshaft boots and the rear driveshafts. Check the guards and plate for cracks, damage or looseness at intervals shown in the Maintenance Schedule. Have the guards and skid plate replaced if they are cracked or damaged. If the guard and plate bolts are loose, tighten them securely. Servicing Your Honda 183 20 TRX520FM6-31HR56500.book 184 ページ２０１９年４月２日火曜日午後４時８分 Drivetrain Boots Refer to Safety Precautions on page 111. REAR FRONT (1) (1) (1) rubber driveshaft boots (2) (3) (2) (2) rubber propeller shaft boots (3) rubber yoke joint boot Check the rubber driveshaft boots (1), rubber propeller shaft boots (2) and rubber yoke joint boot (3) for cuts, damage or leaking grease. If necessary, have your dealer replace them. 184 Servicing Your Honda 20 TRX520FM6-31HR56500.book 185 ページ２０１９年４月２日火曜日午後４時８分 Electrical Battery Your ATV has a maintenance-free type battery. You do not have to check the battery electrolyte level or add distilled water as you would with a conventional-type battery. NOTICE Your battery is a maintenance-free type and can be permanently damaged if the cap strip is removed. Electrical accessories use current from the battery, even when the ignition is OFF (w). Limited operation also allows the battery to discharge. If you have electrical accessories on your ATV or do not ride frequently, we recommend that you charge the battery frequently (see Battery Charging, page 189). If you do not expect to ride your ATV for at least two weeks, we recommend you remove the battery, or at least disconnect the battery cables (negative cable first). If you plan to store your ATV, see Battery Storage, page 186. 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 185 20 TRX520FM6-31HR56500.book 186 ページ２０１９年４月２日火曜日午後４時８分 Battery Battery Storage Refer to Safety Precautions on page 111. If you plan to store your ATV, we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life. If you do not remove the battery, we recommend disconnecting the battery cables (negative cable first). You will get the best storage results from removing the battery and slow charging it every 30 days (see Battery Charging, page 189). Before you remove the battery, be sure to read all the information that follows, as well as the information on the battery label. WARNING 3 WARNING The battery gives off explosive hydrogen gas during normal operation. A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you. Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance. 186 Servicing Your Honda 20 TRX520FM6-31HR56500.book 187 ページ２０１９年４月２日火曜日午後４時８分 Battery The battery is located in a compartment under the rear fender cover. UNDER REAR FENDER COVER (2) (1) (4) (5) (3) (5) (1) rubber band (4) positive (+) terminal lead (2) negative (–) terminal lead (5) terminal nuts (3) battery Removal 1. Make sure the ignition switch is OFF (w). 2. Remove the seat (page 122). 3. Remove the rear fender cover (page 123). 4. Release the rings and remove the rubber band (1). 5. Disconnect the negative (–) terminal lead (2) from the battery (3) first, then disconnect the positive (+) terminal lead (4). 6. Remove the battery taking care not to drop the terminal nuts (5). (cont’d) Servicing Your Honda 187 20 TRX520FM6-31HR56500.book 188 ページ２０１９年４月２日火曜日午後４時８分 Battery 7. Charge the battery (see following section). 8. Store your battery in an easy-to-reach location off the floor, in an area protected from freezing temperature and direct sunlight. 9. Clean the compartment after removing the battery for storage. Dry the compartment. 10. Slow charge the battery (see following section) once every 30 days. Installation 1. Check that the battery rubber (6) for damage. If necessary, replace the battery rubber. 2. Make sure the battery rubber is properly installed. 3. Reinstall the battery in the reverse order of removal. Be sure to connect the positive (+) terminal first, then the negative (–) terminal. 4. Make sure all bolts and other fasteners are secure. 5. Install the removed parts in reverse order of removal. (6) (6) battery rubber After the battery is reconnected, check the clock. Readjust the clock if necessary (page 26). 188 Servicing Your Honda 20 TRX520FM6-31HR56500.book 189 ページ２０１９年４月２日火曜日午後４時８分 Battery Battery Charging Refer to Safety Precautions on page 111. (1) (1) charger Be sure to read the information that came with your battery charger and follow the instructions on the battery. Improper charging may damage the battery. We recommend using a charger (1) designed specifically for your Honda, which can be purchased from your dealer. These units can be left connected for long periods without risking damage to the battery. However, do not intentionally leave the charger connected longer than the time period recommended in the charger’s instructions. Avoid using an automotive-type battery charger. An automotive charger can overheat an ATV battery and cause premature damage. Servicing Your Honda 189 20 TRX520FM6-31HR56500.book 190 ページ２０１９年４月２日火曜日午後４時８分 Appearance Care Frequent cleaning and polishing will keep your Honda looking newer longer. Frequent cleaning also identifies you as an owner who values his ATV. A clean ATV is also easier to inspect and service. General Recommendations Refer to Safety Precautions on page 111. • To clean your ATV, you may use: – water – Hondabrite – a mild, neutral detergent and water – a mild spray and wipe cleaner/polisher – a mild spray and rinse cleaner/degreaser and water • Avoid products that contain harsh detergents or chemical solvents that could damage the metal, paint, plastic, and camouflage coating on your ATV (Honda SxS). • If your ATV is still warm from recent operation, give the engine and exhaust system time to cool off. • Park in a shady area. Washing your ATV in bright sunlight may cause the finish to fade because water droplets intensify the sun’s brightness. • Spotting is also more likely because surface water can dry before you have time to wipe it off. • Clean your ATV regularly to protect surface finishes. • We recommend the use of a low pressure garden hose to wash your ATV. High pressure washers (like those at coin-operated car washers) can damage certain parts of your ATV. NOTICE High pressure water (or air) can damage certain parts of your ATV. Water entering the muffler may damage the oxygen sensor. • After cleaning, inspect for damage, wear, and leaks (fuel, oil, coolant and brake fluid). 190 Servicing Your Honda 20 TRX520FM6-31HR56500.book 191 ページ２０１９年４月２日火曜日午後４時８分 Appearance Care Washing Your ATV with a Mild Detergent Refer to Safety Precautions on page 111. 1. Cover or plug the exhaust outlet prior to washing your ATV. 2. Rinse your ATV thoroughly with cool water to remove loose dirt. 3. Fill a bucket with cool water. Mix in a mild, neutral detergent, such as dish washing liquid or a product made especially for washing motorcycles or automobiles. 4. Wash your ATV with a sponge or soft towel. As you wash, check for heavy grime. If necessary, use a mild cleaner/degreaser to remove the grime. 5. After washing, rinse your ATV thoroughly with plenty of clean water to remove any residue. Detergent residue can corrode alloy parts. 6. Dry your ATV with a chamois or a soft towel. Leaving water on the surface to air dry can cause dulling and water spots. As you dry, inspect for chips and scratches. 7. Remove the cover or the plug from exhaust outlet. Then, start the engine and let it idle for several minutes. The engine heat will help dry moist areas. 8. As a precaution, ride your ATV at a slow speed and apply the brakes several times. This will help dry the brakes and restore normal braking performance. If the inside of the headlight lens appears clouded immediately after washing, it should clear after a few minutes of riding. Servicing Your Honda 191 20 TRX520FM6-31HR56500.book 192 ページ２０１９年４月２日火曜日午後４時８分 Appearance Care Spray Cleaning Your ATV Refer to Safety Precautions on page 111. Avoid using spray cleaner products on the tires or suspension components. Suggestions for using spray cleaner(s) follow: ATV condition Dust and fingerprint smudges. Light road grimes. Heavy grime. Oil leaks. Brake dust. Dull, corroded chrome or aluminum. 192 Servicing Your Honda Recommended Cleaning Apply a spray cleaner/polish and wipe paint, chrome, glass, and clear plastic. Spray any difficult-to-reach or very dirty areas with a spray cleaner/degreaser. Rinse and dry. Apply a spray cleaner/polish and wipe with a non-abrasive cloth. Use a spray cleaner/degreaser. If necessary, rub with a sponge. Rinse and dry. Apply a spray cleaner/polish and wipe with a non-abrasive cloth. Apply a high quality chrome/ aluminum polish and wipe with a non-abrasive cloth. 20 TRX520FM6-31HR56500.book 193 ページ２０１９年４月２日火曜日午後４時８分 Appearance Care Exhaust Pipe and Muffler Maintenance Refer to Safety Precautions on page 111. The exhaust pipe and muffler are stainless steel but may become stained by mud or dust. To remove mud or dust, use a wet sponge and a liquid kitchen abrasive, then rinse well with clean water. Dry with chamois or a soft towel. If necessary, remove heat stains by using a commercially available fine texture compound. Then rinse by the same manner as removing mud or dust. Servicing Your Honda 193 20 TRX520FM6-31HR56500.book 194 ページ２０１９年４月２日火曜日午後４時８分 Appearance Care Finishing Touches Refer to Safety Precautions on page 111. After washing your ATV, consider using a commercially available spray cleaner/polish or quality liquid or paste wax to finish the job. Use only a non-abrasive polish or wax made specifically for motorcycles or automobiles. Apply the polish or wax according to the instructions on the container. If a surface on your ATV is chipped or scratched, your dealer has touch-up paint to match your ATV’s color. Be sure to use your ATV’s color code (page 229) when you buy touch-up paint. If the frame has a chip that exposes the metal, first apply primer (to prevent corrosion) and then apply the touch-up paint. Several thin layers of touch-up paint are better than one thick coat. 194 Servicing Your Honda 20 TRX520FM6-31HR56500.book 195 ページ２０１９年４月２日火曜日午後４時８分 Tips Here’s helpful advice on how to prepare for an off-road adventure, how to transport and store your Honda, and how to be an environmentally responsible ATV owner. Tips Preparing for a Ride.................................................................. 196 What to Take to the Riding Area............................................ 196 What to Take on the Trail ...................................................... 