2014-2016 Honda Foreman (TRX500) Service & Repair Manual

HOW TO USE THIS MANUAL A Few Words About Safety Service Information The service and repair information contained In thiS manual is Intended for use by qualified, professionallechnicians Attempting service or repairs without the proper training. 1000s, and equipment could cause I njury to you or others II could also damage the vehicle or create an unsafe condition. This manual descnbes the proper methods and procedures for performing seNIC8 , m8lntenance and repairs . Some procedures reqUire Ihe use of specially deslQned lools and dedicated equipment. Any person who inlends to use a replacement part. service procedure or a lool lhal is not recommended by Honda, must determine the nsks to their personal safety and Ihe safe operation of the vehicle If you need to replace a part use Honda GenUine parts with the correct part number or an equlvalenl part We strongly recommend thaI you do not use replacement parts of infenor 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 resull In faulty operation, damage to the vehicle, or Injury to olhers . For Your Safety AWARNING Improper service or repairs can create an unsafe condition that can cause your customer to be senously hurt or killed. Foll ow the procedures and precautions in this manual and other service matenals carefully. Because thiS manual is intended for the professional service technician, we do not provide warnings about many baSIC shop safety pracIJces (e g .. Hot parts-wear gloves) If you have 001 received shop safety lralning or do not feel confident about your knowledge of safe servicing practICe, we recommend that you do not attempt to perform the procedures described in thiS manual Some of the most Important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard Ihat can arise in performing service or repair procedures. Only you can decide whether or not you should perform a given task AWARNING Faiture 10 properly follow instructions and precautions can cause you to be senousty hurt or killed Follow the procedures and precautioos In this manual carefully. Important Safety Precautions Make sure you have a clear understanding of all baSIC shop safety practices and thaI you are wearing appropnate clothing and usrng safety equipment. When performing any servICE! task , be especlalty careful of the f~owing: Read aN of the inslruc\)ons 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 , dnll, 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 Of safety shoes Handling hot or sharp parts can cause severe bums Of a.sts Before you grab something that looks like it can hurt you stop and put on gloves. Protect yourself and others whenever you have the vehide up In the air. Any tI me you tift 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 otheJWise. ThiS Will help eliminate several potential hazards: Carbori monoxide poisoning from engme exhaust. Be sure there is adequate venlilahon whenever you run the engine • Bums from hot parts or oooIant. let the eng ine and exhaus t system cool before WOrking in those areas . • InjUry from moving pans . If the instrucIJon tells you to run the engine. be sure your hands , fingers and clothing are out of the way GascMlne vapors and hydrogen gases from batteries are explOSive To reduce the possibility of a fire or explosion . be careful when work.ing around gasoline or batteries. Use only a nonflammable soivent, nOI gascMlne, to clean parts. Never drain or store gasoline in an open container. Keep aU cIgarettes sparks and flames away from the battery and all fuet-related parts. 1

HOW TO USE THIS MANUAL How To Use This Manual This manual descnbes the servICe procedures for the TRX500FM1/FM2/FM5IFM6IFM7/FE1/FE2JFA51FA6/FA7 Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removalflnstaliation of components that may be required to perform service described in the following sections. Section 41hrough 25 describe parts of the vehicle, grouped according to location. If you are not familiar with this vehicle, read Technical features In Section 1. Follow the Maintenance Schedule (section 3) 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), California Air Resources Board (CARB) and Environment Canada. Performing the first scheduled maintenance is very imponant It compensates for the initial wear that occurs during the break-in period. Find the section you want on this page, then tum 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. Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI section troubleshooting first. Your safety, and the safety of others, is very imponant. 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 wam 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 ! and one of three signal words, DANGER, WARNING. or CAUTION These signal words mean: 'd.g m a 3j i You WILL be KILLED or SERIOUSLY HURT if you dan', follow Instructions. tl11@j iW N' YOuCAN be KILLED or SERIOUSLY HURT if you don't follow instrucllOns. NM'U·a You CAN be HURT if you don't follow instrucllOns. • Instructions - how to service this vehicle correctly and safely. As you read this manual, you will find information that IS preceded by a ~ symbol. The purpose of this message is to help prevent damage to your vehicle, other propefly. or the environment. Date of Issue: September, 2014

HOW TO USE THIS MANUAL SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to Ihese 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: · Molykole® BR-2 plus manufactured by Dow Coming U.S.A. · Multi-purpose M-2 manufactured by Milsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide. NLGI #2 or equivalent). Example: ~ · Molykote® G·n Paste manufactured by Dow Coming U.S.A. · Honda Moly 60 (U.S.A. only) · Rocol ASP manufactured by Rocollimited , U.K. · Rocol Paste manufactured by Sumico lubricant, Japan ..-'iSitI Use silicone grease . .- n 1' '' '1 Apply a locking agent. Use a medium strength locking agent unless otherwise specified. .,(oru Apply sealant. 1 I Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise speCified. >- Use fork or suspension fluid.

CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE PGM-FI SYSTEM FRONT WHEEUSUSPENSION/STEERING '" REAR WHEEUSUSPENSION '" ~ BRAKE SYSTEM :J: u FRONT DRIVING MECHANISM REAR DRIVING MECHANISM BATTERY/CHARGING SYSTEM ~ F=~~~~====~~~~====================== U LIGHTS/METERS/SWITCHES ~ ~~==~~~~~~~~~~~~======= t; ELECTRIC SHIFT PROGRAM (ESP: FE models) ~ F=====================~==========~======== ELECTRIC POWER STEERING (EPS, FM2 IFM6IFM7IFE2IFA6IFA7) WIRING DIAGRAMS INDEX

1. GENERAL INFORMATION SERVICE RULES .. · .. ·· .... · .. · ...... ····· ········· 1·2 LUBRICATION & SEAL POINTS " ...... .... 1·22 MODEL IDENTIFiCATION .............. ......... 1·3 CABLE & HARNESS ROUTING ........ .. ... 1·26 SPECiFiCATIONS .. ·· .. ··· .......... ·· .... · .. ·· .... 1·5 EMISSION CONTROL SYSTEMS ........... 1-48 TORQUE VALUES ........... .......... .......... 1·13 TECHNICAL FEATURE ................ ........ 1·50 1-1

GENERAL INFORMATION SERVICE RULES 1. Use Honda Genuine 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 nol interchangeable with English fasteners. 4. Install new gaskets, O-rings , coller pins , and lock plates when reassembling. 5. When lightening bolts or nuts. begin with the larger diameter or inner bolt first. Then lighten to the specified torque diagonally in incremental sleps 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 1-26 ). 9. Do not bend or twist control cables. Damaged control cables wilt not operate smoothly and may stick or bind . 10.00 not tow your ATV behind a car or other vehicle. ABBREVIATION Throughout this manual, the following abbreviation are used to identify the respective parts or systems. " Ierm Full l erm 2 Wheel Drive 4WD 4 Wheel Drive CKP sensor , sensor ala lin ~eIS) Trouble Code ngine Coni"" sensor Un" I EPS II e Read Only " Power ESP . IACV I, Air Coni"" Valve IAT sensor lake Air sensor ~~ sensor iquid ystalDisplay I ICS System . MIL i i PCM (FE/FA models) in Conlrol I Ws:~rvice connector i~ 'hroltle i "ensor - , Speed sensor DESTINATION CODE Throughout this manual, the follOWing codes are used to identify individual types for each region. ~ .=,---D _ E _ S _ T_ INATION COOE.--,..------------.REGIO : N :=~====:::======j ! AC U.S.A. r-- CM Canada , 1-2 I

GENERAL INFORMATION MODEL IDENTIFICATION This manual covers 10 types of TRXSOO models: FM1 -left foot operated gearshift FM2 - Left foot operated gearshift/Electric Power Steering (EPS) FM5 - Left fool operated gearshift/Independent rear suspension FM6 -left fool operated gearshift/Electric Power Steering (EPS)Jlndependent rear suspension FM7 - Left foot operated gearshift/Electric Power Steering (EPS)Jlndependent rear suspension/Aluminum wheel FEl - Electric shift program (ESP) FE2 - Electric shift program (ESP)/Electric Power Steering (EPS) FA5 - Dual clutch transmission (OCT)Jlndependent rear suspension FA6 - Dual clutch transmission (DCT)lEleclric Power Steering (EPS)llndependent rear suspension FA? - Dual clutch transmission (Dell/Electric Power Steering (EPS)/lndependent rear suspension/Aluminum wheel Be sure to refer to the procedure that pertains to the appropriate version of the TRX500. '14 model shown: SERIAL NUMBERS/LABELS The Vehicle Identification Number (VIN) [1] is stamped on the front side of the frame through the front fender. The throttle body identification number [1] is stamped on the lower side of the throttle body. [11 1-3

GENERAL INFORMATION FMIFE models: The engine serial number [11 is stamped on the left side of the rear crankcase. FM1 /FM2JFE1 /FE2: The certification label [1] (U.S.A. type) or safety certification label [2J (Canada type) is attached on the left front frame down pipe. The color label [1J is attached on the left front frame down pipe. When ordering color-coded parts, always specify the designated color code. 111 1-4 FA models: The engine serial number [11 is stamped on the upper side of the rear crankcase. FM5/FM6/ FM7fFA5/FA6/FA7: The certification label [1] (U.S.A. type) or safety certification label [2) (Canada type) is attached on the left front frame pipe. The vehicle emission control information label [1] is attached on the left front frame pipe. - U.S.A. and Canada type [1] - Canada type [2] U.S.A. and Canada type: Canada type: 111 121

2014-2016 Honda Foreman (TRX500) Service & Repair Manual

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