2005–2011 Honda TRX500 TM/FM/FE/FPM/FPE FourTrax Foreman ATV Service Manual

The Honda service manual covers the 2005–2011 TRX500 FourTrax Foreman in TM, FM, FE, FPM, and FPE configurations, with factory procedures for scheduled maintenance, mechanical repair, and electrical fault diagnosis.

• Engine repair: Cylinder head, valvetrain, cylinder, and piston inspection, plus engine removal and installation procedures, supported by wear limits and assembly specifications.
• Clutch and transmission: Centrifugal clutch, change clutch, gearshift linkage, and internal transmission service, including crankcase separation and assembly.
• Fuel and lubrication: Constant vacuum carburetor overhaul and adjustment, oil pump inspection, oil cooler service, and cooling fan diagnostics with related service data.
• Final drives: Front and rear driving mechanisms, final gearcase disassembly, bearing replacement, and gear mesh inspection with backlash and shim data.
• Chassis and brakes: Double-wishbone suspension, steering, swingarm, hydraulic front disc brakes, and rear drum brakes, with inspection limits and component torque values.
• Electrical testing: Charging and ignition diagnostics, alternator stator and starter clutch service, electric starter testing, and sensor and switch checks.
• Electronic controls: ESP, EPS, and Selectable 4WD diagnosis, including fault code charts, control circuit checks, and the relevant motor service procedures.

Written for qualified professional technicians, this manual assumes appropriate mechanical training, workshop equipment, and familiarity with safe service practices.

Engine, Carburetor and Lubrication Work

Cylinder head procedures include valve guide replacement and valve seat inspection/refacing, with related valve clearance checks. Internal engine procedures cover the crankshaft and balancer.

The carburetor chapter provides pilot screw settings and high-altitude adjustment, supported by emission-control information.

Lubrication diagrams trace the oil circuit and service points. The oil filter instructions identify the correct installation direction because reversed installation can cause severe engine damage.

Final Drives, Shifting and Chassis Service

Gear tooth contact-pattern views support front and rear final drive setup. The manual distinguishes serviceable drive shaft components from the outboard CV joint, which cannot be disassembled and requires shaft replacement if worn or damaged.

Transmission data include gear ratios and secondary reduction assemblies, alongside internal gear and shift mechanism inspection procedures.

Chassis sections supply suspension geometry, brake service limits, swingarm pivot and steering shaft tightening specifications, and reverse lock system inspection.

ESP, EPS and Electrical Fault Isolation

The TM uses two-wheel drive; the remaining variants have selectable four-wheel drive. ESP applies to FE/FPE models, while power steering applies to FPM/FPE, keeping shift control and steering diagnostics tied to the correct equipment.

Troubleshooting flowcharts pair voltage, resistance, and continuity specifications with connector terminal views. These checks help distinguish wiring or connection faults from an EPS motor or ECU fault before replacement is considered.

ESP coverage includes fault code retrieval and clearing. For EPS, the manual describes Honda Diagnostic System (HDS) diagnosis, the DLC/SCS connector method, and torque sensor neutral-position initialization; clearing fault codes does not perform that initialization.

Model-specific wiring diagrams are supported by 24 pages of cable and harness routing and EPS system schematics.

Always follow workshop safety procedures and consult a qualified professional if you are unsure about safely servicing the ATV.

Selected Compression and Oil-Capacity Specifications

This small selection illustrates the manual’s test conditions and service-fill distinctions.

Compression pressure is 440 kPa (64 psi) at 380 rpm with the engine at normal operating temperature and the throttle fully open. The camshaft decompression device explains the comparatively low specified pressure.

Engine oil capacity after draining and filter replacement is 2.5 liters (2.6 US qt). For the front differential on four-wheel-drive models, capacity is 185 cm³ after draining and 230 cm³ after disassembly.

Text Search, Bookmarks and Wiring Detail

Search and diagram access: Most text is OCR-searchable, but two clutch service pages and the wiring diagrams are image-only. Embedded bookmarks navigate chapters and individual wiring diagrams; small wiring labels require enlargement for clear reading.

The download contains one printable English PDF with 550 pages, including one cover page, 13 “MEMO” pages, and one blank page.