This document is an owner's manual for the Honda TRX500FA6 and TRX500FA7 Fourtrax Rubicon ATVs. The TRX500FA6 is a 4x4 model with Power Steering, while the TRX500FA7 is a 4x4 model with Power Steering and Aluminium Wheels.
Function Description:
The Honda TRX500FA6/FA7 Fourtrax Rubicon is a recreational All-Terrain Vehicle (ATV) designed for off-road use by a single rider. It is equipped with an engine, transmission, braking system, and suspension, all designed for off-road performance. The ATV features an electronically controlled Electric Power Steering (PS) system to assist in turning the handlebar, making steering easier. It also includes a front differential lock feature with a speed limiter and speed limiter over-ride, designed to provide maximum traction in challenging situations like mud, by locking all four wheels to rotate at the same speed. The speed limiter restricts the ATV to 32 km/h (20 mph) in this mode, which can be momentarily overridden up to 64 km/h (40 mph) by pushing the start/over ride button. The ATV offers two shift modes: AUTO (automatic shift mode) for everyday riding, where the transmission automatically shifts to maintain optimal engine speed, and ESP (manual shift mode), which allows the rider to manually shift gears without a clutch. The vehicle is designed to carry cargo on front and rear racks, with specific load limits. It is also capable of towing a trailer using a trailer hitch.
Important Technical Specifications:
- Dimensions:
- Overall length: 2,147 mm (84.5 in)
- Overall width: 1,205 mm (47.4 in)
- Overall height: 1,235 mm (48.6 in)
- Wheelbase: 1,292 mm (50.9 in)
- Ground clearance: 239 mm (9.4 in)
- Capacities:
- Passenger capacity: Operator only
- Maximum weight capacity: 260 kg (573 lb) (includes rider, all cargo, and accessories)
- Front cargo rack weight limit: 45 kg (99 lb)
- Rear cargo rack weight limit: 85 kg (187 lb)
- Tow weight limit: 600 kg (1,322 lb) (combined weight of trailer and all cargo)
- Tongue weight: 14 kg (30 lb) recommended
- Tongue and rear cargo weight: 85 kg (187 lb) maximum
- Fuel tank capacity (including reserve): 14.7 ℓ (3.88 US gal, 3.23 Imp gal)
- Fuel tank reserve capacity: 4.9 ℓ (1.29 US gal, 1.08 Imp gal)
- Engine oil capacity (after disassembly): 4.4 ℓ (4.6 US qt, 3.9 Imp qt)
- Engine oil capacity (after draining): 3.6 ℓ (3.8 US qt, 3.2 Imp qt)
- Engine oil capacity (after draining & oil filter change): 3.8 ℓ (4.0 US qt, 3.3 Imp qt)
- Cooling system capacity: 1.6 ℓ (1.7 US qt)
- Engine Specifications:
- Displacement: 475 cm³ (29.0 cu-in)
- Bore & stroke: 92.0 × 71.5 mm (3.62 × 2.81 in)
- Compression ratio: 9.5 : 1
- Idle speed: 1,400 ± 100 min⁻¹ (rpm)
- Power Transmission:
- Primary reduction: 2.680
- Secondary reduction (drive range): 1.520
- Secondary reduction (low range): 2.187
- Final reduction (front): 3.230
- Final reduction (rear): 3.153
- Gear ratio (1st): 3.058, (2nd): 2.157, (3rd): 1.588, (4th): 1.181, (5th): 0.848, (reverse): 3.996
- Final drive: Shaft
- Chassis & Suspension:
- Caster: 1°
- Trail: –1 mm (0.04 in)
- Tyre size, front: AT25 × 8-12 (MAXXIS MU25)
- Tyre size, rear: AT25 × 10-12 (MAXXIS MU26)
- Tyre pressure, front & rear (cold): 30 kPa (4.4 psi)
- Electrical:
- Battery: GYZ16H, 12 V – 16 Ah (10 HR)
- Generator: 0.595 kW/5,000 min⁻¹ (rpm)
- Accessory socket rated capacity: DC 12 V, 120 Watts (10 A) or less
- Fuses:
- Main fuse 1: 40 A
- Main fuse 2: 10 A
- ES (shift motor) fuse: 30 A
- Other fuses: 20 A × 3, 10 A
- PS (Electric Power Steering) fuse: 40 A
- Spark Plug:
- Standard spark plug: BKR5E-11 (NGK) or K16PR-U11 (DENSO)
- Spark plug gap: 1.00 – 1.10 mm (0.039 – 0.043 in)
- Valve Clearance (cold):
- Intake: 0.15 mm (0.006 in)
- Exhaust: 0.23 mm (0.009 in)
Usage Features:
- Indicators & Displays: The ATV is equipped with a multi-function display that shows various indicators such as 4WD, LOW, Gear Position, Fuel Gauge, Digital Clock, Odometer, Tripmeter, Coolant Temperature Gauge, Hour Meter, Maintenance Tripmeter/Hour Meter, PGM-FI, and PS (Electric Power Steering) indicators. These provide crucial information for safe and enjoyable riding.
- Controls: Key controls include the Ignition Switch (ON/OFF), Range Select Lever (Drive/Low), 4WD Switch (2WD/4WD), Front Differential Lock and Speed Limiter Over-Ride (Differential Lock Switch and Start/Over Ride Button), Engine Stop Switch (RUN/OFF), Headlight Switch (ON/OFF), Headlight Dimmer Switch (HI/LO), Horn Button, Recoil Starter, Throttle Lever, Drive Mode Select Switch (AUTO/ESP), Gearshift Switches (upshift/downshift), Front Brake Lever, Rear Brake Lever/Parking Brake Lever, and Rear Brake Pedal.
- Storage: The ATV includes a utility box on the front fender and a storage compartment below the rear cargo rack for small, lightweight items.
- Safety Features: Includes a Bank Angle Sensor Ignition Cut-off System that stops the engine if the vehicle overturns. A reverse speed limiter helps maintain a safe speed when riding in reverse.
Maintenance Features:
- Maintenance Schedule: A detailed schedule outlines required service intervals for various components, including engine oil and filter, rear and front final gear oil, coolant, air cleaner, throttle, reverse inhibitor system, spark plug, valves, spark arrester, suspension, brakes, tyres, guards, drivetrain boots, and battery.
- User-Performable Tasks: Some maintenance tasks, such as checking and adding engine oil, checking coolant level, cleaning the air cleaner, and checking throttle freeplay, are designed to be performed by the owner with basic mechanical skills.
- Dealer-Recommended Tasks: More complex tasks, like valve clearance adjustment, coolant replacement, and certain electrical system checks, are recommended to be performed by a Honda dealer due to the need for special tools and technical expertise.
- Tool Kit: A tool kit and gear change tool are provided for routine maintenance and emergency repairs.
- Battery Maintenance: The ATV uses a maintenance-free battery. Instructions are provided for battery storage and charging to maintain its service life.
- Appearance Care: Guidelines for cleaning and polishing the ATV are provided to maintain its appearance and protect finishes, including specific instructions for aluminium wheels and the exhaust pipe/muffler.
- Troubleshooting: A section on "Taking Care of the Unexpected" provides guidance on dealing with common problems like engine not starting, transmission issues, flat tyres, high coolant temperature, blown fuses, and crashes.
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