2005–2006 Honda FourTrax Foreman 500 TRX500TM/FM/FE ATV Service Manual (P/N 61HP001)

Working on a mid-2000s Foreman calls for model-specific service information. This Honda factory service manual covers the 2005–2006 FourTrax Foreman 500 TRX500TM, TRX500FM, and TRX500FE, including foot-shift, Electric Shift Program (ESP), and selectable 4WD configurations.

• Maintenance and fuel system: Maintenance schedules, carburetor disassembly and inspection, pilot-screw adjustment, high-altitude jetting, and air-cleaner service.

• Engine repair: Engine removal and installation, cylinder-head disassembly, valve-guide replacement, valve-seat refacing, camshaft timing, and cylinder/piston inspection.

• Clutch and transmission: Centrifugal and change-clutch repair, gearshift-linkage service, crankcase separation, transmission inspection, and crankshaft/balancer removal and installation.

• Final drives: Front drive-shaft service, differential inspection, bearing replacement, gear-backlash adjustment, and front and rear final-gear assembly.

• Steering, suspension, and brakes: Wheel-hub and knuckle service, ball-joint replacement, swingarm bearings, front hydraulic brake bleeding, caliper repair, and rear drum-brake service.

• Electrical diagnosis: Charging, ignition, and starter tests, ESP problem-code troubleshooting, selectable 4WD fault diagnosis, and model-specific wiring diagrams.

Written for qualified professional technicians, this manual assumes basic Honda maintenance knowledge and access to the special tools and test equipment specified for the work.

Engine and Transmission Repair

The cylinder head, valves, camshaft, cylinder, and piston have in-frame service procedures. Transmission and crankshaft work requires engine removal and crankcase separation. Inspection tables distinguish standard dimensions from service limits for gears, bushings, shafts, and valve-train components.

Clutch coverage separates the centrifugal clutch from the change clutch, with component inspection and assembly instructions for each. The alternator, starter clutch, and recoil starter have dedicated service sections. Crankshaft installation includes balancer timing checks.

Before heavy chassis or engine work, ensure your workspace is well-ventilated and use appropriately rated lifting equipment.

Carburetor and Oil-Cooling Service

Carburetor coverage includes diaphragm/vacuum-piston checks, float-valve inspection, the pilot-screw idle-drop procedure, and high-altitude adjustment. These sections address hard starting, mixture faults, and poor running at different engine speeds.

Lubrication service covers the upper and lower oil coolers, oil pump, relief valve, and cooling fan. The Lubrication System Diagram shows oil distribution through the engine and transmission. The maintenance section warns that installing the oil filter backward can cause severe engine damage.

Final Drives, Steering, and Brakes

The front differential chapter covers face cams, cam followers, limited-slip torque inspection, and shim selection. Gear-tooth contact-pattern views show drive-side and coast-side contact. Separate front and rear backlash procedures help distinguish their different shim arrangements before parts are selected.

An overly thick front ring-gear shim can lock the gears as the case-cover bolts are tightened.

Chassis procedures distinguish TM wheel-hub bearings from FM/FE knuckle bearings and include steering-shaft and swingarm-pivot bearing replacement. Brake repair extends to front master-cylinder and caliper disassembly, plus rear brake-drum, shoe, and pedal service. Model-specific tie-rod and toe specifications support steering alignment.

ESP and Selectable 4WD Fault Diagnosis

FE-model ESP diagnosis includes problem-code retrieval and erasure, angle-sensor checks, and shift control motor testing. Separate fault paths for the sensor, wiring, gear-position switch, throttle-position sensor, and ECM help narrow down a shifting fault before replacing the control motor.

FM/FE selectable 4WD diagnosis covers front and rear vehicle-speed sensors and the front final clutch, supported by a Troubleshooting Chart and System Diagram.

Separate A/CM-type TM, U-type TM, FM, and FE Wiring Diagrams account for model and regional differences. Cable & Harness Routing illustrations show connector locations and wire paths. The manual is organized into 26 sections, including general troubleshooting and an alphabetical index.

A Preview of Clutch and Starter Wear Limits

Change-clutch spring inspection uses minimum free lengths of 42.49 mm (1.673 in) for TM/FM models and 41.23 mm (1.623 in) for the FE. These service limits distinguish the springs used by the foot-shift and ESP variants.

Starter-motor inspection specifies a brush-length service limit of 9.0 mm (0.35 in), alongside armature-continuity and commutator checks.

Text Search, Chapter Bookmarks, and Wiring Detail

Search and diagram detail: Embedded OCR text supports keyword searches, although recognition errors can affect exact matches and some wiring labels. PDF bookmarks link to the service chapters. Small wire-color codes and connector labels in the TM and FE wiring diagrams require zooming for comfortable reading.

The download is one printable, English-language, 449-page PDF: 448 manual pages, including the cover and one blank page, plus one additional introductory page.