2004-2016 Honda Foreman TRX500 Service Manual
Original Honda Foreman TRX500FM1/FM2/FM5/FM6/FM7/FE1/FE2/FA5/FA6/FA7 Service Manual.
Genuine service information used by Honda dealerships.
Models covered by this manual:
- Foreman TRX500FM1
- Foreman TRX500FM2
- Foreman TRX500FM5
- Foreman TRX500FM6
- Foreman TRX500FM7
- Foreman TRX500FE1
- Foreman TRX500FE2
- Foreman TRX500FA5
- Foreman TRX500FA6
- Foreman TRX500FA7
Manual Chapters:
CONTENTS
01 - GENERAL INFORMATION
- SERVICE RULES
- MODEL IDENTIFICATION
- SPECIFICATIONS
- TORQUE VALUES
- LUBRICATION & SEAL POINTS
- CABLE & HARNESS ROUTING
- EMISSION CONTROL SYSTEMS
- TECHNICAL FEATURE
02 - FRAME/BODY PANELS/EXHAUST SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- BODY PANEL LOCATIONS
- SEAT
- RADIATOR CAP LID
- OIL CHECK LID
- TANK COVER ASSEMBLY
- CENTER MUDGUARD
- ENGINE GUARD
- FRONT FENDER/CARRIER
- REAR FENDER COVER
- STEP BRACKET
- TOOL BOX LID
- REAR FENDER/CARRIER
- SKID PLATE
- EXHAUST SYSTEM
03 - MAINTENANCE
- SERVICE INFORMATION
- MAINTENANCE MINDER INDICATOR
- MAINTENANCE SCHEDULE
- FUEL LINE
- THROTTLE OPERATION
- AIR CLEANER
- AIR CLEANER HOUSING DRAIN TUBE
- SPARK PLUG
- VALVE CLEARANCE
- ENGINE OIL
- ENGINE OIL FILTER
- ENGINE IDLE SPEED
- RADIATOR COOLANT
- COOLING SYSTEM
- DRIVE TRAIN BOOTS
- FRONT/REAR FINAL GEAR OIL
- RANGE SELECT SYSTEM (FA models)
- BRAKE FLUID
- BRAKE SHOES WEAR (FM1/FM2/FE1/FE2)
- BRAKE PADS WEAR
- BRAKE LIGHT SWITCH
- BRAKE SYSTEM
- REVERSE INHIBITOR SYSTEM
- GUARDS
- CLUTCH SYSTEM (FM/FE models)
- SUSPENSION
- SPARK ARRESTER
- NUTS, BOLTS, FASTENERS
- WHEELS/TIRES
- TIE-ROD AND JOINT BOOTS
- STEERING SHAFT HOLDER BEARING
- STEERING SYSTEM
04 - PGM-FI SYSTEM
- SERVICE INFORMATION
- PGM-FI SYSTEM LOCATION
- PGM-FI SYSTEM DIAGRAM
- PGM-FI TROUBLESHOOTING INFORMATION
- SYMPTOM TROUBLESHOOTING
- DTC INDEX
- DTC TROUBLESHOOTING
- MIL CIRCUIT INSPECTION
- SENSOR UNIT (MAP/TP SENSOR)
- ECT SENSOR
- BANK ANGLE SENSOR
- IAT SENSOR
- PCM/ECM
- 02 SENSOR
05 - IGNITION SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- COMPONENT LOCATION
- SYSTEM DIAGRAM
- IGNITION SYSTEM INSPECTION
- IGNITION COIL
- IGNITION TIMING
- CONDENSER (Canada type)
06 - ELECTRIC STARTER
- SERVICE INFORMATION
- TROUBLESHOOTING
- COMPONENT LOCATION
- SYSTEM DIAGRAM
- STARTER MOTOR
- STARTER RELAY SWITCH
- DIODE
- IN-GEAR START DIODE (After '14)
07 - FUEL SYSTEM
- SERVICE INFORMATION
- FUEL LINE TROUBLESHOOTING
- SYSTEM COMPONENTS
- FUEL LINE INSPECTION
- FUEL PUMP UNIT
- FUEL TANK
- AIR CLEANER HOUSING
- THROTTLE BODY
- IACV
- FUEL INJECTOR
08 - COOLING SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM FLOW PATTERN
- SYSTEM TESTING
- COOLANT REPLACEMENT
