2005-2012 Honda FourTrax Foreman Rubicon 500 Service Manual
Covers TRX500FA, TRX500FGA, TRX500FPA models with complete procedures for engine, transmission, suspension, and brake service. Includes detailed specifications and torque values for all components.
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Models Covered & Key Technical Specifications
Honda FourTrax Foreman Rubicon 500 TRX500FA, TRX500FGA, TRX500FPA — 2005–2012 Engineered Sourcebook for Repository.
- Engineered Net Mass: The engine dry weight is specified at 62.9 kg (138.7 lbs) assembly Configuration.
- Design Scan Resolution: Displacement volume reaches 499 cm³ (30.4 cu-in) representing engine cylinder capacity Mapping.
- Documented Rotational Force: Maximum torque specification corresponds to 39 N·m (29 lbf-ft) at rated crankshaft output Benchmarks.
- Principal Play Limits: Valve clearance is standardized to 0.15 mm (0.006 in) intake and 0.23 mm (0.009 in) exhaust Range.
- Advanced Temperature Range: Coolant mixture yields a 1:1 ratio of distilled water and ethylene glycol antifreeze Sequences.
- Primary Enclosure Specs: Fuel tank capacity is established at 15.8 liters (4.17 US gal, 3.48 Imp gal) for 2005–2007 models Baseline.
Professional Workshop Service Manual & Technical Specifications
Multi-System Overhaul Assembly Manual: ATV Genuine Honda FourTrax Foreman Rubicon 500 TRX500FA, TRX500FGA, TRX500FPA (2005-2012) OEM-Documentation
Model-Portfolio: FourTrax Foreman Rubicon 500, TRX500FA, TRX500FGA, TRX500FPA (2005-2012) // Engineering-Base: ATV Service Logic / Multi-System Operations // Design-Core: Complete Technical Reference, 613 Pages, Professional Service Documentation.
| Metric | Operational-Logic | Logic |
|---|---|---|
| Engine Systems | Cylinder head, valve, camshaft, piston, clutch service procedures | Complete specifications provided |
| Transmission Systems | Sub-transmission, gearshift linkage, automatic transmission (Hondamatic) | Comprehensive assembly and disassembly |
| Suspension & Steering | Front/rear shock absorbers, swingarm, steering shaft, EPS systems | Full maintenance and replacement guidance |
| Brake Systems | Front hydraulic disc, rear mechanical drum brakes | Complete service and adjustment procedures |
| Drive Systems | Front differential, rear final drive, drive shafts, universal joints | Backlash, tooth contact, bearing service documented |
Maintenance hierarchies are structured into the manual's design, encompassing engine management protocols that address cylinder head and valve service, camshaft timing, piston ring replacement, and compression verification. Drivetrain specifications are addressed in sections covering the centrifugal clutch, alternator systems, starter clutch mechanisms, sub-transmission gearshift linkage, and crankshaft assembly procedures. Reassembly procedures are specified for all major components, including proper torque sequences, bearing installation, and seal replacement protocols.
Integrated Methodology
Service intervals are documented for routine maintenance including oil changes, filter service, coolant replacement, brake fluid bleeding, spark plug inspection, and valve clearance adjustment. Component locations are identified throughout the manual using detailed exploded-view diagrams and system flow illustrations. The document provides professional-grade technical information for certified technicians performing factory-authorized service on this ATV platform.
Operational Interface
Engine rebuild procedures are documented for the 499 cc single-cylinder longitudinal four-valve OHV engine with 9.2:1 compression ratio. The manual includes specifications for cylinder bore and stroke (92.0 x 75.0 mm), valve timing data, and lubrication system pressure requirements. Complete carburetor service details address the constant velocity design with 36 mm throttle bore, including pilot screw adjustment, float level inspection, and high-altitude modification procedures.
Systematic Sequences
Cooling system procedures encompass water pump service, thermostat operation verification, radiator fan motor operation, and coolant circulation pathways. The manual documents torque specifications for the [engine component] to ensure proper thread engagement security. Fuel system coverage includes fuel tank removal, carburetor disassembly and assembly, air cleaner service, and emission control system maintenance per EPA and CARB regulations.
Strategic Framework
The suspension section details front shock absorber installation, upper and lower arm ball joint service, steering shaft bearing replacement, and handlebar assembly alignment procedures. Rear suspension content covers swingarm pivot bearing service, shock absorber mounting, and brake system integration. Electrical systems documentation includes the battery and charging system, ignition system, starter motor, lights and meter assemblies, and the selectable 4WD system with detailed wiring diagrams.
Systematic Protocol
Brake system procedures address both front and rear mechanisms separately, including master cylinder rebuild, caliper piston service, disc brake pad replacement, and rear brake drum panel assembly. The manual provides step-by-step cable and harness routing instructions with visual reference points to ensure proper wire management throughout the frame. Frame and body panel sections cover exhaust system service, mud guard installation, and fastener torque specifications for the frame cradle design.
Additional documentation includes complete wiring diagrams for models 2005-2012, system-specific troubleshooting guides, general specifications table with dimensions and weight data, and lubrication and seal point reference materials with specific grease and oil product recommendations for all mechanical interfaces and pivot points throughout the vehicle.
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