2005-2011 Honda TRX500 FE/FM/FPE/FPM Service Manual

Diagnostic procedures and component service for Honda TRX500 FE/FM/FPE/FPM. Covers troubleshooting and system diagnostics. PN 61500-HN0-A50.

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Document Details

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Document Number / Seller:
25021 / Patrick King
File Size:
76.79 MB
File Type:
PDF
Language:
English
Pages:
550
Printable:
Yes
Category:
ATV
Last updated / verified
Jan 9, 2026

Models Covered & Key Technical Specifications

Honda TRX500 Series (2005–2011) Service Manual Diagnostic procedures and component service for Honda TRX500 FE/FM/FPE/FPM. Covers troubleshooting and system diagnostics. PN 61500-HN0-A50. | TRX500 Series Repository.

  • Measured Holding Capacity: The engine contains 2.5 liters (2.6 US qt, 2.2 Imp qt) at draining with filter change, calibrated to maintain optimal lubrication Sequences.
  • Established Measurement Bounds: For hydraulic operation, 475.3 cc (28.99 cu-in) cylinder displacement is designed for single-cylinder architecture Baseline.
  • Factory Circuit Specs: 92.0 × 71.5 mm (3.62 × 2.81 in) bore and stroke specifications provide the standard engine design Requirements.
  • Approved RPM Specs: The centrifugal clutch operates at 1,400 ± 100 rpm (min⁻¹) idle speed, governing peak crankshaft load Threshold.
  • Reference Installation Footprint: Double-cradle frame geometry with 1,292 mm (50.9 in) wheelbase establishes primary suspension geometry Mapping.
  • Critical Charge Quantity: Battery capacity reaches 12 V-12 Ah for electrical system support, determining starter motor activation Configuration.

Professional Workshop Service Manual & Technical Specifications

Enhanced Field Hydraulic Manual: Honda TRX500 Series (2005–2011) Service Manual Field-Reference

Model-Portfolio: Honda TRX500 FE/FM/FPE/FPM (2005-2011) // Application-Range: 2005-2011 / FourTrax Foreman // Procedure-Type: Repair & Diagnostic Procedures

Technical Specs Table Assessment-Parameter Baseline Architecture
Engine Displacement 475.3 cm³ Single cylinder, longitudinally installed
Bore x Stroke 92.0 x 71.5 mm Standard engine configuration
Compression Ratio 8.3:1 Optimal combustion efficiency
Fuel Tank Capacity 15.8 liters Extended operation range
Front Wheel Travel 170 mm Enhanced suspension performance
Rear Wheel Travel 170 mm Consistent ride stability

The repository is divided into sections covering all major systems. Systematically requiring thorough mechanical understanding, this document meticulously outlines procedures for disassembly, inspection, repair, and reassembly. It provides critical specifications and diagnostic guidance essential for maintaining the vehicle's peak operational condition and emission compliance.

General Information:

This chapter details essential service rules, model identification, abbreviations, and destination codes pertinent to the TRX500 series, ensuring clarity and precision in all maintenance tasks.

Technical Features:

Explores the integrated engine control module (ECM) and electric power steering (EPS) system, highlighting their technological advancements and operational principles for rider benefit.

Frame/Body Panels/Exhaust System:

Documents the removal and installation procedures for all body panels and the exhaust system, including torque values and troubleshooting for common issues.

Maintenance:

Provides a comprehensive schedule for routine maintenance, covering checks and replacements for critical components like the air cleaner, spark plugs, and brakes.

Lubrication System:

Details the service procedures for the oil pump, oil cooler, and cooling fan, ensuring optimal lubrication and thermal management.

This manual documents torque specifications for various components to ensure proper thermal expansion compensation.

FAQ

Determine the **specific** torque specifications for the crankcase bolts? keyboard_arrow_down

54 N·m (5.5 kgf·m, 40 lbf·ft) is the specified torque for the frame side upper engine hanger nut, and 32 N·m (3.3 kgf·m, 24 lbf·ft) is for the engine side upper engine hanger bolts, ensuring secure engine mounting.

What **designated** safety precautions should be followed when working on the fuel system? keyboard_arrow_down

Work in a well-ventilated area and avoid flames or sparks to prevent fire or explosion; bending or twisting control cables can impair operation. Additionally, place approved fuel containers under drain hoses when removing the carburetor.

Check the **critical** lubrication requirements for the starter clutch bolt? keyboard_arrow_down

12 N·m (1.2 kgf·m, 9 lbf·ft) is the specified torque for the starter clutch bolt, requiring engine oil application to its threads and seating surface before tightening.

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Reviews (5)

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The engine removal instructions were spot on. Smooth download process as well!
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This manual is a lifesaver. The detailed instructions helped me fix my ATV without any hassle. Highly recommended!
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I appreciated the quick download link sent to my email. The diagrams made everything clear and easy to follow.
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This guide covers everything you need to know. The customer support was quick to respond and very helpful!
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The troubleshooting section saved me a lot of time. Excellent service and support when I had questions.