2005-2014 Foreman Rubicon 500 TRX500FA Service & Repair Manual

A Few Words About Safety Service Information The saNtee and repair information contained in thiS manual is intended for use by qualified, professional tectlmclans. Attempllng service or repaIrs without the proper training, lools, and eqUipment could cause injury to you or others. It could also damage the vehicle Of creale an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use 01 specialty designed tools and dedicated eqUipment Any person who Imends to use a replacement part, service procedure or a 1001 thai IS not recommended by Honda, must determIne the rISks to their personal salety and the sale operahon 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 01 interior quality For Your Customer's Safety Proper seNICe and maintenance are essential to the customer's safety and the reliability of the vehICle. Any error or oversight while servicing a vehicle can resuh in faulty operation, damage to the vehicle. or injury to others For Your Safety Because thiS manual IS Intended lor 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 sate servicing practice , we recommended that you do not attempt to perform the procedures descnbed In this manual Some 01 the most Important general servICe salety precautions are given below. However. we cannot warn you of f!N9ry conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Important Safety Precautions AWARNING Improper servICe or repairs can create an unsale condl\lon that can cause your customer or others to be seriously hurt or killed Follow the procedures and precautions in this manual and other servICE! matenals carefully AWARNING Failure to properly IoIlow instructions 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 clear understanding of all basic shop safety praC\lces and that you are wearrng appropriate clothing and using safety equipment. When performing any service task, be especially careful 01 the following· • Read aU 01 the instructions before you begin and make sure you have the loc:Xs. the re~cemenl or repair parts. and the skills required to perform the tasks salely and completely. • Protect your eyes by USing proper salety 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. II there IS any doubt, put on eye protection. • Use other protective wear wnen 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 )"Ourself and others whenever you have the vehicle up in the air. Any lime you bf1the Vehlde, either WIth a hoist or a jack. make sure that It IS always securely supported Use}ack stands. Make sure the engine is off before you begin arry serviclOg procedures, unless the rnstruction tells you to do otherwise. This wdl help eliminate several potennal hazards: • Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventitallon whenever you run the engine. • Burns from hot parts or coolant. lat Ihe engine and exhaust system cool before working in l hose areas • InjUry from moving parts. JI the instruction tells you to run the engine. be sure your hands, fingers and dolhing are out of the way. Gasoline vapors and hydrogen gases from battanes are explosive. To reduce the possibility of a fire or explosion, be careful when wor1<Jng around gasoline or batteries. • Use only a nonf\ammabie solvent. not gasoline. to clean parts. • Never dram or store gasoline In an open CQfllamer. • Keep all clgaretles. sparks and Ilames away from the battery and all fuel-related parts. •

HOW TO USE THIS MANUAL ThIrI seMce manual describet; the S8rv>Cf1 proe&durfl tor the TRXSOOFAJFGAlFPA Fellow IN Mall'llenanee Schedule (Secbon 3) reoommendabOnS 10 __ lllal thu vehoeIe IS on peak operating CXIOditJon and !he IllTUS&IOr! IeveI5 are WIthin \he standards set by the U.S. E rMfO(U'nel'ltal Prolectlon Agency (EPA) and Caltlo<nia Air Resources Boord (CARB). P8I1orming the flrst seheduled /TIalnUllmnc8 ~ very Important. II compensates lor me inl1lBII wear thai OCCtlfll dunog the break",," ..... Sec1101'18 1 and 3 apply 10 !he whole I'&hK:Ie See\lOll 2 Illustrates procedutM for removalllnslallau(Ul at componenl5 thai may be required to p&rtorm servlce described in the follow~ 8eCI'OOS SoctIMl 4 through 24 descnbe parts 01 the Y&I1!C1e. grouped accordiog to location. Find tile MdIon you _rn on thts page. then tum to the taole 01 COI\1e<ltl on the Iif5I page 01 Ina sectIOn Mos t MctlOM Start WIth an assembly Of system illustration. serYlCft In/Qrmalion ana troubleshoOllng for the sactlOn. The subsequent pagH give 08lailed procedure II you don' know the IiQl,llca 01 the IJOObIe, go 10 sectlOIl 26 T...-"" 'rbc.I CAN be KILLED 01 SERIOUSLY mWi'j l q' W' HURT II you don' tl olJow iI'lllructions A$ you read IhI$ manual. you w,H lind InlormabQn lhal ~ preceded by. LN01'fCE 1 symbol The purpose 01 \hIS message 18 to help prtMlllt damage to your vehicle, OIh.er propl'llt)l. or the enviroomenl w z 13 z w III iii III '" J: U -' '" u a: ... u w -' w CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVE/CAMSHAFT CYLlNDERIPISTON CENTRIFUGAL CLUTCH ALTERNATORISTARTER CLUTCH SUB-TRANSMISSION/GEARSHIFT LINKAGE CRANKSHAFT/AUTOMATIC TRANSMISSION FRONT WHEEUSUSPENSION/STEERING REAR WHEEUSUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM REAR DRIVING MECHANI SM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES SELECTABLE 4WD SYSTEM HONDAMATIC ELECTRIC POWER STEERING (EPS) WIRING DIAGRAMS TROUBLESHOOTING INDEX