197 Transporting Your Honda ......................................................... 198 Storing Your Honda.................................................................. 200 Preparation for Storage.......................................................... 201 Removal from Storage ........................................................... 203 You & the Environment ............................................................ 204 Tips 195 20 TRX520FM6-31HR56500.book 196 ページ２０１９年４月２日火曜日午後４時８分 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. The Forest Service and the Bureau of Land Management (USA only), the Ministry of Natural Resources (Canada only), riding clubs, and off-road magazines are good sources of information. What to Take to the Riding Area Along with your ATV and riding gear, you should take along some tools and supplies in case you have a problem. For some of the difficulties you might encounter, see Taking Care of the Unexpected, which begins on page 205. We recommend that you always take water, food, a first aid kit, and your owner’s manual. Other items you should consider loading on your truck or trailer include: • a tool kit • tire repair supplies and tools, and tires • extra parts, control levers, cables, and spark plugs • wire, duct tape, and rope • extra gasoline For safety, all refueling should be done at a gas station on the way to the riding area or at your base camp. 196 Tips 20 TRX520FM6-31HR56500.book 197 ページ２０１９年４月２日火曜日午後４時８分 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. If you decide to take some tools, spare parts, or other supplies on the trail, be sure you can carry them safely and know how to use them. Also, be sure to follow the loading guidelines and weight limits (page 68). Tips 197 20 TRX520FM6-31HR56500.book 198 ページ２０１９年４月２日火曜日午後４時８分 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. Follow these procedures: 1. Set the parking brake and place the transmission in gear. 198 Tips 20 TRX520FM6-31HR56500.book 199 ページ２０１９年４月２日火曜日午後４時８分 Transporting Your Honda 2. Secure the vehicle with tie-down straps in the areas shown. • Suitable tie-down straps are available from your dealer. • Ordinary rope is not recommended because it can stretch under load. • Using tie-down straps in any other areas can damage your ATV. 3. Rock the vehicle back and forth to make sure the tie-down straps are tight and the vehicle is secure. (1) (2) (3) (4) (1) front cargo rack (2) front carry pipe (3) rear cargo rack (4) trailer hitch Tips 199 20 TRX520FM6-31HR56500.book 200 ページ２０１９年４月２日火曜日午後４時８分 Storing Your Honda If you won’t be riding for an extended period, such as during the winter, thoroughly inspect your ATV and correct any problem before storing it. That way, needed repairs won’t be forgotten and it will be easier to get your ATV running again. For more information about storage, refer to the Honda Winter Storage Guide, available from your dealer (USA only). We suggest you perform the following procedures to keep your ATV in top condition. These storage procedures will reduce the deterioration that can occur during storage. 200 Tips 20 TRX520FM6-31HR56500.book 201 ページ２０１９年４月２日火曜日午後４時８分 Storing Your Honda Preparation for Storage Refer to Safety Precautions on page 111. 1. Change the engine oil and filter (page 134). 2. Make sure the cooling system is filled with a 50/50% antifreeze solution (page 142). 3. Fill the fuel tank. Make sure the fuel fill cap is properly installed. 4. To prevent rusting in the cylinder, perform the following: • Remove the spark plug cap from the spark plug (page 160). • Remove the spark plug. Do not connect the spark plug to the spark plug cap. • Pour a tablespoon (15 – 20 cc) of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth. • With the engine stop switch in the RUN (e) position, press the start/override button several times to crank the engine and distribute the oil. • Reinstall the spark plug and spark plug cap. (cont’d) Tips 201 20 TRX520FM6-31HR56500.book 202 ページ２０１９年４月２日火曜日午後４時８分 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 189) once a month. WARNING 3 WARNING The battery gives off explosive hydrogen gas during normal operation. A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you. Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance. 6. Wash and dry your ATV. Wax all painted surfaces. 7. Inflate the tires to their recommended pressures (page 178). 8. Store your ATV in an unheated area, free of dampness, away from sunlight, with a minimum of daily temperature variation. 9. Place your ATV on blocks to lift all tires off the floor. 10. Cover your ATV with a porous material. Avoid using plastic or similar non-breathing, coated materials that restrict air flow and allow heat and moisture to accumulate. NOTICE Do not store your ATV in an upright position for extended periods of time. The ATV should be stored with all four tires on the ground. This can damage the vehicle, and leaking gasoline could be a hazard. 202 Tips 20 TRX520FM6-31HR56500.book 203 ページ２０１９年４月２日火曜日午後４時８分 Storing Your Honda Removal from Storage Refer to Safety Precautions on page 111. 1. Uncover and clean your ATV. 2. If your ATV has been stored for more than four months — change the engine oil (page 134). 3. If your ATV has been stored for more than two months — ask your dealer to drain and replace the fuel. 4. Charge the battery (page 189) as required. Install the battery. 5. Perform a pre-ride inspection (page 63), then test-ride your ATV at low speeds. Tips 203 20 TRX520FM6-31HR56500.book 204 ページ２０１９年４月２日火曜日午後４時８分 You & the Environment Owning and riding an ATV can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport of off-road riding. Following are tips on how you can be an environmentally responsible ATV owner. • Tread Lightly. Stay on existing roads and trails, avoid surfaces that are easily damaged, and ride only in areas approved for offroad vehicles. • Keep the Noise Down. Loud vehicles can be offensive. Ride as quietly as possible, don’t remove your spark arrester, and don’t modify the muffler or any other part of your air intake and exhaust systems. Such modifications not only increase noise, they also reduce engine performance and may be illegal. • Choose Sensible Cleaners. Use a biodegradable detergent when you wash your ATV. Avoid aerosol spray cleaners that contain chlorofluorocarbons (CFCs) which damage the atmosphere’s protective ozone layer. Don’t throw cleaning solvents away; see the following guidelines for proper disposal. • Recycle Wastes. It’s illegal and thoughtless to put used engine oil in the trash, down a drain, or on the ground. Used oil, gasoline, and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water, lakes, rivers, and oceans. Before changing your oil, make sure you have the proper containers. Put oil and other toxic wastes in separate sealed containers and take them to a recycling center. Call your local or state office of public works or environmental services to find a recycling center in your area, and to get instructions on how to dispose of non-recyclable wastes. 204 Tips 20 TRX520FM6-31HR56500.book 205 ページ２０１９年４月２日火曜日午後４時８分 Taking Care of the Unexpected With all the challenges you can encounter off-road, there’s a chance that sometime something may go wrong. This section gives practical advice to help you deal with a wide range of problems. Take time to read this section before you ride. Also review the tips in Preparing for a Ride (page 196). Taking Care of the Unexpected General Guidelines ................................................................... 206 If Your Engine Quits or Won’t Start .......................................... 208 If You Have a Flat Tire............................................................... 211 If the High Coolant Temperature Indicator Lights ...................... 215 If a Fuse Blows.......................................................................... 217 If You Crash ............................................................................. 222 If You Lose Your Key ................................................................ 223 If the Battery Is Low (or Dead)................................................... 224 If a Component Fails................................................................. 