2005-2011 Honda Foreman 500 TRX500TM/FM/FE/FPM/FPE Service Manual

Documents 2005-2011 Honda Foreman 500 TRX500TM, TRX500FM, TRX500FE, TRX500FPM, TRX500FPE ATV service procedures including engine, chassis, electrical systems, and maintenance. PN C4256-90954

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Honda Models Covered & Key Technical Specifications

Models: Honda Foreman 500 (TRX500TM, TRX500FM, TRX500FE, TRX500FPM, TRX500FPE)
Sub-models / Variants: 2WD, 4WD, Electric Power Steering (EPS), Electric Shift Program (ESP), Left foot operated gearshift
Build Years: 2005–2011
Technical Data:

  • Engine displacement: 475.3 cc
  • Engine type: Single cylinder, longitudinally installed, OHV
  • Bore and stroke: 92.0 mm x 71.5 mm
  • Compression ratio: 8.3:1
  • Cooling system: Air cooled with cooling fan and oil cooler
  • Transmission: Constant mesh, 5-speeds with reverse
  • Final drive: Hypoid gear oil SAE #80
  • Ground clearance: 190 mm (7.5 in)
  • Fuel tank capacity: 15.8 liters (4.17 US gal)
Technical Specifications
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Document Number / Seller:
29502 / Elizabeth Jackson
File Size:
49.10 MB
File Type:
PDF
Language:
English
Pages:
550
Printable:
Yes
Category:
ATV
Last updated / verified
Dec 24, 2025

Honda Manual Features & Content Preview

2005–2011 Honda Foreman 500 Technical Documentation

  • Covers 2005–2011 Honda Foreman 500 (TRX500TM, TRX500FM, TRX500FE, TRX500FPM, TRX500FPE) including 2WD, 4WD, ESP, and EPS configurations
  • Official OEM publication covering the full range of 2005–2011 Foreman 500 mechanical and electrical systems
  • Includes 27 comprehensive chapters detailing maintenance, engine, chassis, and electrical system specifications
  • Stored against your account so you can retrieve it after a hard-drive loss
  • Full-text search finds any part number in seconds
  • Documents the specific EPS system and torque sensor initialization routines
  • Features technical reference values for over 50 specific fastener torque locations
  • Suitable for printing individual sections for shop-floor use
  • This 550-page factory manual is the definitive resource for maintaining the engine, powertrain, and specialized EPS components found on these specific ATV units

Operational and Service Overview

The 2005–2011 Honda Foreman 500 service manual provides a structured analysis of every vehicle system, from the longitudinal engine configuration to the complex electric power steering assembly. Major sections detail the frame and body panel removal, the intricacies of the 5-speed transmission, and the integrated engine control module (ECM) functionality. Separate chapters provide technical depth for the cylinder head, transmission case, suspension components, and the cooling system.

Engine and Chassis Specifications

This Honda Foreman 500 publication documents critical clearances, capacities, and settings necessary for precision work. Engine oil capacity is listed at 2.4 liters (2.5 US qt) after draining. Cylinder head bolt torque is specified at 39 Nm (29 ft-lb) in the assembly data. Intake valve clearance for the Honda Foreman 500 is listed at 0.15 ± 0.02 mm in the cylinder head specification table. Front brake disc thickness is documented at 3.8–4.2 mm, while rear final drive gear oil capacity is 75 cm³ after draining. This 550-page Honda Foreman 500 manual provides the technical reference required for servicing the engine, chassis, and electrical systems for the 2005–2011 vehicle range.

Manual FAQ, Purchase & Download Details

Can you confirm if the manual includes technical coverage for engine top-end, clutch, and transmission systems for the listed models? keyboard_arrow_down

Document contains dedicated chapters for engine components, including cylinder head and valve sections, as well as comprehensive chapters covering the clutch, gearshift linkage, and transmission assemblies. These sections provide detailed technical content and reference data for the 2005-2011 Honda Foreman 500 series.

Which chapters provide references for wiring diagrams, cable routing, and harness configurations? keyboard_arrow_down

Manual includes a dedicated section for wiring diagrams and a specific reference chapter for cable and harness routing, along with electrical system specification tables.

What kind of visual information is provided for component breakdowns in this service document? keyboard_arrow_down

Manual contains numerous exploded views and system illustrations to aid in identifying component arrangements across various vehicle systems. These visual aids are designed to provide clear references for the layout of engine, chassis, and electrical assemblies.

Does the document list standard torque values and specification tables for important fasteners? keyboard_arrow_down

General Information section contains extensive specification tables listing both standard bolt torque values and specific engine and frame tightening values.

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