2005-2011 Foreman 500 Trx500 Service & Repair Manual

A Few Words About Safety Service Information The servICe and repair InformatiOn contained in thiS manual is intended IOf use by qualified, professIOnal techntclans. Anempllng serviCe or repairs without the proper training, tools, and equipment could cause injury to you or others. II coutd also damage the vehICle or creale an unsafe condition. This manual describes the proper methods and procedures for performing service maintenance, and repairs. Some procedures reqwe the use 01 special ly designed tools and dedicated eqUipment Any person who Intends 10 use a replacement pan, service procedure or a tool thai IS not recommended by Honda must determine lhe fl sks to their personal safery and lhe sale operation of the vehicle II you need to replace a part. use genuine Honda parts with the correct part number Of an equivalent part We strongly recommend thai you do not use replacement parts of inferior quality. For Your Customer's Safety Proper service and maintenance are essential to lhe custome r's safety and the reliability of the vehicle Any error or oversight while servICing a veh icle 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--w"ear gloves). If you have not recefved shop safety tra,ning or do not feel confident about your knowledge of safe serviCing practice, we reconvnended that you do not attempt to perform the procedures described in thiS manua l. Some of the most Important general service safety precautions are gIVen below However , we cannot warn you of every conceivable hazard that can anse In performing seMes and repair procedures. Only you can decide whether Of not you shoukl perform a gIVen task. Important Safety Precautions AWARNING Improper service or repairs can create an unsafe conditioo 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 carefu lly. AWARNING Failure to properly folklw instl1JctJ ons and precautIOns can cause you to be seriously hurt or killed Follow the procedures and precautions In thiS manual carefully Make sure you have a dear understanding of all basIC shop safely practICes and that you are wearing appropriate dothing and uSing safety eqUipment. When performing any serv i ce task. be especia lly careful of the 10UOWlIlQ: • Read all of the Instl1Jctlons before )'Ou begin, and make sure you have the tOOls, the replacement Of repair parts. and the skills required to pertorm the tasks salely and oomplete ly. • Protect your eyes by using proper safety glasses . goggles or face shields any tJme you hammer, drill, grind, pry or work around pressurized air or liqUids. and springs or other slored-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. Arty time you 11ft the vehicle, either With a hOist or a jack, make sure that It IS always securely supported . Use jack stands. Make sure the eng ine IS off before you begin any serviCing procedures, unless the instruction tells you to do otnelWlse. This will help eliminate several potenti al hazards: • Carbon monoXide poisoning from angine exhaust. Be sure there IS adequate ventilation whenever you run the engine . • Burns from hot parts or coolant lei the engine and exhaust system COOl before WOr1ting In those areas. • Injury trom ffiOVlllg parts If the instruction tells you to run the eng.ne, be sure your hands , fingers and cklthing 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 worlOOg around gasoline or banenes. • Use onty a nonflammable solvent. not gasoline, to clean parts • Never drain or store gasoline in an open conlainer. • Keep all cigarenes, sparks and flames away from the battery and all fuel-related parts.

