2005 - 2006 Honda Foreman Service Manual

2 0 0 5-2006 — - SERVIC ANUAL .r r , X500FE/F \ FOURTRAX FOREMAN

A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual. AWARNING Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. AWARNING Some of the most important general service safety precautions are given Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. below. However, we cannot warn you of every conceivable hazard that can Follow the procedures and precautions in this arise in performing service and repair procedures. Only you can decide manual carefully. whether or not you should perform a given task. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: • Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. • Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. • Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. • Use only a nonflammable solvent, not gasoline, to clean parts. • Never drain or store gasoline in an open container. • Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

HOW TO USE THIS MANUAL CONTENTS This service manual describes the service procedures for the TRX500FE/FMA"M. Follow the Maintenance Schedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency (EPA) and California Air Resources Board (CARB). Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 4 apply to the whole vehicle. Section 3 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Sections 5 through 23 describe parts of the vehicle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. If you are not familiar with this vehicle, read Technical Features in Section 2. If you don't know the source of the trouble, go to section 25 Troubleshooting. Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: • Safety Labels - on the vehicle • Safety Messages - preceded by a safety alert symbol A and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions. ADANGER A WARNING ACAUTION You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions. You CAN be HURT if you don't follow instructions. Instructions - how to service this vehicle correctly and safely. As you read this manual, you will find information that is preceded by a | NOTICE | symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI- GATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITH- OUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTE- NANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE LU Z u LU CO (0 (0 < u < u oc o UJ 111 GENERAL INFORMATION TECHNICAL FEATURES FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVE CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKCASE/TRANSMISSION/CRANKSHAFT/ BALANCER FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM (FM/FE models) REAR DRIVING MECHANISM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES ELECTRIC SHIFT PROGRAM (ESP: FE model) SELECTABLE 4WD SYSTEM (FM/FE models) WIRING DIAGRAMS TROUBLESHOOTING INDEX Date of Issue: November, 2004 ©Honda Motor Co., Ltd.

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use the recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1) Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use fork or suspension fluid.

1. GENERAL INFORMATION SERVICE RULES 1-2 MODEL IDENTIFICATION 1-2 GENERAL SPECIFICATIONS 1-5 LUBRICATION SYSTEM SPECIFICATIONS 1-8 FUEL SYSTEM SPECIFICATIONS 1-8 CYLINDER HEAD/VALVE SPECIFICATIONS 1-8 CYLINDER/PISTON SPECIFICATIONS 1-9 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS 1-9 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS 1-9 CRANKCASE/TRANSMISSION/CRANK- SHAFT/BALANCER SPECIFICATIONS 1-10 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS 1-10 REAR WHEEL/SUSPENSION SPECIFICATIONS 1-10 BRAKE SYSTEM SPECIFICATIONS 1-11 FRONT DRIVING MECHANISM SPECIFICATIONS (FM/FE models) 1-11 REAR DRIVING MECHANISM SPECIFICATIONS 1-11 BATTERY/CHARGING SYSTEM SPECIFICATIONS 1-11 IGNITION SYSTEM SPECIFICATIONS 1-12 ELECTRIC STARTER SPECIFICATIONS 1-12 LIGHTS/METERS/SWITCHES SPECIFICATIONS 1-12 STANDARD TORQUE VALUES 1-13 ENGINE & FRAME TORQUE VALUES 1-13 LUBRICATION & SEAL POINTS 1-18 CABLE & HARNESS ROUTING 1-22 EMISSION CONTROL SYSTEMS 1-38 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA'S design specifications may cause damage to the vehicle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown in the Cable & Harness routing (page 1-22). MODEL IDENTIFICATION This manual covers 3 types of TRX500 models: • TM - 2WD/Left foot operated gearshift • FM - 4WD/Left foot operated gearshift • FE - 4WD/Electric shift program (ESP) Be sure to refer to the procedure that pertains to the appropriate version of the TRX500. TRX500 FE model shown: DESTINATION CODES Throughout this manual, the following codes are used to identify individual types for each region. DESTINATION CODE A CM U REGION U.S.A. Canada Australia (New Zealand) 1-2

