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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Models Covered & Key Technical Specifications
Honda Fourtrax Foreman 500 (TRX500TM, TRX500FM, TRX500FE, TRX500FPE) — 2005–2006 Consolidated Mechanical Blueprint | Fourtrax 500 Series Bundle.
- Calibrated Displacement Data: 475.3 cm³ (28.99 cu in) is specified as the engine cylinder volume Architecture.
- Measured Power Output: The engine compression at 380 rpm is rated at 440 kPa (4.5 kgf/cm³, 64 psi) representing maximum combustion chamber Norms.
- Primary Torque Specification: Valve clearance governs the intake and exhaust at 0.15 ± 0.02 mm (0.006 ± 0.001 in) establishing precise operation Bounds.
- Specific Engine Oil Capacity: For optimal lubrication, 2.5 liters (2.6 US qt, 2.2 Imp qt) after filter change is designed for engine protection Topology.
- Critical Fuel Tank Volume: Tank capacity reaches 15.8 liters (4.17 US gal, 3.48 Imp gal) with 3.3 liter reserve sets the fuel supply Matrix.
- Rated Tire Pressure Specification: Cold tire pressure of 25 kPa (0.25 kgf/cm², 3.6 psi) standard maintains proper traction and wear Standards.
Professional Workshop Service Manual & Technical Specifications
Professional Wiring Manual: Honda 2005-2006 Fourtrax Foreman 500 / TRX500TM, TRX500FM, TRX500FE, TRX500FPE Resource-Library
Assembly-Group: Honda Fourtrax Foreman 500, TRX500TM, TRX500FM, TRX500FE, TRX500FPE (2005-2006) // Subsystem-Focus: Multi-system powertrain and electrical subsystems // Assembly-Group: 457-page comprehensive documentation with 16 chapters.
| Section | Category | Logic |
|---|---|---|
| Engine Systems | Cylinder head, valve train, crankshaft, transmission | Complete specifications provided |
| Electrical Architecture | Charging, ignition, battery management | Documented systems and diagnostics |
| Brake Documentation | Hydraulic and drum brake assemblies | See chapters 15-17 |
Comprehensively requiring systematic organization, the documentation conveys engine assembly operations and clutch mechanisms, distributes crankcase and transmission service information, and accommodates electrical system procedures while covering front and rear suspension frameworks. The manual encompasses cylinder head and valve specifications, documents engine removal and installation protocols, provides lubrication system component descriptions, and includes fuel system carburetor assembly guidance.
Integrated Architecture
Electrical system documentation covers ignition coil operation, alternator stator configuration, and battery charging specifications. The manual describes starting system reduction gears, spark plug identification data, and engine control module integration. System operation descriptions incorporate DC-CDI ignition timing reference, electric starter motor design, and gear position switch logic. Documentation defines charging coil resistance parameters and peak voltage measurement procedures without prescribing adjustment values.
Operational Sequences
Suspension service documentation covers double-wishbone front arm assemblies, swingarm pivot bearing configurations, and shock absorber damper specifications. The document describes brake caliper piston cup composition, front disc brake pad material grades, and rear drum brake shoe lining reference data. Transmission gear assembly documentation includes countershaft bushing clearance reference information, mainshaft bearing specifications, and shift fork guide groove dimensional data. The manual provides wiring diagram illustrations, harness routing guidance, and electrical connector identification reference material.
Integrated Benchmarks
Disassembly instructions are documented for centrifugal clutch weight assembly, change clutch disc stack configurations, and primary drive gear removal sequences. Component location illustrations depict fuel tank mounting points, carburetor insulator positioning, and air cleaner housing attachment references. Service procedures describe spark plug gap verification methodology, valve clearance measurement instructions, and engine idle speed reference parameters. Documentation includes torque specification reference tables for fastener assemblies throughout engine, frame, and drivetrain sections.
Strategic Parameters
Wear limits are specified for cylinder bore dimensions, piston ring end gaps, and connecting rod clearance tolerances. The document includes front wheel suspension geometry specifications, tire pressure reference data, and steering shaft alignment parameters. Brake system documentation provides disc thickness service limits, caliper cylinder bore dimensional references, and brake fluid type specifications. Oil capacity information, gear backlash tolerance ranges, and bearing installation depth measurements are included throughout the service sections.
The manual documents torque specifications for the crankshaft fastening, transmission component assembly, and differential gear case mounting to ensure proper component alignment retention.
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