HOW TO USE THIS MANUAL This servICe manual describes the servlCil procedures for the TRXSOOTMlFMfFPMIFElFPE_ FoHow the Maintenance Schedule (SectIOn 4) recommeodallOf1s 10 ensurB that the vehICle,s Ifl peak operallrlg OOndl~on end the em<sstOn levels ara within the standards set by the US EnVIronmental ProteClIOn Agency (EPA) and California Air Resources Board (CARBI . ?enorming the lirst schedul()d maintenance IS very Important It oomper.sates lor the 10111.11 wear thai occurs dUring the IJlllak'll1 period. Sec1ions 1 and 4 apply to 1M whole vehicle. $echon 3 Illustrates procedures for remO'ial lonslllila!lOl'1 01 components lha! may be r&Q",red to perform seN.::e descflbed In the following sedlons. Secuons 5 1hrough 24 descnbe parts 01 the WhlCie, groupOO IlCCOfdil1g 10 k:>c.alioo Find the sec1ion you want on thiS page. the., tum to the tab"" 01 eontet'l!S on the first page 01 the sectKlO. Mos1 sec1ions stan w,\t1 an assembly or system illustratIOn, servICe InlormalKll'1 and Iroubleshootlng lor Ihe section The subsequent pages give detailed procedllre II )'OIJ are not famlllllr WIth thiS vehicle, read Techrucal Features In SectIon 2. If 'fOIl don1 know the source of the trouble, go to section 26 Troubleshooting. VOll' safety. and the safety 01 otl1ers. is ...or)' ImporLant To help you make Informed deci sUJf1S we haw prOllKled safety messages and other InfofmatlOl1 throllghout thiS manllal. Of course. it is not pfaC1ical or possible to wan"! YOll abollt all the hazards associated with sefViclng thIS wrucls. Voll must llse your own good jlldgement Voll w~1 ~nd impOrtant safety In!ormatlon in a va"sty of forms mcllldmg: • Safety Labels - on the vehicle • Safety Messages - preced&d by a safely alen symbol ! and one of three Signal wards. DANGER. WARNING. Of CAUTION These &gnal words mean f\i.tidA4i l You WILL be KILLED 01 SERIOUSLY _ ...... __ ._ HURT ~)IOO don't foHow Instructions Vau CAN be KILLED or SERIOUSLY m','WW 'N' HURT ~ you don" foHOw instructions troi\iu[mi You CAN be HURT II you dont fallOW __ ••••• _ instructkms • Instructions - how 10 service Ihis ~ehlCle correctly and safely As you read thIS manual. 1'00 will l ind ,nformation that Is preceded Dy a :H01'ICEJ symbol The purpose at this message Is 10 help prevent damage to your vehlde. other property, or ths eOVlfoomenl w z '" z w '" iii '" « l: " -' « " a: I- " W -' W CONTENTS GENERAL INFORMATION TECHNICAL FEATURES FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVE CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE FRONT WHEEUSUSPENSION/STEERING REAR WHEEUSUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM (Except TM model) REAR DRIVING MECHANISM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES SELECTABLE 4WD SYSTEM (Except TM model) ELECTRIC POWER STEERING (EPS) WIRING DIAGRAMS TROUBLESHOOTING INDEX

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 texl without the use of the symbols. fI Replace the parl(s) with new one(5) before assembly. - ~ Use the recommended engine oil, unless otherwise specified. I- ~ +OIYbdenum 0;' solution (midure 01 Ihe engine 0;' and molybdenum grease in a ratio 01 "'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: Molykoteill' BA·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: MolykoteOJl G'n Paste manufactured by Dow Corning U.S.A. ~ Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Roeol Umited, U.K. Aoeol Paste manufactured by Sumico Lubricant, Japan ~ Use silicone grease. n,. Apply a locking agent. Use a medium strength locking agent unless otherwise specified. I- .,(' mru Apply sealant. t-- I 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··························· 1-3 GENERAL SPECIFICATIONS ······················ 1-6 LUBRICATION SYSTEM SPECIFICATIONS······································ 1- 10 FUEL SYSTEM SPECIFICATIONS ············ 1-10 CYLINDER HEADIV ALVE SPECIFICATIONS ······································ 1- 10 CYLINDER/PISTON SPECIFICATIONS .... 1-11 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS .. ···································· 1- 11 ALTERNATOR/STARTER CLUTCH SPECIFICATION ··································· .... · 1- 11 CRANKCASE/TRANSMISSION/ CRANKSHAFT/BALANCER SPECIFICATIONS ······································ 1- 12 FRONT WHEEL/ SUSPENSION/ STEERING SPECIFICATIONS ····· ·· ········ ·· ········ ············· 1- 13 REAR WHEEL/SUSPENSION SPECIFICATIONS ..................................... 1- 13 BRAKE SYSTEM SPECIFICATIONS ········1-13 FRONT DRIVING MECHANISM SPECIFICATIONS (Except TM model) ···· 1-14 REAR DRIVING MECHANISM SPECIFICATIONS ··································· .. 1-14 BATTERY/CHARGING SYSTEM SPECIFICATIONS ................. .................... 1-14 IGNITION SYSTEM SPECIFICATIONS ···· 1-15 ELECTRIC STARTER SPECIFICATION····· 1-15 LIGHTS/ METERS/ SWITCHES SPECIFICATIONS ··········· ··· ··· ·········· ···· ··· · .. 1-15 STANDARD TOROUE VALUES ··············· 1-16 ENGINE & FRAME TORQUE VALUES ···· 1- 16 LUBRICATION & SEAL POINTS .............. 1-22 CABLE & HARNESS ROUTING ··············· 1-26 EMISSION CONTROL SYSTEMS ··· ·· ······· 1-50 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 fo r 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 atl parts for proper installation and operation. 8. Route all electrical wires as shown in the Cable & Harness routing (page 1-26). ABBREVIATION Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbrev. t enn Full tenn r ECU Electronic Control Unit EPS Electric Power Steering ESP Electric Shift Program DLC Data Link Connector ECM Engine Control Module CKP sensor Crankshaft Position sensor VS sensor Vehicle Speed sensor HDS Honda Diagnostic System DTC Diagnostic Trouble Code SCS connector Service Check Short connector DESTINATION CODES Throughout this manual, the following codes are used to identify individual types for each reg ion. r DE STINATI ON REGI ON CODE A U.S.A CM Canada U Australia (New Zealand) 1-2 I