• SYMBOLS The symbols used throughout this manual show speciftc 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. fI Replace the pari (s) with new one (5) before assembly. 'I Use recommended engine oil, unless otherwise specified. , Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1) . • .5iiiM+ Use multi-purpose grease (Lithium based multi-purpose grease NLGI 1I2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NlGI #2 or equivalent) . ... Example: Molykote* BA-2 plus manufactured by Dow Corning 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 equiyalent). Example: MOlykotelt G·n Paste manufactured by Dow Corning U.S.A. .AID Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan ...-'iSiII Use silicooe grease. Dg Apply a locking agent. Use a middle strength locking agent unless otherwise specified. "Gilll Apply sealant. I Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. - I I .. Use Fork or Suspension Fluid.

1. GENERAL INFORMATION SERVICE RULES ············,,··,,········ ······· ··· ·· ··· ' -2 MODEL IDENTIFICATION ···,,······················ ' -2 GENERAL SPECIFICATI ONS ····· ····· ·· ·· ····· ··· ' -7 LUBRICATION SYSTEM SPECiFiCATiONS ·· ······ ··········· ····················· ,-9 FUEL SYSTEM SPECIFICATIONS ·············· ' -9 COOLING SYSTEM SPECIFICATIONS ······ ' -9 CYLINDER HEADIVALVE/ CAMSHAFT SPECIFICATIONS ················· , -,O CYLINDER/ PISTON SPECIFICATIONS ···· ' -,O CENTRIFUGAL CLUTCH SPECIFICATIONS ························· ·· ··········· , - '0 ALTERNATOR / STARTER CLUTCH SPECIFICATIONS······················ ················ , -" SUB-TRANSMISSION/ GEARSHIFT LINKAGE SPECIFICATIONS ·,,··· ··· ····························· , -,, CRANKSHAFT/AUTOMATIC TRANSMISSION SPECIFICATIONS ······································ , -" FRONT WHEEL/ SUSPENSION/STEERING SPECIFICATIONS ·· ··· ················ ·· ··············· , -'2 REAR WHEEL/ SUSPENSION SPECIFICATIONS ... ............... .. ... ........ .. .." ' -'2 BRAKE SYSTEM SPECIFICATIONS ........ '- '2 FRONT DRIVING MECHANISM SPECIFICATIONS ... ... ....... ......... ............... '-'3 REAR DRIVING MECHANISM SPECIFICATIONS ................... .... ...... ........ '- '3 BATIERY/CHARGING SYSTEM SPECIFICATIONS .............. ... .................... '-'3 IGNITION SYSTEM SPECIFICATIONS .... '-'3 ELECTRIC STARTER SPECIFICATIONS ··' - '3 LIGHTS / METERS/ SWITCHES SPECIFICATIONS ························ ··· ····",,·· ' -'4 STANDARD TORQUE VALUES ··············· '-'5 ENGINE & FRAME TORQUE VALUES ···· ' - '5 LUBRICATION & SEAL POINTS ·············· ' -2' CABLE & HARNESS ROUTING .. .... .. ....... '-24 EMISSION CONTROL SYSTEMS .. .. ........ '-49 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 toots 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, coner 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 prop er installation and operation. S. Route all electrical wires as show in the Cable and Harne ss Routing (page ' -24 ). MODEL IDENTIFICATION This manual covers 3 types of TRX500 models: • FA - 4WD/Automatic transmission • FGA - 4WD/ Automotic transmission/GPScape • FPA - 4WD/ Automotic transmission/GPScape/EPS '05, ' 06 shown: 1-2

GENERAL INFORMATION ABBREVIATION Throughout this manual, the following abb reviations are used to identify the respective parts or systems. DESTINATION CODE Throughout this manual, the following codes are used to identify individual types for each r egio n. 1-3

GENERAL INFORMATION The Vehicle Identification Number (VI N) is stamped on the front side of the frame. The engine serial number is stamped on the right side of the crank- case. The name plate is attached on the front frame pipe (U type only). U type only: I ~~==~~~~~~~~~~~ P ~LA~TE ~ The vehicle safety certification label is attached on the right side of the ~ frame (U.s.A. and Canada). U.S.A. and Canada: CERTIFICATION LABEl _____ -' 1-4

The ca rbur etor identification number is stamped on the left side of the carburetor body. '05 - '07: GENERAL INFORMATION The vehicle emission control information label is attached on the right side of the frame (U.S.A. only). U.S.A. only: ~~~~p CONTROL LABEL After '07: The vehicle emiss ion contro l information label is attached on the rear ,-----------------, fender near the banery. U.S.A. and Canada: IGNITION CERTIFICATION (eM type) EMISSION rnNTRn, INFORMATION LABEL (eM type) EMISSI:ON·CONTROl INFORMATION LABEL (A, eM type ) 1-5

GENERAL INFORMATION The color label is attached on the front side of the frame. When order- ing color coded parts, always specify the designated color code. 1-6

2005-2014 Foreman Rubicon 500 TRX500FA Service & Repair Manual

You're Reading a Preview

Recently Viewed