225 Taking Care of the Unexpected 205 20 TRX520FM6-31HR56500.book 206 ページ２０１９年４月２日火曜日午後４時８分 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. If something goes wrong during a ride, the first thing to do is stop as soon as you safely can. Do not continue riding if you have a flat tire, or you hear an unusual noise, or your ATV just doesn’t feel right. If you continue riding, you could cause more damage and endanger your own safety. After stopping, take time to assess the situation. Carefully inspect your ATV to identify the problem, then consider your options before you decide what to do. If a problem is relatively minor and you have the tools, supplies, and skills to make a permanent repair, you may be able to fix it on the trail and continue riding. Or, you may be able to make a temporary repair that allows you to slowly ride back to your base where you can make a permanent repair or get help. When a problem is more serious — or you don’t have the tools, supplies, experience, or time to deal with it — you need to choose the safest way to get yourself and your ATV back to base. For example, if you are close enough, you (or you and another person) might be able to push it back. 206 Taking Care of the Unexpected 20 TRX520FM6-31HR56500.book 207 ページ２０１９年４月２日火曜日午後４時８分 Taking Care of the Unexpected Should you ever have a problem while riding, please follow these guidelines: • Always put personal safety first. • Take time to assess the situation and your options before deciding what to do. • If the problem is relatively minor and you have the tools, supplies, and skills to make a temporary repair, be sure to have permanent repairs made as soon as possible. • Do not continue riding if you are hurt or your ATV is not in safe riding condition. Additional recommendations for specific problems follow. Taking Care of the Unexpected 207 20 TRX520FM6-31HR56500.book 208 ページ２０１９年４月２日火曜日午後４時８分 If Your Engine Quits or Won’t Start Proper operation and maintenance can prevent starting and engine performance problems. In many cases, the cause of the problem may be a simple operational oversight. If you have a problem starting the engine — or experience poor engine performance — the following information may help you. If you can’t correct the problem, see your dealer. If your ATV won’t start, listen as you press the start/override button. If you don’t hear the starter motor turning, refer to the Starter motor doesn’t operate symptom. If you can hear the starter motor working normally, refer to the Starter motor works, but the engine won’t start symptom. 208 Taking Care of the Unexpected 20 TRX520FM6-31HR56500.book 209 ページ２０１９年４月２日火曜日午後４時８分 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. blown fuse Replace with a new fuse of the same rating (page 217). battery lead loose Tighten the battery lead. low (or dead) battery Charge the battery (page 189). If charging doesn’t help, see your dealer. faulty starter motor If all possible causes are negative, the starter motor may be faulty. See your dealer. SYMPTOM: Starter motor works, but the engine won’t start. POSSIBLE CAUSE WHAT TO DO out of fuel Fill the fuel tank. flooded engine See Flooded Engine (page 83). loose or unconnected Install the spark plug cap spark plug cap securely. If the engine still won’t start, see your dealer. loose battery cables Tighten the battery terminal bolts. weak battery Charge the battery (page 189). If charging doesn’t help, see your dealer. Taking Care of the Unexpected 209 20 TRX520FM6-31HR56500.book 210 ページ２０１９年４月２日火曜日午後４時８分 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. Refer to If the High Coolant Temperature Indicator Lights, page 215. runs erratically, misfires See your dealer. blubbers (rich fuel See your dealer. mixture) sooty exhaust (rich fuel See your dealer. mixture) detonates or pings If applicable, switch to the under load recommended octane gasoline (page 126) or change your brand of gasoline. If the problem persists, see your dealer. afterfires (backfires) See your dealer. pre-ignition (runs on See your dealer. after ignition switched OFF) SYMPTOM: Engine starts, but runs poorly or dies when hot. POSSIBLE CAUSE WHAT TO DO poor or inadequate See your dealer. fuel flow due to (ensure clean fuel supply) clogged fuel filter 210 Taking Care of the Unexpected 20 TRX520FM6-31HR56500.book 211 ページ２０１９年４月２日火曜日午後４時８分 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. (The plug method is applied from the outside of the tire and is the same as that for conventional tubeless tires.) A plug-type repair kit, available at most auto parts stores or service stations, provides a plug, an installation tool, tire cement, and an instruction sheet. Follow the instructions provided with the repair kit to make a temporary repair. As soon as possible, have the tire permanently repaired by your dealer. Any tire that cannot be repaired should be replaced. Whenever the ATV is to be operated far from service facilities or available transportation, we recommend that you carry a tire pump and a repair kit with the vehicle. If the leak is more serious, or a temporary repair doesn’t hold, the tire must be replaced. The tire will also need to be replaced if it is damaged (page 182). Replacing a tire involves removing and reinstalling the wheel (page 213). (cont’d) Taking Care of the Unexpected 211 20 TRX520FM6-31HR56500.book 212 ページ２０１９年４月２日火曜日午後４時８分 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. WARNING 3 WARNING Riding your ATV with a temporary tire repair can be risky. If the temporary repair fails, you can crash and be seriously injured or killed. If you must ride with a temporary tire repair, ride slowly and carefully until the tire is permanently repaired or replaced. 212 Taking Care of the Unexpected 20 TRX520FM6-31HR56500.book 213 ページ２０１９年４月２日火曜日午後４時８分 If You Have a Flat Tire Emergency Wheel Removal/Installation Refer to Safety Precautions on page 111. (1) (1) (2) (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. Raise the front (or rear) wheels off the ground and place a support block under the vehicle. 4. Remove the wheel nuts. 5. Remove the wheel. • Avoid getting grease, oil, or dirt on the front brake disc or pad surfaces when removing and installing each wheel. Any contamination can cause poor brake performance or rapid pad wear after reassembly. (cont’d) Taking Care of the Unexpected 213 20 TRX520FM6-31HR56500.book 214 ページ２０１９年４月２日火曜日午後４時８分 If You Have a Flat Tire Installation 1. Position the wheel. 2. Position each wheel nut so that the tapered side faces the wheel rim (2). 3. Hand-tighten the wheel nuts on the wheel, then lower the ATV to the ground before tightening the nuts in a crisscross (rather than circular) pattern to the specified torque: 47 lbf·ft (64 N·m, 6.5 kgf·m) If a torque wrench was not used for installation, see your dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capability. 214 Taking Care of the Unexpected 20 TRX520FM6-31HR56500.book 215 ページ２０１９年４月２日火曜日午後４時８分 If the High Coolant Temperature Indicator Lights Normally, the high coolant temperature indicator will only light momentarily when you turn the ignition to ON (q). High coolant temperature may be caused by restriction of air flow to the radiator (such as mud caked on the radiator), extended idling, an oil leak, a coolant leak, a low oil level, a low coolant level, or extended operation under adverse conditions. If the all segment of the coolant temperature gauge and high coolant temperature indicator are on while you’re riding, don’t ignore it. Pull safely to a stop. Stop the engine as soon as it’s safe to do so, and let it cool. NOTICE Continuing to ride with high coolant temperature or an overheated engine can cause serious engine damage. • A steaming engine indicates a coolant leak. Shut the engine off and wait until the steaming stops. Look for a leak, but don’t touch the engine or radiator system. Let everything cool off first. • Check for any restriction of air flow to the radiator. • If there’s no obvious problem, leave the engine on so the fan and coolant circulating system can continue working. Monitor the coolant temperature gauge and high coolant temperature indicator. The indicator may turn off after a brief stop with no load on the engine. • Check the radiator fan. If the fan is not working, turn the engine off. Open the fuse box (page 218) and check the radiator fan fuse. If the fuse is blown, replace it with the proper (same rating) spare fuse. Start the engine. If the all segment of the coolant temperature gauge and high coolant temperature indicator stays on, turn the engine off. If the radiator fan is working, visually check the coolant level in the reserve tank, located under the left front fender. It isn’t necessary to touch the radiator system. (cont’d) Taking Care of the Unexpected 215 20 TRX520FM6-31HR56500.book 216 ページ２０１９年４月２日火曜日午後４時８分 If the High Coolant Temperature Indicator Lights • If the reserve tank is low or empty, don’t ride without adding coolant (page 143). After adding coolant, turn the engine on and check the coolant temperature gauge and high coolant temperature indicator. If the indicator doesn’t turn off, do not ride. The engine needs repair. Transport your ATV to your dealer (page 198). If the temperature drops to normal, check the coolant level. If it has gone down, add more coolant. • Check for an oil leak. • Check the oil level. If necessary, add the recommended oil (page 132) to the upper level mark. If you must leave your ATV to get oil, secure it as much as possible. • Start the engine, and check that the coolant temperature gauge and high coolant temperature indicator goes off. If you are able to resume riding, continue to monitor the coolant temperature gauge and high coolant temperature indicator frequently. If there is an oil leak — do not ride the ATV until the leak is repaired by your dealer (page 198). If there’s a mild coolant leak, you can ride for awhile, carefully watching the coolant temperature gauge and indicator. Be prepared to stop and add more coolant or water. If the leak is bad, transport your ATV to your dealer (page 198). 216 Taking Care of the Unexpected 20 TRX520FM6-31HR56500.book 217 ページ２０１９年４月２日火曜日午後４時８分 If a Fuse Blows All of the electrical circuits on your ATV have fuses to protect them from damage caused by excess current flow (short circuit or overload). If something electrical on your ATV stops working, the first thing you should check for is a blown fuse (1). Check all the fuses before looking elsewhere for another possible cause of the problem. Replace any blown fuses and check component operation. (1) (1) (1) blown fuse The main fuse and the circuit fuses are located under the rear fender cover. The EPS (Electric Power Steering) fuse is located under the rear fender cover. Recommended Fuses main fuse 1 main fuse 2 other fuses EPS (Electric Power Steering) fuse 40 A 10 A 20 A × 4, 10 A 40 A (cont’d) Taking Care of the Unexpected 217 20 TRX520FM6-31HR56500.book 218 ページ２０１９年４月２日火曜日午後４時８分 If a Fuse Blows Main Fuses Access 1. To prevent an accidental short circuit, turn the ignition switch to OFF (w) before checking or replacing the fuses. 