Precision Maintenance: Honda TRX500 FE/FPE/FM/FPM/TM FourTrax Foreman Service Manual (ATV) 2005-2011

Honda TRX500 FourTrax Foreman Service Manual - 2005-2011

This factory-authorized service manual provides technical data for the maintenance and repair of the Honda TRX500 series. A critical system requirement includes the Torque Sensor Initialization process, which is mandatory whenever the steering shaft, EPS unit, or ECU is removed or replaced to ensure steering alignment and system uptime.

Technical Applicability & Serial Ranges

The documentation covers the following 475.3cc single-cylinder OHV longitudinally installed engine configurations:

• TRX500TM (2WD): Left foot operated gearshift (2005-2011).
• TRX500FM (4WD): Left foot operated gearshift (2005-2011).
• TRX500FE (4WD): Electric Shift Program (ESP) variant (2005-2011).
• TRX500FPM (4WD/EPS): Electric Power Steering with manual foot shift (2005-2011).
• TRX500FPE (4WD/EPS/ESP): Electric Power Steering and Electric Shift Program (2005-2011).

Operational Parameters & Service ROI

• System Calibration: Detailed procedures for the Electric Shift Program (ESP) and Electric Power Steering (EPS) diagnostics.
• Engine Integrity: Precise cylinder compression benchmarks of 440 kPa (64 psi) at 380 rpm for performance validation.
• Drivetrain Accuracy: Specific gear backlash tolerances for front and rear final drives (0.05-0.25 mm) to prevent premature gear failure.
• Emission Compliance: Full maintenance schedules to maintain EPA and CARB standard compliance.

Document Metadata

• Print Status: Factory Service Manual
• Total Pages: 550+
• Filing Category: ATV Service/Workshop Manual

Technical Depth & Factory Benchmarks

Engine architecture utilizes an OHV valvetrain with a 92.0 x 71.5 mm bore and stroke. Critical clearances include:

• Valve Clearance (Cold): 0.15 ± 0.02 mm (0.006 ± 0.001 in) for both intake and exhaust.
• Cylinder Service Limit: 92.10 mm (3.626 in) with a maximum 0.10 mm taper/warpage limit.
• Clutch Engagement: Centrifugal weight lining thickness limit is 1.3 mm (0.05 in).

Visual Navigation Aids

• System Wiring: Triple-phase output alternator and DC-CDI ignition circuit diagrams.
• Lubrication Mapping: Forced pressure/wet sump flow paths and oil cooler line routing ('05-'06 upper/lower vs. later models).
• Component Exploded Views: Complete chassis, engine, and front/rear driving mechanism breakdowns.

Table of Contents

• 1. General Information: Specifications, Torque Values, Routing.
• 2. Technical Features: System Architecture.
• 3. Frame/Body Panels/Exhaust System: Component Removal.
• 4. Maintenance: Regular Service Schedules.
• 5-6. Lubrication & Fuel Systems: Oil Pump and Carburetor (VE Type).
• 8-12. Engine & Drivetrain: Cylinder Head, Clutch, Transmission, and Crankshaft.
• 13-17. Chassis & Driving Mechanism: Front/Rear Suspension, Brakes, and Differential.
• 18-24. Electrical & EPS: Charging, Ignition, ESP (Electric Shift), and EPS (Power Steering).

Operational Limits & Specifications

• Engine Oil (GN4): 2.5 Liters (2.6 US qt) at filter change; 3.0 Liters (3.2 US qt) at disassembly.
• Front Differential: Hypoid Gear Oil SAE #80; 185 cm³ (6.3 oz) capacity.
• Torque Sequence: - Cylinder Head Cap Nuts: 39 N·m (29 lbf·ft)
  • Centrifugal Clutch Lock Nut: 118 N·m (87 lbf·ft)
  • Rear Wheel Hub Nut: 137 N·m (101 lbf·ft)
• Tire Pressure (Cold): 25 kPa (3.6 psi) standard for non-EPS; 30 kPa (4.4 psi) front for EPS models.