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

Manual includes high quality images and color diagrams. It is searchable and indexed.