- THERMOSTAT
- RADIATOR/COOLING FAN
- RADIATOR RESERVE TANK
- WATER PUMP
09 - LUBRICATION SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- LUBRICATION SYSTEM DIAGRAM (FM/FE models)
- LUBRICATION SYSTEM DIAGRAM (FA models)
- OIL PUMP (FM/FE models)
- RELIEF VALVE (FM/FE models)
- OIL PRESSURE CHECK (FA models)
- OIL PUMP/RELIEF VALVE (FA models)
10 - CYLINDER HEAD/VALVE
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM COMPONENTS
- CYLINDER COMPRESSION
- CYLINDER HEAD COVER
- CYLINDER HEAD
- CAMSHAFT
11 - CYLINDER/PISTON
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM COMPONENTS
- CYLINDER/PISTON
12 - CLUTCH/GEARSHIFT LINKAGE (FM/FE models)
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM COMPONENTS
- FRONT CRANKCASE COVER
- CENTRIFUGAL CLUTCH
- CHANGE CLUTCH
- GEARSHIFT LINKAGE
13 - DUAL CLUTCH TRANSMISSION (DCT: FA models)
- SERVICE INFORMATION
- SYSTEM COMPONENTS
- SYMPTOM TROUBLESHOOTING
- COMPONENT LOCATION
- SYSTEM DIAGRAM
- TROUBLESHOOTING INFORMATION
- DTC INDEX
- DTC TROUBLESHOOTING
- FRONT CRANKCASE COVER/SPACER
- CENTRIFUGAL CLUTCH
- SHIFT SOLENOID VALVE
- SHIFT SPINDLE ANGLE SENSOR
- SHIFT CONTROL MOTOR/REDUCTION GEARS
- SHIFT DRUM POSITION SWITCH
- REVERSE SWITCH
- EOT SENSOR
- REAR VS SENSOR
- FRONT VS SENSOR
- DRIVE MODE SELECT SWITCH
- SHIFT VALVE BODY
- DUAL CLUTCH/PRIMARY DRIVEN GEAR
- GEARSHIFT LINKAGE
- REVERSE STOPPER SHAFT
14 - SUB-TRANSMISSION (FA models)
- SERVICE INFORMATION
- SYSTEM COMPONENTS
- SUB-TRANSMISSION
- RANGE SELECT LEVER LINKAGE
- SUB-TRANSMISSION SWITCH
15 - ALTERNATOR/STARTER CLUTCH
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM COMPONENTS
- RECOIL STARTER (Canada type)
- ALTERNATOR STATOR
- FLYWHEEL/STARTER CLUTCH
16 - CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM COMPONENTS
- CRANKCASE SEPARATION
- TRANSMISSION
- CRANKSHAFT/BALANCER
- CRANKCASE BEARING
- CRANKCASE ASSEMBLY
17 - ENGINE REMOVAL/INSTALLATION
- SERVICE INFORMATION
- SYSTEM COMPONENTS
- ENGINE REMOVAL
- ENGINE INSTALLATION
18 - FRONT WHEEL/SUSPENSION/STEERING
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM COMPONENTS
- HANDLEBAR
- THROTTLE HOUSING
- FRONT WHEEL
- TIRES
- WHEEL HUB AND KNUCKLE
- SUSPENSION ARM
- FRONT SHOCK ABSORBER
- STEERING SHAFT (FM1/FM5/FE1/FA5)
- STEERING SHAFT/EPS UNIT (FM2/FM6/FM7/FE2/FA6/FA7)
- TIE-ROD
19 - REAR WHEEL/SUSPENSION
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM COMPONENTS
- REAR WHEEL
- REAR SHOCK ABSORBER
- SWINGARM (FM1/FM2/FE1/FE2)
- REAR WHEEL HUB/KNUCKLE (FM5/FM6/FM7/FA5/FA6/FA7)
- REAR SUSPENSION ARM (FM5/FM6/FM7/FA5/FA6/FA7)
20 - BRAKE SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM COMPONENTS