2. Remove the seat (page 122). 3. Remove the rear fender cover (page 123). 4. To access the main fuse 1 (2), remove the fuse cover (3). 5. To access the main fuse 2 (4), remove the fuse box cover (5). UNDER REAR FENDER COVER (5) (3) (2) (4) (6) (2) main fuse 1 (5) fuse box cover (6) spare fuse (3) fuse cover (4) main fuse 2 6. Pull the main fuse 1 (2) out. If the main fuse 1 is blown, install the spare fuse on the underside of the rear fender cover (page 121). 218 Taking Care of the Unexpected 20 TRX520FM6-31HR56500.book 219 ページ２０１９年４月２日火曜日午後４時８分 If a Fuse Blows 7. Pull the main fuse 2 (4) out with the fuse puller on the underside of the rear fender cover (page 121). If the main fuse 2 is blown, install the spare fuse (6). 8. Install the fuse cover. Circuit Fuses Access (7) (8) (7) circuit fuses (8) spare fuses 9. To check or replace a circuit fuse (7), pull the old fuse out of its retaining clips with the fuse puller on the underside of the rear fender cover (page 121). If the fuse is blown, replace it with a spare fuse (8) of the same rating. If you do not have a replacement fuse with the proper rating for the circuit, install one with a lower rating. NOTICE Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electrical system. 10. Install the fuse box cover. 11. Install the rear fender cover. 12. Install the seat. (cont’d) Taking Care of the Unexpected 219 20 TRX520FM6-31HR56500.book 220 ページ２０１９年４月２日火曜日午後４時８分 If a Fuse Blows EPS (Electric Power Steering) Fuse Access 1. Turn the ignition switch to OFF (w) before checking the fuse. 2. Remove the seat (page 122). 3. Remove the rear fender cover (page 123). 4. To access the EPS fuse (1), remove the fuse cover (2). If the EPS fuse is blown, install the spare fuse (page 121). 5. Install the fuse cover. 6. Install the rear fender cover. 7. Install the seat. UNDER REAR FENDER COVER (2) (1) (1) EPS fuse 220 Taking Care of the Unexpected (2) fuse cover 20 TRX520FM6-31HR56500.book 221 ページ２０１９年４月２日火曜日午後４時８分 If a Fuse Blows If you do not have a spare fuse and you cannot ride the ATV without fixing the problem, take a fuse of the same rating or a lower rating from one of the other circuits that you can do without temporarily. If you replace a blown fuse with a spare fuse that has a lower rating, replace the fuse with the correct rating as soon as you can. Also remember to replace any spare fuses that were installed. If the replacement fuse of the same rating burns out in a short time, there is probably a serious electrical problem on your ATV. Leave the blown fuse in that circuit and have your ATV checked by your dealer. Taking Care of the Unexpected 221 20 TRX520FM6-31HR56500.book 222 ページ２０１９年４月２日火曜日午後４時８分 If You Crash Personal safety is your first priority after a crash. If you or anyone else has been injured, take time to assess the severity of the injuries and whether it is safe to continue riding. If you cannot ride safely, send someone for help. Do not ride if you will risk further injury. If you decide you are capable of riding safely, carefully inspect your ATV for damage and determine if it is safe to ride. Check the tightness of critical nuts and bolts securing such parts as the handlebar, control levers, brakes, and wheels. If there is minor damage, or you are unsure about possible damage but decide to try riding the ATV back to your base, ride slowly and cautiously. Sometimes, crash damage is hidden or not immediately apparent. When you get home, thoroughly check your ATV and correct any problems you find. Also, be sure to have your dealer check the frame and suspension after any serious crash. 222 Taking Care of the Unexpected 20 TRX520FM6-31HR56500.book 223 ページ２０１９年４月２日火曜日午後４時８分 If You Lose Your Key Be sure to record your key number (1). Store the spare key and recorded key number in a safe location. You’ll need this number to have a duplicate key made. If you lose your key and aren’t carrying a duplicate, either get your spare or have one made. If you don’t know your key number, call the dealer where you purchased your Honda ATV. They may have it listed in their records. If they don’t, transport your ATV to them or the nearest dealer. The dealer will probably have to remove the ignition switch assembly to find the key number so they can make a key for you. (1) (1) key number Taking Care of the Unexpected 223 20 TRX520FM6-31HR56500.book 224 ページ２０１９年４月２日火曜日午後４時８分 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. (Canada only) Your ATV will operate even if the battery is low (or dead), as long as the engine is running. If the engine is not running, it may be started using the recoil starter. 1. Shift the shift lever in neutral position. 2. Apply the parking brake. 3. Turn the ignition switch to the ON (q) position. 4. Use the recoil starter (page 86) to start the engine. 224 Taking Care of the Unexpected 20 TRX520FM6-31HR56500.book 225 ページ２０１９年４月２日火曜日午後４時８分 If a Component Fails The brake levers or pedal, control cables, and other components can be damaged as you ride in dense brush or over rocky terrain. Making a trailside repair depends on how serious the damage is and what tools and supplies you have with you. • If any component of the brake system is damaged, you may be able to ride carefully back to your base using the other brake components for slowing or stopping. • If you damage a throttle cable or other critical component, your ATV may be unsafe to ride. Carefully assess the damage and make any repairs that you can. But if there is any doubt, it’s best to be conservative and safe. Taking Care of the Unexpected 225 20 TRX520FM6-31HR56500.book 226 ページ２０１９年４月２日 226 Taking Care of the Unexpected 火曜日午後４時８分 20 TRX520FM6-31HR56500.book 227 ページ２０１９年４月２日火曜日午後４時８分 Technical Information This section contains dimensions, capacities, and other technical data, plus information on government requirements and how to break-in your ATV. Technical Information Vehicle Identification ................................................................ 228 Specifications ........................................................................... 230 Break-in Guidelines................................................................... 235 Emission Control Systems ......................................................... 236 Oxygenated Fuels ..................................................................... 240 Technical Information 227 20 TRX520FM6-31HR56500.book 228 ページ２０１９年４月２日火曜日午後４時８分 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 144). FRONT (1) (1) VIN The engine number (2) is stamped on the upper side of the rear crankcase. (2) REAR (2) engine number 228 Technical Information 20 TRX520FM6-31HR56500.book 229 ページ２０１９年４月２日火曜日午後４時８分 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 and code in the Quick Reference section at the rear of this manual. LEFT SIDE (1) (1) color label Technical Information 229 20 TRX520FM6-31HR56500.book 230 ページ２０１９年４月２日火曜日午後４時８分 Specifications Dimensions overall length overall width overall height wheelbase ground clearance Fuel & Lubricants fuel recommendation fuel tank capacity fuel tank reserve engine oil capacity engine oil recommendation 86.0 in (2,185 mm) 47.4 in (1,205 mm) 48.7 in (1,238 mm) 50.9 in (1,294 mm) 9.8 in (250 mm) unleaded gasoline, pump octane number of 86 or higher 3.88 US gal (14.7 ℓ) including reserve 1.29 US gal (4.9 ℓ) after disassembly: 3.5 US qt (3.3 ℓ) after draining: 3.1 US qt (2.9 ℓ) after draining & oil filter change: 3.2 US qt (3.0 ℓ) API Service Classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label, SAE 10W-30, JASO T 903 standard MA, Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil 230 Technical Information 20 TRX520FM6-31HR56500.book 231 ページ２０１９年４月２日火曜日午後４時８分 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 passenger capacity maximum weight capacity operator only 573 lb (260 kg) rider, all cargo and accessories Engine Specifications displacement 31.6 cu-in (518 cm3) bore & stroke 3.78 × 2.81 in (96.0 × 71.5 mm) compression ratio 9.5 : 1 spark plug BKR5E-11 (NGK) or (standard) K16PR-U11 (DENSO) spark plug gap 0.039 – 0.043 in (1.00 – 1.10 mm) valve clearance intake: 0.006 ± 0.001 in (cold) (0.15 ± 0.02 mm) exhaust: 0.009 ± 0.001 in (0.23 ± 0.02 mm) idle speed 1,400 ± 100 rpm (NO ADJUSTMENT) Technical Information 231 20 TRX520FM6-31HR56500.book 232 ページ２０１９年４月２日火曜日午後４時８分 Specifications Power Transmission primary reduction secondary reduction final reduction front rear transmission ratio 1st 2nd 3rd 4th 5th reverse final drive Chassis & Suspension caster 1° trail -0.04 in (-1 mm) tire size, front AT25 × 8-1211 tire size, rear AT25 × 10-1211 tire pressure, front: front & rear (cold) 4.4 psi (30 kPa) rear: 4.4 psi (30 kPa) 232 Technical Information 2.103 1.875 3.230 3.153 4.230 2.388 1.608 1.178 0.848 5.743 shaft MAXXIS MU25 MAXXIS MU26 20 TRX520FM6-31HR56500.book 233 ページ２０１９年４月２日火曜日午後４時８分 Specifications Electrical battery generator Lights headlight assist headlight brake/tail light neutral indicator reverse indicator high coolant temperature indicator PGM-FI indicator differential lock indicator PS (Electric Power Steering) indicator Fuses main 1 main 2 other EPS (Electric Power Steering) GYZ16H 12 V – 16 Ah (10HR) 0.481 kW/5,000 rpm 12 V 35/35 W × 2 12 V 50 W LED LED LED LED LED LED LED 40 A 10 A 20 A × 4, 10 A 40 A Technical Information 233 20 TRX520FM6-31HR56500.book 