2005–2012 Honda FourTrax Foreman Rubicon 500 Service & Repair Manual

• Covers 2005–2012 Honda FourTrax Foreman Rubicon 500 models with 4WD and automatic transmission: TRX500FA, TRX500FGA with GPScape, and TRX500FPA with GPScape and EPS.
• Engine repair extends to valve-guide replacement, valve-seat refacing, camshaft timing, cylinder and piston inspection, and crankshaft and balancer service.
• Centrifugal clutch disassembly and inspection accompany internal sub-transmission repair, including gear, shift-fork, and shift-drum checks.
• Front differential and rear final-drive overhaul procedures cover backlash, tooth-contact inspection, and shim selection. Front differential slip-torque testing is also included.
• Brake repair covers front hydraulic caliper and master-cylinder overhaul, system bleeding, and rear drum brake inspection and adjustment.
• Steering and suspension sections detail wheel-hub bearing replacement, ball-joint service, swingarm pivot work, and separate procedures for EPS-equipped models.

This 601-page PDF contains Honda factory service and repair procedures. It was written for qualified, professional technicians with the training, tools, and equipment these jobs require. Body panel and exhaust removal instructions establish access for engine and chassis work, with exploded assembly drawings showing component arrangement.

Carburetor, Lubrication, and Cooling Service

The fuel chapter covers CV carburetor disassembly, vacuum-piston and diaphragm inspection, starter-enrichment valve service, and pilot-screw adjustment.

Carburetor specifications distinguish VE6AE for A/CM versions (U.S. and Canada) from VE6AF for U versions (Australia, U.K., and Sweden). High-altitude adjustment coverage excludes U versions. The changes identified after 2007 concern fuel-tank and hose permeation controls on the carbureted fuel system.

Routine maintenance includes valve-clearance adjustment and oil and filter changes. The Lubrication System Diagram traces the oil supply behind the oil-pressure tests and pump inspection procedures. The Cooling System Flow Pattern supports radiator, thermostat, and water-pump service, including pressure testing and coolant air bleeding.

The cylinder-head section warns of severe engine damage from incorrect head-cover installation when the rocker arms and pushrod ends are misaligned.

Hondamatic Diagnosis and Repair Limits

The automatic-transmission chapter covers crankcase separation, unit removal, and checks of the swash-plate and ball-nut mechanisms. The Hondamatic automatic unit is replaced as an assembly; internal overhaul of that unit is outside the repair scope.

Electrical fault finding uses blink codes, control-motor tests, and throttle-position and angle-sensor checks. The Hondamatic Circuit Diagram connects the ECM to the sensors and shift controls. The manual explains when ECM, sensor, carburetor, or throttle-cable work requires the Hondamatic initial setting.

EPS, 4WD, and Electrical Fault Tracing

EPS diagnosis includes HDS Pocket Tester access and a DLC/SCS connector method, plus torque-sensor initialization. The indicator displays main fault codes only; HDS provides subcode and freeze-data information. EPS ECU replacement and the steering jobs that require initialization are identified.

The Selectable 4WD System Diagram supports front-final-clutch and vehicle-speed-sensor diagnosis. EPS Connector Location drawings identify harness connections. Full wiring diagrams are separated by model year, model, and destination code, including EPS-equipped versions.

For a parasitic draw, the battery and charging section provides current-leakage testing and a diagnostic flowchart. Ignition peak-voltage testing, starter motor overhaul, and lighting and switch checks have dedicated sections. GPScape troubleshooting addresses GPS-receiver communication faults and backup-power checks.

Model-Year Differences and Factory Specifications

Tie-rod assembly orientation differs between 2005–2006 and later models. Shock lower-pivot service also distinguishes the earlier bearings from the later bushings, keeping these chassis procedures tied to the correct build.

Factory tables supply assembly torque specifications, including the centrifugal clutch lock nut, alongside intake-valve clearance data, wear limits, electrical test values, and oil capacities for different service operations. Special-tool references include the U.S. clutch holder set 07ZMB-HN2A100 and EPS diagnostic SCS connector 070PZ-ZY30100.

Before handling heavy structural components or draining fluids, work in a well-ventilated area and wear appropriate protective equipment.