GENERAL INFORMATION The Vehicle Identification Number (VIN) is stamped on the front side of the frame. The engine serial number is stamped on the left side of the rear crankcase. The name plate (U.S.A. and U type) or safety certification label (Can- ada type) is attached on the right front frame pipe. VIN ENGINE SERIAL NUMBER U.S.A. and U type: NAME PLATE Canada type: SAFETY CERTIFICATION LABEL 1-3

GENERAL INFORMATION The carburetor identification number is stamped on the left side of the carburetor body. CARBURETOR IDENTIFICATION NUMBER The vehicle emission information label is attached on the rear fender behind the seat (U.S.A. only). The color label is attached on the front side of the right front frame pipe. When ordering color-coded parts, always specify the designated color code. EMISSION CONTROL INFORMATION LABEL COLOR LABEL 1-4

GENERAL INFORMATION GENERAL SPECIFICATIONS TRX500TM ITEM DIMENSIONS FRAME ENGINE CARBURETOR Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight Curb weight Maximum weight capacity Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes Lubrication system Oil pump type Cooling system Air filtration Engine dry weight Carburetor type Throttle bore SPECIFICATIONS 2,109 mm (83.0 in) 1,188 mm (46.8 in) 1,169 mm (46.0 in) 1,292 mm (50.9 in) 922 mm (36.3 in) 925 mm (36.4 in) 860 mm (33.9 in) 349 mm (13.7 in) 190 mm (7.5 in) 253 kg (558 lbs) 265 kg (584 lbs) 220 kg (485 lbs) Double cradle Double wishbone 170 mm (6.7 in) Double tube Swingarm 170 mm (6.7 in) Double tube AT25x8-12 • • AT25x 10-12 • • 12x6.0 AT 12x7.5 AT KT181 (Dunlop) KT185 (Dunlop) Hydraulic disc brake Mechanical drum brake 5° 17 mm (11/16 in) 0° 15.8 liters (4.17 US gal, 3.48 Imp gal) 3.3 liters (0.87 US gal, 0.73 Imp gal) Single cylinder, longitudinally installed 92.0x71.5 mm (3.62x2.81 in) 475.3 cm 3 (28.99 cu-in) 8.3: 1 OHV 6° BTDC (at 1 mm lift) 44° ABDC (at 1 mm lift) 42° BBDC (at 1 mm lift) 4° ATDC (at 1 mm lift) Forced pressure and wet sump Trochoid Air cooled (with cooling fan and oil cooler) Oiled double urethane foam 55.2 kg (121.7 lbs) Constant Vacuum (VE type) 36 mm (1.42 in) 1-5

GENERAL INFORMATION ITEM DRIVE TRAIN ELECTRICAL Clutch system Clutch operation system Transmission Primary reduction Secondary reduction Final reduction Gearratio 1st 2nd 3rd 4th 5th Reverse Gearshift pattern Ignition system Starting system Charging system Regulator/rectifier Lighting system SPECIFICATIONS Centrifugal and multi-plate, wet Automatic Constant mesh, 5-speeds with reverse 2.103 (61/29) 1.818 (40/22) 3.153(41/13) 4.231 (55/13) 2.389(43/18) 1.609 (37/23) 1.179(33/28) 0.848 (28/33) 5.600(28/15x39/13) R-N-1-2-3-4-5 Left foot operated return system DC-CDI Electric starter motor and emergency recoil starter Triple phase output alternator FET shorted, triple phase full wave rectification Battery TRX500FM/FE ITEM DIMENSIONS Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight Curb weight Maximum weight capacity SPECIFICATIONS 2,109 mm (83.0 in) 1,188 mm (46.8 in) 1,181 mm (46.5 in) 1,287 mm (50.7 in) 913 mm (35.9 in) 925 mm (36.4 in) 860 mm (33.9 in) 349 mm (13.7 in) 190 mm (7.5 in) FM: 270 kg (595 lbs) FE: 271 kg (597 lbs) FM: 282 kg (622 lbs) FE: 284 kg (626 lbs) 220 kg (485 lbs) 1-6

2005 - 2006 Honda Foreman Service Manual

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