2005-2011 Honda TRX500 FE/FM/FPE/FPM Service Manual
Complete service manual for Honda TRX500 Foreman 475cc models. Covers engine, transmission, suspension, hydraulic disc brakes, and electrical systems across all variants including ESP and EPS equipped models.
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Sample pages from the 2005-2011 Honda TRX500 FE/FM/FPE/FPM Service Manual manual
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Models Covered & Key Technical Specifications
Honda TRX500 Series (2005–2011) Precision Engineering Collection | 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
Complete undefined Installation Manual: ATV Precision Maintenance: Honda TRX500 FE/FPE/FM/FPM/TM FourTrax Foreman Service Manual (ATV) 2005-2011 Repository
Technical-Benchmarks: TRX500TM, TRX500FM, TRX500FE, TRX500FPM, TRX500FPE // Reference-Category: Single-cylinder OHV Propulsion Logic / Constant Mesh 5-speed Transmission with Centrifugal and Multi-Plate Wet Clutch System // Reference-Category: Double Cradle Frame Architecture with Double Wishbone Front Suspension and 170mm Travel; Hydraulic Front Disc and Mechanical Rear Drum Brake Configuration.
| System Component | Technical Specification | Documentation Status |
|---|---|---|
| Engine & Drivetrain | 475.3 cm³ OHV, 92.0 x 71.5 mm bore/stroke, 8.3:1 compression | Complete specifications provided |
| Suspension & Steering | Double wishbone front, swingarm rear, 170mm wheel travel | Documented with torque values |
| Brake System | Hydraulic front disc, mechanical rear drum | Comprehensive coverage included |
Coverage is segmented into twenty major sections encompassing the complete service and maintenance architecture for TRX500TM, TRX500FM, TRX500FE, TRX500FPM, and TRX500FPE model variants. The document systematically addresses General Information and Technical Features, progresses through Frame and Body Panel service, incorporates Maintenance scheduling protocols, and provides detailed Lubrication System procedures. Coverage extends to the Fuel System with carburetor assembly and installation methodologies, Engine Removal and Installation guidance, Cylinder Head and Valve servicing, Cylinder and Piston component procedures, and comprehensive Clutch and Gearshift Linkage information.
Core Topology
Fundamental to the manual's structure, Alternator and Starter Clutch servicing receives dedicated coverage alongside Crankcase, Transmission, Crankshaft, and Balancer operations. The document includes extensive Front Wheel, Suspension, and Steering system procedures covering handlebar assembly, throttle housing, tire service, wheel hub and knuckle disassembly, suspension arm maintenance, and front shock absorber inspection protocols. Rear Wheel and Suspension sections document rear shock absorber service and swingarm bearing procedures for all model variants.
Precise Nexus
The Brake System documentation is comprehensive, covering front disc brake fluid replacement and air bleeding procedures, front master cylinder disassembly and inspection, and front brake caliper service methodologies. Rear brake drum and shoe service receives full treatment with detailed assembly and installation guidance. Front Driving Mechanism coverage (excluding TM model) includes front drive shaft boot and joint servicing, front final drive removal and installation, front final gear disassembly with inspection procedures, and front final gear case bearing replacement methodologies. Repair information is provided for the differential assembly, pinion gear installation, and comprehensive gear tooth contact pattern verification procedures.
Modular Benchmarks
Rear Driving Mechanism documentation provides equivalent coverage to the front system, including rear axle removal and bearing replacement procedures, rear final drive removal and installation, rear final gear disassembly with backlash inspection, and pinion bearing and shim replacement methodologies. The manual documents torque specifications for all critical fasteners to ensure proper oscillation integrity throughout the vehicle's operational envelope. Safety procedures are documented for all service operations, with emphasis on proper support techniques and hazard prevention during engine removal, transmission service, and suspension work.
Operational Parameters
Fluid capacities are listed for engine oil (2.4-3.0 liters depending on service scope), rear final gear case oil (75-100 cm³), and front differential oil (185-230 cm³), with all specifications cross-referenced to SAE grades and viscosity requirements. The document includes cable and harness routing diagrams for the 2005-2006 and after-2006 model years, accommodating Electric Power Steering (EPS) model variations. Wiring diagrams provide comprehensive electrical system documentation including alternator stator, electric starter motor, battery charging system, ignition system circuitry, and electric shift program (ESP) control systems for FE and FPE models.
Systematic Threshold
Troubleshooting sections are provided for compression diagnostics, excessive smoke conditions, valve-related noise, and hard starting scenarios across all major systems. The manual addresses high altitude carburetor adjustment procedures with specific jet replacement guidance, pilot screw opening specifications, and idle speed verification methodologies. Maintenance schedule recommendations follow EPA and CARB standards with interval-based service requirements for air filter inspection, spark plug replacement, valve clearance adjustment, and brake system maintenance. Emission control system information documents the closed crankcase ventilation design, air cleaner configuration, and fuel permeation control technologies implemented across the model years covered.
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