234 ページ２０１９年４月２日火曜日午後４時８分 Specifications Torque Specification engine oil drain bolt engine oil filter cover bolts rear final gear oil drain bolt rear final gear oil fill cap front final gear oil drain bolt front final gear oil fill cap wheel nuts 18 lbf·ft (25 N·m, 2.5 kgf·m) 7 lbf·ft (10 N·m, 1.0 kgf·m) 9 lbf·ft (12 N·m, 1.2 kgf·m) 9 lbf·ft (12 N·m, 1.2 kgf·m) 9 lbf·ft (12 N·m, 1.2 kgf·m) 9 lbf·ft (12 N·m, 1.2 kgf·m) 47 lbf·ft (64 N·m, 6.5 kgf·m) 234 Technical Information 20 TRX520FM6-31HR56500.book 235 ページ２０１９年４月２日火曜日午後４時８分 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 235 20 TRX520FM6-31HR56500.book 236 ページ２０１９年４月２日火曜日午後４時８分 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. The Vehicle Emission Control Information Label (1) is attached on the left front of the frame. (Canada only) The Vehicle Emission Control Information Label (2) is attached on the left side of the frame. LEFT SIDE LEFT FRONT (1) (2) (1) vehicle emission control information label (2) vehicle emission control information label (Canada only) 236 Technical Information 20 TRX520FM6-31HR56500.book 237 ページ２０１９年４月２日火曜日午後４時８分 Emission Control Systems Source of Exhaust Emissions The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. Exhaust Emission Control System The exhaust emission control system includes a PGM-FI system and oxygen sensor. No adjustment to this system should be made although periodic inspection of the components is recommended. The exhaust emission control system is separate from the crankcase emission control system. Evaporative Emission Control System (USA - 50 States [meets California]) An evaporative emissions control system uses a canister filled with charcoal to adsorb fuel vapor from the fuel tank while the engine is off. The vapor is drawn into the engine and burned while driving. Models sold in and used in California: An add-on or modified part must be compliant with applicable ARB evaporative emission control standards. A violation of this requirement is punishable by civil and/or criminal punishment. Crankcase Emission Control System The engine is equipped with a Closed Crankcase System to prevent discharging crankcase vapors into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner, throttle-body and intake-manifold. Technical Information 237 20 TRX520FM6-31HR56500.book 238 ページ２０１９年４月２日火曜日午後４時８分 Emission Control Systems Problems That May Affect ATV Exhaust Emissions If you are aware of any of the following symptoms, have the vehicle inspected and repaired by your ATV dealer. Symptoms: 1. Hard starting or stalling after starting 2. Rough idle 3. Misfiring or backfiring during acceleration 4. After-burning (backfiring) 5. Poor performance (driveability) and poor fuel economy Federal regulations prohibit removing or disabling a device or element of design that may affect your engine’s emission performance unless your ATV will be used exclusively in competition. If you modify your engine for use in sanctioned competition events, you must deface or destroy the emission control information label. If you loan, sell, or give your competition modified Honda ATV to someone else, under applicable law, you must inform the new owner/operator in writing that the vehicle is to be used for competition only. 238 Technical Information 20 TRX520FM6-31HR56500.book 239 ページ２０１９年４月２日火曜日午後４時８分 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 use; or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS: • Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases. • Removal of, or puncturing of any part of the intake system. • Lack of proper maintenance. • Removing or disabling any emissions compliance component, or replacing any compliance component with a non-compliant component. Fuel Permeation Emission Control System This vehicle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Environment Climate Change Canada (ECCC). The fuel tank, fuel hoses, and fuel vapor charge hoses used on this vehicle incorporate fuel permeation control technologies. Tampering with the fuel tank, fuel hoses, or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal regulations. Technical Information 239 20 TRX520FM6-31HR56500.book 240 ページ２０１９年４月２日火曜日午後４時８分 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement. Before using an oxygenated fuel, try to confirm the fuel’s contents. Some states/provinces require this information to be posted on the pump. The following are the EPA-approved percentages of oxygenates for non-road vehicles: ETHANOL (ethyl or grain alcohol) up to 10% by volume You may use gasoline containing up to 10% ethanol by volume. Gasoline containing ethanol may be marketed under the name “Gasohol”. Do not use gasoline containing more than 10% ethanol by volume. The use of gasoline containing a higher percentage (e.g. E15, E20, E85) of ethanol has not been approved for use in this vehicle and may cause starting and/or performance problems and can also damage metal, rubber, and plastic parts of the fuel system and are not be covered by the Distributor’s Limited Warranty. 240 Technical Information 20 TRX520FM6-31HR56500.book 241 ページ２０１９年４月２日火曜日午後４時８分 Oxygenated Fuels METHANOL (methyl or wood alcohol) up to 5% by volume. You may use gasoline containing up to 5% methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system. If you notice any undesirable operating symptoms, try another service station or switch to another brand of gasoline. Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty. Oxygenated fuels can damage paint and plastic. Be careful not to spill fuel when filling the fuel tank. Wipe up any spills immediately. NOTICE Oxygenated fuels can damage paint and plastic. Damage caused by spilled fuel is not covered by warranty. Technical Information 241 20 TRX520FM6-31HR56500.book 242 ページ 242 Technical Information ２０１９年４月２日火曜日午後４時８分 20 TRX520FM6-31HR56500.book 243 ページ２０１９年４月２日火曜日午後４時８分 Consumer Information This section contains information on your warranty and how to get an official Honda service manual. Consumer Information Authorized Manuals ................................................................. 244 Warranty Coverage .................................................................. 245 Warranty Service ...................................................................... 246 Contacting Honda .................................................................... 247 Your Honda Dealer ................................................................... 248 Consumer Information 243 20 TRX520FM6-31HR56500.book 244 ページ２０１９年４月２日火曜日午後４時８分 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 Common Service Manual which explains theory of operation and basic service information for various systems on Honda motorcycles, scooters, ATVs, SxSs and PWCs. The Winter Storage Guide in conjunction with the Owner's Manual and Service Manual can help you prepare your Honda motorcycle, scooter, ATV, and SxS for winter storage. These Honda manuals are written for the professional technician, but most mechanically capable owners should find them easy to use if they have the proper tools and observe proper safety standards. Special Honda tools are necessary for some procedures. Publication Item No. 61HR406 61CSM00 S9507 31HR5650 Description 2020 TRX520FM1/FM2/FM5/FM6/FM7/ FE1/FE2/FA5/FA6/FA7 Service Manual Common Service Manual Winter Storage Guide 2020 TRX520FM6 Owner’s Manual Order online: www.helminc.com Order Toll Free: 1-888-CYCLE93 (1-888-292-5393) (NOTE: For Credit Card Orders Only) Monday - Friday 8:00 AM - 6:00 PM EST 244 Consumer Information 20 TRX520FM6-31HR56500.book 245 ページ２０１９年４月２日火曜日午後４時８分 Warranty Coverage Your new Honda is covered by these warranties: • TRX Limited Warranty • Emission Control System Warranty 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. Canada: Please refer to the Warranty Booklet posted on our website at www.honda.ca. It is important to realize that your warranty applies to defects in material or workmanship of your Honda. Your warranty coverage does not apply to normal wear or deterioration associated with using the ATV. Your warranty coverage will not be voided if you choose to perform your own maintenance. However, you should have the proper tools and service information, and be mechanically qualified. Failures that occur due directly to improper maintenance are not covered. Almost all of your warranty coverage can be extended through the Honda Protection Plan (USA only). For more information, see your dealer. Consumer Information 245 20 TRX520FM6-31HR56500.book 246 ページ２０１９年４月２日火曜日午後４時８分 Warranty Service Please remember that recommended maintenance interval servicing is not included in your warranty coverage. Additionally, your warranty does not apply to the normal wear of items (such as brakes, tires, etc.). If you believe you have a problem with your ATV, call the service department of your dealer. Make an appointment for an inspection and diagnosis. Remember, as the owner of the ATV, you will be asked to authorize that inspection. Your dealer will give you the results of the inspection. If the problem is covered under warranty, your dealer will perform the warranty repairs for you. If you have questions about warranty coverage or the nature of the repair, it is best to talk to the Service Manager of your dealer. Sometimes, in spite of the best intentions of all concerned, a misunderstanding may occur. If you aren’t satisfied with your dealer’s handling of the situation, we suggest you discuss your problem with the appropriate member of the dealership’s management team. If the problem has already been reviewed with the Service Manager, Parts Manager, Sales Manager, etc., contact the Owner of the dealership or their designated representative. 