2015-2023 Honda Pioneer 500 520 UTV Service Manual P/N 61HL507

Honda original Service manual for Pioneer SXS500M and SXS520M UTVs.
Manual Part number: 61HL507

Manual Chapters:

HOW TO USE THIS MANUAL
TABLE OF CONTENTS
1. GENERAL INFORMATION
 - SERVICE RULES
 - TYPE CODE
 - SERIAL NUMBERS/LABELS
 - GENERAL SPECIFICATIONS
 - CYLINDER/PISTON SPECIFICATIONS
 - BRAKE SYSTEM SPECIFICATIONS
 - STANDARD TORQUE VALUES
 - MAINTENANCE
 - COOLING SYSTEM
 - ALTERNATOR/STARTER CLUTCH
 - DRIVE SHAFT/FINAL GEAR
 - LUBRICATION & SEAL POINTS
 - CABLE & HARNESS ROUTING
 - EMISSION CONTROL SYSTEMS
 - LIFT AND SUPPORT POINTS
 - ELECTRIC SHIFT SYSTEM WITH AT MODE
 - VEHICLE SPEED LIMITATION
2. FRAME/BODY PANELS/EXHAUST SYSTEM
 - SERVICE INFORMATION
 - TROUBLESHOOTING
 - BODY PANEL LOCATIONS
 - SEAT REAR COVER
 - SEAT BOTTOM COVER
 - REAR SIDE COVER
 - RADIATOR SHROUD
 - FRONT GRILLE
 - DOOR
 - INSTRUMENT PANEL
 - REAR FLOOR COVER
 - FRONT FLOOR PLATE
 - FRONT BUMPER
 - SIDE NET
 - OCCUPANT PROTECTIVE STRUCTURE (OPS)
 - SEAT BELT
 - UNDER GUARD
 - REAR FENDER/CARRIER/CENTER
 - CARGO BED
 - MUFFLER
 - REFLECTOR
3. MAINTENANCE
 - SERVICE INFORMATION
 - MAINTENANCE SCHEDULE
 - FUEL LINE
 - AIR CLEANER
 - SPARK PLUG
 - BATTERY
 - VALVE CLEARANCE
 - ENGINE OIL
 - COOLING SYSTEM
 - REVERSE INHIBITOR SYSTEM
 - CLUTCH SYSTEM
 - DRIVE SHAFT BOOTS
 - FINAL DRIVE OIL
 - BRAKE FLUID
 - BRAKE PADS WEAR
 - UNDERBODY
 - SUSPENSION
 - EXHAUST SYSTEM
 - WHEELS/TIRES
 - STEERING SYSTEM
 - SIDE NET
 - CHASSIS LUBRICATION POINTS
 - EVAPORATIVE EMISSION CONTROL
4. PGM-FI SYSTEM
 - SERVICE INFORMATION
 - PGM-FI SYSTEM LOCATION
 - PGM-FI TROUBLESHOOTING INFORMATION
 - MCS INFORMATION
 - ERASING DTC
 - SYMPTOM TROUBLESHOOTING
 - DTC INDEX
 - DTC TROUBLESHOOTING
 - MIL CIRCUIT INSPECTION
 - ECT SENSOR
 - IAT SENSOR
 - SENSOR UNIT (MAP/TP SENSOR)
 - ENGINE IDLE SPEED
5. IGNITION SYSTEM
 - SERVICE INFORMATION
 - TROUBLESHOOTING
 - COMPONENT LOCATION
 - IGNITION SYSTEM INSPECTION
 - IGNITION COIL
 - IGNITION TIMING
6. ELECTRIC STARTER
 - SERVICE INFORMATION
 - COMPONENT LOCATION
 - SYSTEM DIAGRAM
 - STARTER MOTOR
 - STARTER RELAY SWITCH
 - NEUTRAL DIODE
 - BRAKE INHIBITOR RELAY
7. FUEL SYSTEM
 - SERVICE INFORMATION
 - SYSTEM COMPONENTS
 - FUEL LINE TROUBLESHOOTING
 - FUEL LINE INSPECTION
 - FUEL PUMP
 - SELF MANAGEMENT RELAY
 - FUEL PUMP RELAY
 - FUEL TANK
 - AIR CLEANER HOUSING
 - INTAKE AIR DUCT
 - ACCELERATOR PEDAL
 - THROTTLE BODY
 - IACV
 - FUEL INJECTOR
 - EVAP PURGE CONTROL SOLENOID VALVE
 - EVAP CANISTER
8. COOLING SYSTEM
 - SERVICE INFORMATION
 - TROUBLESHOOTING
 - SYSTEM FLOW PATTERN
 - SYSTEM TESTING
 - COOLANT REPLACEMENT
 - THERMOSTAT
 - RADIATOR/COOLING FAN
 - RADIATOR RESERVE TANK
 - WATER PUMP
9. LUBRICATION SYSTEM
 - SERVICE INFORMATION
 - LUBRICATION SYSTEM DIAGRAM
 - OIL PUMP
 - RELIEF VALVE
10. CYLINDER HEAD VALVE
 - SERVICE INFORMATION
 - TROUBLESHOOTING
 - SYSTEM COMPONENTS
 - CYLINDER COMPRESSION
 - CYLINDER HEAD COVER
 - CYLINDER HEAD
 - CAMSHAFT
11. CYLINDER/PISTON
