2005-2006 Honda Fourtrax Foreman 500 Service Manual

Complete service documentation for the TRX500 series (TRX500TM, TRX500FM, TRX500FE, TRX500FPE). Covers engine, transmission, electrical systems, brake adjustment, and 4WD differential maintenance procedures.

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Honda Models Covered & Key Technical Specifications

Models: Honda Fourtrax Foreman 500 (TRX500TM, TRX500FM, TRX500FE, TRX500FPE)
Sub-models / Variants: 2WD, 4WD, Left foot operated gearshift, Electric shift program (ESP)
Build Years: 2005–2006
Technical Data:

  • Engine displacement: 475.3 cm³ (28.99 cu in)
  • Compression pressure: 440 kPa (64 psi) at 380 rpm
  • Valve clearance (IN/EX): 0.15 ± 0.02 mm (0.006 ± 0.001 in)
  • Engine oil capacity (after drain/filter): 2.5 liters (2.6 US qt)
  • Fuel tank capacity: 15.8 liters (4.17 US gal)
  • Idle speed: 1,400 ± 100 rpm
Technical Specifications
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Document Number / Seller:
24302 / Cynthia Jones
File Size:
48.53 MB
File Type:
PDF
Language:
English
Pages:
449
Printable:
Yes
Category:
ATV
Last updated / verified
Jun 17, 2025

Honda Manual Features & Content Preview

Official 2005–2006 Honda Fourtrax Foreman 500 Service Coverage

  • Covers 2005–2006 Honda Fourtrax Foreman 500 TRX500FE, TRX500FM, and TRX500TM variants, including 2WD and 4WD configurations with ESP
  • Official Honda Motor Co., Ltd. service publication dated November 2004
  • Contains 26 categorized sections including frame, engine, fuel system, electrical, suspension, and wiring diagrams
  • File link appears in your order confirmation straight away
  • Suitable for printing individual sections for shop-floor use
  • This 449-page factory manual serves as the primary technical reference for the TRX500 Foreman series, providing the original build specs required for maintenance and component servicing

Document Structure and Technical Depth

Operational and Maintenance Documentation

This publication organizes service requirements by vehicle system, beginning with foundational general information, identification codes, and maintenance schedules. The core coverage spans engine, chassis, and electrical architecture, detailing procedures for the cylinder head, valve train, clutch systems, and drivetrain mechanisms. The layout includes specific what an OEM service publication covers by grouping components according to their location on the TRX500.

Engine and Chassis Specifications

Technical data previews include critical reference values such as the 475.3 cm³ engine displacement and the compression pressure specification of 440 kPa at 380 rpm. Valve clearance for the intake and exhaust is documented at 0.15 ± 0.02 mm in the specification table. Engine oil capacity for the 2005–2006 Honda Fourtrax Foreman 500 is listed at 2.5 liters after a filter change. The manual details torque settings for over 100 individual fasteners and provides extensive wiring diagrams for the 2WD/4WD select and ESP systems.

This 449-page factory Honda service manual documents the complete technical requirements for the 2005–2006 Honda Fourtrax Foreman 500 TRX500FE/FM/TM series, providing precise engine, chassis, electrical, and fuel system specifications for professional maintenance.

Document Reference: Date of Issue: November, 2004; Honda Motor Co., Ltd.

Manual FAQ, Purchase & Download Details

Does this manual cover the TRX500FE, TRX500FM, and TRX500TM model variants manufactured for the 2005 and 2006 model years? keyboard_arrow_down

Manual is designed for the 2005-2006 Honda Fourtrax Foreman 500 series, including the TRX500FE, TRX500FM, and TRX500TM submodels. It contains information intended to help distinguish between these specific configurations.

What is the official publication date for this service manual? keyboard_arrow_down

Document lists November 2004 as the date of issue.

Which sections of the document include exploded views and component breakdown illustrations for the engine and chassis systems? keyboard_arrow_down

Manual includes system illustrations at the beginning of most sections, such as those found in the engine removal, cylinder head, and suspension chapters. These diagrams show the layout of assemblies like the transmission, clutch, and front driving mechanisms. You can use these exploded views to identify the relationship between various parts across the vehicle.

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