246 Consumer Information 20 TRX520FM6-31HR56500.book 247 ページ２０１９年４月２日火曜日午後４時８分 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. If you have a difference of opinion with your dealer, please remember that each dealership is independently owned and operated. That’s why it’s important to work to resolve any differences at the dealership level. If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address: Motorcycle Division, American Honda Motor Co., Inc., P.O. Box 2200, Torrance, CA 90509-2200, mailstop: 100-4C-7B, telephone: (866) 784-1870. Canada: Honda Canada Inc., Customer Relations Dept, 180 Honda Boulevard, Markham, Ontario L6C 0H9, telephone: (888) 946-6329, facsimile: (877) 939-0909. E-mail: [email protected] Please include the following information in your letter: • name, address, and telephone number • product model, year, and VIN • date of purchase • dealer name and address We will likely ask your dealer to respond, or possibly acknowledge your comments directly. Consumer Information 247 20 TRX520FM6-31HR56500.book 248 ページ２０１９年４月２日火曜日午後４時８分 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. The service department will also handle warranty inspections and repairs. The parts department offers Honda Genuine Parts, Pro Honda products, Honda Genuine Accessories (USA only), and Honda accessories and products (Canada only). The same quality that went into your Honda can be found in Honda Genuine replacement parts. You’ll also find comparable quality in the accessories and products available from the parts department. The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage (USA only). Your Honda dealer can inform you about competition and other riding events in your area. You’ll also find that your dealer is a source of information about safety training available in your local area. We’re sure you’ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda. 248 Consumer Information 20 TRX520FM6-31HR56500.book 249 ページ２０１９年４月２日火曜日午後４時８分 Consumer Information 249 20 TRX520FM6-31HR56500.book 250 ページ２０１９年４月２日火曜日午後４時８分 Index Index A accessories .................................................................................70 accessory socket .........................................................................49 age recommendation .................................................................61 air cleaner, dust cover .............................................................................154 filter ......................................................................................150 housing drain tube ................................................................155 air pressure, gauge ....................................................................................121 tire ........................................................................................177 American Honda, contacting ....................................................247 apparel, protective ......................................................................58 appearance care .......................................................................190 authorized manuals ..................................................................244 B bank angle sensor ignition cut-off system ...................................83 battery .....................................................................................185 brake light switch adjustment ...................................................175 brakes, cable .....................................................................................174 fluid ......................................................................................168 front brake lever ......................................................................44 pad wear ...............................................................................171 parking ....................................................................................45 rear brake lever freeplay ........................................................173 rear brake lever/parking brake lever .........................................44 rear brake pedal ......................................................................44 braking .......................................................................................91 break-in guidelines ...................................................................235 250 Index 20 TRX520FM6-31HR56500.book 251 ページ２０１９年４月２日火曜日午後４時８分 Index button, mode select .................................................................14, 19, 20 start/override ...........................................................................39 C capacity, fuel ............................................................................127 care, appearance ......................................................................190 cargo, loading and operational guidelines ..........................................69 weight limit .............................................................................68 cleaning, appearance care ........................................................190 climbing hills ..............................................................................96 clip ...........................................................................................125 clutch system ............................................................................158 color label ................................................................................229 compartment, owner’s manual .....................................................................121 tool kit ..................................................................................120 component fails ........................................................................225 consumer information ..............................................................243 controls & features .....................................................................34 coolant temperature gauge ........................................................28 crash, if you ..............................................................................222 crossing or turning on hills or slopes .........................................101 customer service .......................................................................247 Index 251 20 TRX520FM6-31HR56500.book 252 ページ２０１９年４月２日火曜日午後４時８分 Index D differential lock switch ................................................................36 digital clock ................................................................................26 dimmer switch, headlight ...........................................................41 dipstick .....................................................................................132 display check ..............................................................................16 display, multi-function ................................................................20 drivetrain boots ........................................................................184 E electric power steering (EPS) .......................................................55 emission control systems ..........................................................236 engine, flooded ...................................................................................83 guard ....................................................................................183 number .................................................................................228 oil ..........................................................................................129 pinging ..................................................................................126 starting ....................................................................................80 stop switch ..............................................................................40 stopping ..................................................................................85 won’t start ............................................................................208 environment .............................................................................204 EPS (Electric Power Steering) .......................................................55 exhaust system, cleaning ..................................................................................64 purging .................................................................................164 F flag pole bracket ........................................................................47 flat tire .....................................................................................211 flooded engine ...........................................................................83 front boot guards .....................................................................183 252 Index 20 TRX520FM6-31HR56500.book 253 ページ２０１９年４月２日火曜日午後４時８分 Index front differential lock ..................................................................36 front driveshaft boots ...............................................................184 front driveshaft guards .............................................................183 front final gear oil .....................................................................140 fuel, fill cap ...................................................................................127 gauge ......................................................................................24 oxygenated ...........................................................................240 recommendation ...................................................................126 refueling ................................................................................127 reserve fuel supply .................................................................127 tank capacity .........................................................................127 fuses ........................................................................................217 G gap, spark plug ................................................................160, 231 gasohol ....................................................................................240 gasoline ....................................................................................126 gear shifting ...............................................................................87 guards ......................................................................................183 H headlight dimmer switch ............................................................41 headlight switch .........................................................................41 high coolant temperature indicator ...............................14, 17, 215 hills, crossing or turning on slopes .................................................101 riding down hills ....................................................................100 riding up hills ...........................................................................96 stopping on hills ......................................................................98 Honda service manual ..............................................................244 Index 253 20 TRX520FM6-31HR56500.book 254 ページ２０１９年４月２日火曜日午後４時８分 Index Honda, contacting .............................................................................247 dealer ....................................................................................248 hour meter .................................................................................30 I identification, vehicle ................................................................228 ignition switch ............................................................................34 indicators, 4WD indicator .............................................................18, 20, 35 differential lock indicator .............................................14, 17, 36 gear position indicator .......................................................18, 23 high coolant temperature indicator ............................14, 17, 215 maintenance minder indicator ...........................................20, 31 neutral indicator ................................................................14, 17 PGM-FI indicator ................................................................14, 17 PS (Electric Power Steering) indicator .................................14, 18 reverse indicator ................................................................14, 17 inspection, pre-ride .....................................................................63 K key, lost ........................................................................................223 number .................................................................................223 kit, tool ....................................................................................120 L labels, safety .................................................................................5 lamp check .................................................................................15 limit, weight ...............................................................................68 load limits ...................................................................................68 loading guidelines ......................................................................69 254 Index 20 TRX520FM6-31HR56500.book 255 ページ２０１９年４月２日火曜日午後４時８分 Index lubrication, engine oil ..............................................................................129 front final gear oil ..................................................................140 rear final gear oil ...................................................................138 M maintenance, component locations .............................................................117 hour meter ..............................................................................31 importance ............................................................................109 minder indicator ................................................................20, 31 precautions ...........................................................................111 record ...................................................................................116 safety ....................................................................................110 schedule ................................................................................112 tripmeter .................................................................................31 manual, service .........................................................................244 maximum weight limit ................................................................68 modifications ..............................................................................71 multi-function display .................................................................20 N neutral indicator ...................................................................14, 17 noise emission control system ...................................................239 numbers, serial .........................................................................228 O obstacles, riding over ................................................................103 odometer ...................................................................................27 oil, engine ...................................................................................129 front final gear ......................................................................140 rear final gear ........................................................................138 Index 255 20 TRX520FM6-31HR56500.book 256 ページ２０１９年４月２日火曜日午後４時８分 Index operation component locations ..................................................11 owner’s manual storage ...........................................................121 oxygenated fuels ......................................................................240 P parking .....................................................................................106 parking brake/reverse lever (P/R lever) .........................................45 passengers, no carrying ..............................................................61 pavement, no riding on ..............................................................75 pinging, engine ........................................................................126 plug, spark ...............................................................................160 pre-ride inspection ......................................................................63 problems, unexpected ..............................................................206 propeller shaft boots & yoke joint boot .....................................184 protective apparel .......................................................................58 R rear driveshaft boots .................................................................184 rear driveshaft guards ...............................................................183 rear fender cover removal .........................................................123 rear final gear oil ......................................................................138 recoil starter (Canada only) ...................................................42, 86 removal, rear fender cover ...................................................................123 seat .......................................................................................122 tank cover assembly ..............................................................124 reverse, assist cable ............................................................................159 assist lever .............................................................................159 gear, shifting into ....................................................................89 indicator ............................................................................14, 17 riding in ...................................................................................89 rider training ..............................................................................60 256 Index 20 TRX520FM6-31HR56500.book 257 ページ２０１９年４月２日火曜日午後４時８分 Index riding, basic operation ........................................................................73 clothing ...................................................................................58 over obstacles ........................................................................103 precautions .............................................................................75 preparing for .........................................................................196 safety ........................................................................................2 safety precautions ...................................................................75 through water .......................................................................104 S safety, important precautions ...........................................................111 labels .........................................................................................5 riding precautions ....................................................................75 schedule, maintenance .............................................................112 seat removal .............................................................................122 serial numbers ..........................................................................228 service, customer ...............................................................................247 manuals ................................................................................244 warranty ................................................................................246 shifting gears ..............................................................................87 skidding or sliding ......................................................................95 spark arrester ...........................................................................164 spark knock ..............................................................................126 spark plug ................................................................................160 specifications ............................................................................230 speed limiter override .................................................................36 speedometer ........................................................................18, 20 stalled engine .............................................................................84 stalling on a hill ..........................................................................98 start/override button ...................................................................39 Index 257 20 TRX520FM6-31HR56500.book 258 ページ２０１９年４月２日火曜日午後４時８分 Index starting, engine .....................................................................................80 troubleshooting .....................................................................208 stop switch, engine ....................................................................40 stopping engine .........................................................................85 storage, ATV .......................................................................................200 owner’s manual .....................................................................121 suspension, adjustment ............................................................................165 spring pre-load ......................................................................166 switch, 4WD .......................................................................................35 differential lock .......................................................................36 engine stop .............................................................................40 headlight .................................................................................41 headlight dimmer ....................................................................41 ignition ....................................................................................34 T tank cover assembly removal ....................................................124 throttle, cable .............................................................................156, 157 lever ........................................................................43, 156, 157 tires, air pressure ............................................................................177 flat ........................................................................................211 repairing ................................................................................181 replacing ...............................................................................182 thread conditions ..........................................................179, 180 tool kit .....................................................................................120 trailer hitch .................................................................................48 258 Index 20 TRX520FM6-31HR56500.book 259 ページ２０１９年４月２日火曜日午後４時８分 Index trailer towing, operational guidelines .............................................................69 weight limits ............................................................................68 training, rider .............................................................................60 transporting your ATV ..............................................................198 tripmeter ....................................................................................27 trouble, unexpected .................................................................205 troubleshooting, starting ..........................................................208 turning, on hills or slopes ....................................................................101 on level ground .......................................................................93 U utility box front utility box ........................................................................52 side utility box .........................................................................51 utility pocket ..............................................................................53 V valve clearance .........................................................................163 vehicle identification no. (VIN) ..................................................228 W warning labels ..............................................................................5 warranty, coverage ...............................................................................245 extended ...............................................................................245 service ...................................................................................246 washing your ATV ....................................................................191 water, riding through .......................................................................104 weight limit ................................................................................68 wheel removal ..........................................................................213 Index 259 20 TRX520FM6-31HR56500.book 260 ページ２０１９年４月２日火曜日午後４時８分 Quick Reference The following is a brief, but important collection of information you need to know about your Honda. You’ll also find space to record important notes. Quick Reference How To Avoid Costly Repairs The engine of your Honda can be the most expensive component to repair. Proper maintenance, especially the use of the recommended fluids and filters, prevents premature wear and damage. Frequent causes of costly repairs are: • Engine oil — insufficient quantity, improper oil. • Air cleaner — dirty, leaking because of improper installation (poor seal). Record important information on the following page: Quick Reference 20 TRX520FM6-31HR56500.book 261 ページ２０１９年４月２日火曜日午後４時８分 Quick Reference Engine No. VIN Color Label Owner’s Name Address City/State Phone Dealer’s Name Address City/State Phone Service Mgr. Quick Reference 20 TRX520FM6-31HR56500.book 262 ページ２０１９年４月２日火曜日午後４時８分 Quick Reference Scheduled Maintenance Pre-ride Inspection Fuel/Capacity Engine Oil/ Capacity Maximum Weight Capacity Quick Reference Initial: 100 miles (150 km) Regular: every 600 miles (1,000 km) Check the following items each time before you ride (page 63): engine oil, radiator coolant, fuel, tires, drivetrain boots, guards, nuts & bolts, underbody & exhaust system, air cleaner housing drain tube, leaks, loose parts, cables, lights, throttle, brakes, reverse assist lever, switches, steering. unleaded gasoline, pump octane number 86 or higher 3.88 US gal (14.7 ℓ) reserve: 1.29 US gal (4.9 ℓ) API Service Classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label, SAE 10W-30, JASO T 903 standard MA, Pro Honda GN4 4-stroke oil or equivalent after draining: 3.1 US qt (2.9 ℓ) after draining & oil filter change: 3.2 US qt (3.0 ℓ) 573 lb (260 kg) rider, all cargo and accessories 20 TRX520FM6-31HR56500.book 263 ページ２０１９年４月２日火曜日午後４時８分 Quick Reference Tires Front: Rear: Tire Pressure (cold) Front: Rear: Spark Plugs Coolant Fuses AT25 × 8-1211 MAXXIS MU25 AT25 × 10-1211 MAXXIS MU26 4.4 psi (30 kPa) 4.4 psi (30 kPa) standard: BKR5E-11 (NGK) or K16PR-U11 (DENSO) ethylene glycol antifreeze (silicate-free) for aluminum engines in 50/50 solution with Pro Honda HP Coolant or an equivalent distilled water main 1: 40 A main 2: 10 A other: 20 A × 4, 10 A EPS (Electric Power Steering): 40 A Quick Reference 20 TRX520FM6-31HR56500.book 264 ページ２０１９年４月２日火曜日午後４時８分 Quick Reference These symbols are used in Controls & Features section: SYMBOL COMPONENT SEE PAGE q ON — ignition switch 34 w OFF — ignition switch 34 4WD switch 35 differential lock switch 36 differential lock indicator — lights when the front differential lock 36 mode engages start/override button 39 e RUN — engine stop switch 40 r OFF — engine stop switch 40 y ON — headlight switch 41 t OFF — headlight switch 41 u HI — headlight dimmer switch 41 i LO — headlight dimmer switch 41 Parking Brake/Reverse Lever (P/R lever): 45 P — parking brake R — riding in reverse Quick Reference 20 TRX520FM6-31HR56500.book 265 ページ２０１９年４月２日火曜日午後４時８分 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. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a wellventilated area and wear gloves or wash your hands frequently when servicing your vehicle. For more information go to www.P65Warnings.ca.gov/passengervehicle. 31HR5650 00X31-HR5-6500 WPCXXXX.2019.XX.L PRINTED IN USA

Honda FourTrax Foreman Rubicon TRX520FM6 2020 Owner's Manual 276 Pages

Honda FourTrax Foreman Rubicon TRX520FM6 2020 Owner's Manual

Key Features

Frequently Answers and Questions

What is the minimum recommended age for operating this ATV?

What type of engine does this ATV have?

How do I engage the four-wheel drive system?

Is this ATV suitable for carrying passengers?

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Honda FourTrax Foreman Rubicon TRX520FM6 2020 Owner's Manual 276 Pages

Honda FourTrax Foreman Rubicon TRX520FM6 2020 Owner's Manual

Key Features

Frequently Answers and Questions

What is the minimum recommended age for operating this ATV?

What type of engine does this ATV have?

How do I engage the four-wheel drive system?

Is this ATV suitable for carrying passengers?

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