 - SERVICE INFORMATION
 - SYSTEM COMPONENTS
 - CYLINDER/PISTON
12. CLUTCH/GEARSHIFT LINKAGE
 - SERVICE INFORMATION
 - SYSTEM COMPONENTS
 - FRONT CRANKCASE COVER
 - CHANGE CLUTCH
 - GEARSHIFT LINKAGE
13. ALTERNATOR/STARTER CLUTCH
 - SERVICE INFORMATION
 - SYSTEM COMPONENTS
 - ALTERNATOR STATOR
 - FLYWHEEL/STARTER CLUTCH
14. CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
 - SERVICE INFORMATION
 - SYSTEM COMPONENTS
 - CRANKCASE SEPARATION
 - TRANSMISSION
 - CRANKSHAFT/BALANCER
 - CRANKCASE BEARING
 - CRANKCASE ASSEMBLY
15. ENGINE REMOVAL/INSTALLATION
 - SERVICE INFORMATION
 - SYSTEM COMPONENTS
 - ENGINE REMOVAL
 - ENGINE INSTALLATION
16. STEERING SYSTEM
 - SERVICE INFORMATION
 - SYSTEM COMPONENTS
 - STEERING WHEEL
 - STEERING COLUMN AND SHAFT
 - TIE-ROD BALL JOINT
 - STEERING GEAR BOX
17. DRIVE SHAFT/FINAL GEAR
 - SERVICE INFORMATION
 - SYSTEM COMPONENTS
 - DRIVE SHAFT
 - FRONT FINAL DRIVE REMOVAL
 - FRONT PROPELLER SHAFT
 - FRONT FINAL CLUTCH
 - FRONT FINAL GEAR DISASSEMBLY/INSPECTION
 - DIFFERENTIAL REMOVAL
 - DIFFERENTIAL INSPECTION
 - PINION JOINT NEEDLE BEARING REPLACEMENT
 - FRONT FINAL GEAR CASE BEARING REPLACEMENT
 - FRONT FINAL GEAR ASSEMBLY
 - FRONT FINAL DRIVE INSTALLATION
 - REAR FINAL DRIVE REMOVAL
 - REAR FINAL DRIVE DISASSEMBLY/INSPECTION
 - REAR FINAL DRIVE GEAR CASE BEARING REPLACEMENT
 - REAR FINAL DRIVE ASSEMBLY
 - REAR FINAL DRIVE INSTALLATION
 - DRIVE MODE SELECTOR LEVER LINKAGE
 - DRIVE MODE SELECTOR CABLE ADJUSTMENT
18. WHEEL/SUSPENSION
 - SERVICE INFORMATION
 - SYSTEM COMPONENTS
 - WHEELS
 - FRONT WHEEL HUB/KNUCKLE
 - REAR WHEEL HUB/KNUCKLE
 - FRONT SUSPENSION ARM
 - REAR SUSPENSION ARM
 - SHOCK ABSORBER
19. BRAKE SYSTEM
 - SERVICE INFORMATION
 - TROUBLESHOOTING
 - SYSTEM COMPONENTS
 - BRAKE FLUID REPLACEMENT/AIR BLEEDING
 - BRAKE PAD/DISC
 - MASTER CYLINDER
 - FRONT BRAKE CALIPER
 - REAR BRAKE CALIPER
 - BRAKE PEDAL
 - PARKING BRAKE LEVER
 - PCV
20. BATTERY/CHARGING SYSTEM
 - SERVICE INFORMATION
 - TROUBLESHOOTING
 - COMPONENT LOCATION
 - BATTERY
 - CHARGING SYSTEM INSPECTION
 - ALTERNATOR CHARGING COIL
 - REGULATOR/RECTIFIER
21. LIGHTS/METERS/SWITCHES
 - SERVICE INFORMATION
 - COMPONENT LOCATION
 - HEADLIGHT
 - BRAKE/TAILLIGHT
 - COMBINATION METER
 - SERIAL COMMUNICATION LINE
 - SPEEDOMETER
 - ACCESSORY SOCKET
 - IGNITION SWITCH
 - LIGHTING SWITCH
 - LIGHTING RELAY
 - GEAR POSITION SWITCH
 - COOLING FAN MOTOR
 - FUEL METER/FUEL LEVEL SENSOR
 - BRAKE LIGHT SWITCH
 - PARKING BRAKE SWITCH
 - 4WD INDICATOR SWITCH
 - SEAT BELT SWITCH
22. ELECTRIC SHIFT PROGRAM (ESP)
 - SERVICE INFORMATION
 - ESP COMPONENT LOCATION
 - ESP SYSTEM DIAGRAM
 - TROUBLESHOOTING
 - ESP DTC INDEX
 - DTC TROUBLESHOOTING
 - VS SENSOR
 - SHIFT SPINDLE ANGLE SENSOR
 - SHIFT CONTROL MOTOR/REDUCTION GEARS
 - GEARSHIFT PADDLE/SWITCH
 - MODE SELECT SWITCH
23. WIRING DIAGRAMS
 - '15 - '16 SXS500M
 - '17 SXS500M
 - '18 '21 SXS500M
 - After '21 SXS500M
 - '21 SXS520M
 - After '21 SXS520M
INDEX

Manual includes high quality images and diagrams. It is searchable and indexed.