- BRAKE FLUID REPLACEMENT/AIR BLEEDING
- BRAKE PAD/DISC
- FRONT MASTER CYLINDER
- FRONT BRAKE CALIPER
- REAR BRAKE DRUM/SHOES (FM1/FM2/FE1/FE2)
- REAR BRAKE PEDAL (FM1/FM2/FE1/FE2)
- REAR BRAKE MASTER CYLINDER/BRAKE PEDAL (FM5/FM6/FM7/FA5/FA6/FA7)
- REAR BRAKE CALIPER (FM5/FM6/FM7/FA5/FA6/FA7)
- REAR BRAKE LEVER (FM5/FM6/FM7/FA5/FA6/FA7)
21 - FRONT DRIVING MECHANISM
- SERVICE INFORMATION
- MECHANICAL SYSTEM TROUBLESHOOTING
- MECHANICAL SYSTEM COMPONENTS
- ELECTRICAL SYSTEM COMPONENT LOCATION
- DIFFERENTIAL LOCK SYSTEM DIAGRAM
- BEFORE TROUBLESHOOTING
- SYMPTOM TROUBLESHOOTING
- DIFFERENTIAL LOCK SYSTEM TROUBLESHOOTING INFORMATION
- DIFFERENTIAL LOCK DTC INDEX
- DTC TROUBLESHOOTING
- PULL BACK RELAY
- DIFFLOCK ACTUATOR
- RIGHT HANDLEBAR SWITCH
- RELAYS
- DIODES
- FRONT DRIVE SHAFT
- FRONT FINAL DRIVE REMOVAL
- FRONT PROPELLER SHAFT
- FRONT FINAL GEAR DISASSEMBLY/INSPECTION
- FRONT FINAL GEAR ASSEMBLY
- FRONT FINAL DRIVE INSTALLATION
22 - REAR DRIVING MECHANISM
- SERVICE INFORMATION
- TROUBLESHOOTING
- SYSTEM COMPONENTS
- REAR AXLE (FM1/FM2/FE1/FE2)
- REAR DRIVE SHAFT (FM5/FM6/FM7/FA5/FA6/FA7)
- REAR FINAL DRIVE (FM1/FM2/FE1/FE2)
- REAR FINAL DRIVE (FM5/FM6/FM7/FA5/FA6/FA7)
23 - BATTERY/CHARGING SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- COMPONENT LOCATION
- SYSTEM DIAGRAM
- BATTERY
- CHARGING SYSTEM INSPECTION
- ALTERNATOR CHARGING COIL
- REGULATOR/RECTIFIER
- MAIN RELAY
- DIODE
24 - LIGHTS/METERS/SWITCHES
- SERVICE INFORMATION
- COMPONENT LOCATION
- ASSIST HEADLIGHT
- HEADLIGHT
- BRAKE/TAILLIGHT
- COMBINATION METER
- ACCESSORY SOCKET
- IGNITION SWITCH
- LEFT HANDLEBAR SWITCH
- FRONT BRAKE INHIBITOR SWITCH
- REAR BRAKE LIGHT SWITCH
- GEAR POSITION SWITCH (FM/FE models)
- COOLING FAN
- FUEL GAUGE/FUEL LEVEL SENSOR
- DIODE
25 - ELECTRIC SHIFT PROGRAM (ESP: FE models)
- SERVICE INFORMATION
- ESP COMPONENT LOCATION
- ESP SYSTEM DIAGRAM
- BEFORE TROUBLESHOOTING
- SYMPTOM TROUBLESHOOTING
- ELECTRIC SHIFT DOES NOT OPERATE
- ESP TROUBLESHOOTING INFORMATION
- ESP DTC INDEX
- DTC TROUBLESHOOTING
- VS SENSOR
- SHIFT SPINDLE ANGLE SENSOR
- SHIFT CONTROL MOTOR/REDUCTION GEARS
26 - ELECTRIC POWER STEERING (EPS: FM2/FM6/FM7/FE2/FA6/FA7)
- SERVICE INFORMATION
- EPS COMPONENT LOCATION
- EPS SYSTEM DIAGRAM
- SYMPTOM TROUBLESHOOTING
- EPS TROUBLESHOOTING INFORMATION
- EPS DTC INDEX
- DTC TROUBLESHOOTING
- EPS INDICATOR CIRCUIT INSPECTION
- EPS ECU
27 - WIRING DIAGRAMS
- FM1 model ('14)
- FM1 model (After '14)
- FE1 model ('14)
- FE1 model (After '14)
- FM2 model ('14)
- FM2 model (After '14)
- FE2 model ('14)
- FE2 model (After '14)
- FM5 model
- FM6/FM7 models
- FA5 model
- FA6/FA7 models
INDEX
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