Official Service & Repair Procedures: Honda Foreman 500 TRX500TM, TRX500FM, TRX500FE, TRX500FPM, TRX500FPE ATV Service Manual, 2005-2011 edition

Honda Foreman 500 TRX500 Series ATV Service Manual (2005-2011)

Take complete control of your ATV’s maintenance with the definitive factory-style service guide. This professional-grade manual covers the legendary Honda Foreman 500 TRX500 series from 2005 through 2011. Designed for both high-end shop technicians and dedicated DIY owners, this guide provides the exact technical data required to keep your Foreman 4x4 or 2WD in peak operating condition.

Precision Engineering for Every Foreman Model

This manual isn't a "one-size-fits-all" book. It features dedicated sections and specific procedures for all five major variations of the TRX500 platform:

• Honda Foreman 500 TRX500TM (2005-2011): 2WD with left-foot operated gearshift.
• Honda Foreman 500 TRX500FM (2005-2011): 4WD with left-foot operated gearshift.
• Honda Foreman 500 TRX500FE (2005-2011): 4WD featuring the Electric Shift Program (ESP).
• Honda Foreman 500 TRX500FPM (2005-2011): 4WD with Electric Power Steering (EPS) and foot shift.
• Honda Foreman 500 TRX500FPE (2005-2011): 4WD with Electric Power Steering (EPS) and Electric Shift Program (ESP).

Why This Manual is Essential for Your Garage

The Honda Foreman is built for the toughest trails and farm work, but even the most reliable ATV needs proper care. This manual provides the high-level technical insights that generic guides miss:

• Detailed Serial Number Tracking: Quickly locate your Vehicle Identification Number (VIN) on the front side of the frame or the Engine Serial Number on the right side of the rear crankcase to ensure you are ordering the correct parts.
• Model-Specific Troubleshooting: Expert diagnostic flows for the Electric Shift Program (ESP) and the Electric Power Steering (EPS) systems—essential for identifying sensor issues or motor faults.
• Full Wiring & Routing: Comprehensive diagrams for cable and harness routing, including specific '05-'06 and after-'06 updates to ensure your electrical system is factory-perfect.

Pro-Level Technical Specifications

Stop guessing and start measuring. This guide includes the exact factory tolerances and torque values:

• Engine: Single-cylinder 475.3cc OHV longitudinally installed engine with a 92.0 x 71.5 mm bore and stroke.
• Fluid Capacities: Precise requirements for engine oil (2.5L after filter change), front differential (185cm³), and rear final drive (75cm³).
• Maintenance Specs: Correct spark plug gaps (1.0-1.1 mm), valve clearances (0.15 mm), and idle speeds (1,400 ± 100 rpm).
• Torque Data: Essential values for everything from cylinder head cap nuts (39 N-m) to centrifugal clutch lock nuts (118 N-m).

What’s Included

This comprehensive guide is organized into 27 clear sections for rapid navigation:

1. General Information & Model ID (VIN/Engine Serial)
2. Technical Features (ECM, EPS, & ESP Outline)
3. Frame, Body Panels, & Exhaust Removal
4. Detailed Maintenance Schedules
5. Lubrication & Fuel Systems (Carburetor VE6DA Specs)
6. Engine Overhaul (Cylinder Head, Piston, & Transmission)
7. Front & Rear Driving Mechanisms (Selectable 4WD)
8. Electrical Systems (Ignition, Battery, & Charging)
9. Specialized EPS & ESP Troubleshooting
10. Full-Page Wiring Diagrams & Detailed Index

Whether you are performing a simple oil change or a complete engine rebuild, this manual is the most valuable tool in your toolbox. Avoid costly mistakes by following the official Honda service rules and specialized tool recommendations. Keep your Foreman 500 running like new—order your comprehensive service guide today!