MODEL IDENTIFICATION This manual covers 4 types of TRX500 models: • TM - 2WD/Left foot operated gearshift • FM - 4WD/left foot operated gearshift • FE - 4WO/Eleclric shift program ( ESP) • FPM (EPS mod el) - 4WO/Electric power steering {E PS)/Leh foot operated gearshift • FPE (EPS model) - 4WD/El ectric power steering (EPS) fEleclric sh ift program (ESP) Be su re to refer to the procedure that penains to the appropriate ve rsion of the TRX500. TRXSOO FE model shown : SERIAL NUMBERS GENERAL INFORMATION Th e Vehicle Identification Number (VIN) is stamped on the front side of ~---------=~----~ the frame. 1-3

GENERAL INFORMATION The engine serial number is stamped on the right side of the rear crankcase. The carburetor identification number is stamped on the left side of the carburetor body. LABELS --,. ENGlNE SERIAL NUMBER NUMBER The name plate is attached on the left front frame pipe (U.S.A. and U r:-;-;;:-:-~~c-c~~~~~~~~~~~~- type) . The vehicle certification label is attached on the right side of the frame ~;;~~~~=~FV='Lf~~====:::! (Canada type). I 1-4

The vehicle emission information label is attached on the right side of the frame ('05 - '07: U.S.A. only). GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL below the seat (After '07: U.S.A. and Canada type only). After '07 model: The color label is attached on the front side of the r ight front frame ~~g~~~~~~~~:::~:::J pipe. When ordering color-coded parts, always specify the designated color code. 1-5

GENERAL INFORMATION GENERAL SPECIFICATIONS TRX500TM ITEM SPECIFlCATlONS ,- - ---- --, i DIMENSIONS Overall length 2,109 mm (83.0 in) Overall width 1,188 mm (46.8 in) Overall height 1,169 mm (46.0 in) Wheelbase 1,292 mm (50.9 in) front tread 922 mm (36.3 in) Rear tread 925 mm (36.4 in) Seat height 860 mm (33.9 in) Footpeg height 349 mm (13.7 in) Ground clearance 190 mm (7.5 in) Curb weight 265 kg (584 Ibs) FRAME _ __ h Maximum weight capacity 220 kg (485 Ibs) Frame type Double cradle 1 Front suspension Double wishbone Front wheel travel 170 mm (6.7 in) Front dampe r Double tube Rear suspension Swingarm Rear wheel travel 170 mm (6.7 in) Rear damper Double tube front tire size AT25 x 8-12 ** Rear tire size AT25 x 10-12 ** Front rim size 12 x 6.0 AT Rear rim size 12 x 7.5 AT Front tire brand KT181 (Dunlop) Rear tire brand KT185 (Dunlop) Front brake Hydraulic disc brake Rear brake Mechanical drum brake Caster angle 5° Trail length 17 mm (11 / 16 in) Camber angle 0 0 Fuel tank capacity 15.8 liters (4.17 US gal, 3.48 I mp gal) cc;e;= ___ --1--1Fuel tank reserv;e~c~a~p;a~c;~ty'-------~ 3.~3~I;it.ers (0.87 US gal, 0.73 Imp g~a~I)=~ ENGINE Cylinder arrangement Single cylinder, longitudinally installed Bore and stroke 92.0 x 71.5 mm (3.62 x 2.81 in) Displacement 475.3 cm 3 (28.99 cu-in) Compression ratio 8.3: 1 Valve train OHV Intake valve opens 6° BTDC (at 1 mm lift) closes 44° ABDC (at' mm lift) Exhaust valve opens 42° BBDC (at' mm lift) closes 4° ATDC (at 1 mm lift) lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Air cooled (with cooling fan and oil cooler) Air filtration Oiled double urethane foam .nc;n.o"",,,_r- :Engine dry wei"'gh " t~ ______ h 55.2 kg (121.7 Ibs) CARBURETOR Carburetor type Constant Vacuum (VE type) Thronle bore 36 mm (1.42 in) 1-6

2005-2011 Foreman 500 Trx500 Service & Repair Manual

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