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.
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)
Model Years: 2005–2006
Technical Data:
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Engine displacement: 475.3 cm³ (28.99 cu in)
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Compression pressure: 440 kPa (64 psi) at 380 rpm
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Valve clearance (IN/EX): 0.15 ± 0.02 mm (0.006 ± 0.001 in)
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Engine oil capacity (after drain/filter): 2.5 liters (2.6 US qt)
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Fuel tank capacity: 15.8 liters (4.17 US gal)
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Idle speed: 1,400 ± 100 rpm
Honda Manual Features & Content Preview
2005–2006 Honda FourTrax Foreman 500 Factory Service Manual
Working on a mid-2000s Foreman requires precise factory data, not guesswork. This 449-page factory service manual is the exact reference used by professional technicians to maintain and diagnose the Honda FourTrax Foreman 500 series. Delivered as an instant download, you can immediately access original build specifications right on your shop tablet or phone.
Before diving into heavy chassis or engine work, always ensure your workspace is well-ventilated and use appropriately rated lifting equipment.
- Covers TRX500FE, TRX500FM, and TRX500TM models, including 2WD, 4WD, and ESP configurations.
- Complete technical breakdown across 26 categorized sections, ranging from the fuel system and wiring schematics to suspension geometry.
- Instant download access immediately after checkout ensures zero downtime.
- High-resolution format makes it perfect for printing specific torque charts or wiring paths directly for the shop floor.
System-by-System Technical Data
This manual maps out the entire vehicle architecture. Instead of generic overviews, you get the actual component specifications needed for the cylinder head, valve train, clutch systems, and ESP drivetrain mechanisms. If you want to know more about what an OEM service publication covers, this document groups everything exactly where a mechanic expects it—by system and physical location on the ATV.
Essential Clearances and Specifications
Avoid scrolling through forums for unverified torque values. This guide provides the exact factory numbers for the 475.3 cm³ engine displacement, including a baseline compression pressure of 440 kPa at 380 rpm. You will find the required intake and exhaust valve clearance (0.15 ± 0.02 mm) clearly charted for quick reference. It also confirms the 2.5-liter engine oil capacity required after a filter change. With over 100 individual fastener torque settings and comprehensive wiring diagrams for the 4WD select systems, you have everything necessary to trace electrical faults or verify mechanical wear limits with total confidence.
Document Reference: Date of Issue: November 2004; Honda Motor Co., Ltd.
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