2012 Honda FourTrax Foreman 4x4 Series Service Manual (P/N 61KRN00)

• Covers the 2012 Honda TRX500 models, including FM, FE, FPM, and FPE variants with 4WD, ESP, and EPS configurations.
• PGM-FI troubleshooting includes sensor and injector circuit tests, fuel pressure and pump flow checks, and throttle-position sensor reset.
• Engine repair procedures address the cylinder head, piston assembly, clutch linkage, and transmission, including disassembly and wear inspection.
• Front and rear final-drive service covers bearing replacement, gear backlash measurement, tooth contact checks, and shim selection.
• ESP testing addresses shift-angle sensing and shift-control motor faults; EPS coverage includes torque-sensor initialization and control-unit diagnosis.
• Chassis maintenance and repair instructions cover suspension, steering, wheel bearings, front brake caliper and master-cylinder overhaul, and rear drum brakes.
• Electrical sections address ignition, the electric starter, charging, meters, and switches, with separate wiring diagrams for each model.

This 564-page PDF contains Honda's factory service manual, written for qualified professional technicians with the training, tools, and equipment needed for the work. All four variants have selectable 2WD/4WD:

U.S. and Canadian differences are identified throughout, including Canadian recoil-starter service and electrical components such as the condenser and power relay.

Engine, Drivetrain, and Chassis Repair

The longitudinal engine chapters detail valve-guide replacement and valve-seat refacing, along with camshaft timing and automatic decompressor inspection. Internal repair coverage extends to crankcase separation, crankshaft and balancer installation, and gearshift fork and shift-drum inspection. Centrifugal and wet multi-plate clutches receive separate service procedures.

The manual identifies which assemblies can be serviced with the engine installed and which require removal. Transmission and crankshaft work involves engine removal and crankcase separation.

Front differential procedures include face-cam assembly and limited-slip torque testing. For the latter, Honda specifies differential inspection tool 07KMK-HC5010A for U.S. use. Front driveshaft coverage includes boot and inboard-joint service; a worn or damaged outboard joint requires driveshaft replacement.

Cooling and lubrication chapters document thermostat testing, cooling-system pressure tests, water-pump seal service, and oil-pump clearance inspection.

Suspension repair coverage includes front ball joints and rear swingarm pivot bearings, with toe-alignment checks in the maintenance section.

PGM-FI, ESP, and EPS Diagnostics

Symptom charts address no-start, stalling, and rough running alongside diagnostic trouble code (DTC) testing. Connector views and circuit checks support diagnosis of sensor, wiring, fuel-delivery, and control-module faults.

The ESP section explains how shared PCM faults can affect both shifting and fuel injection. EPS documentation covers protective reductions in steering assist and identifies which steering service operations require torque-sensor neutral-position initialization.

The manual describes HDS pocket-tester diagnosis and indicator blink-code retrieval using SCS service connector 070PZ-ZY30100. PGM-FI and EPS blink-code readouts report main fault codes; HDS provides subcode detail.

Technical Preview and Specifications

Detailed torque tables and lubrication charts help you identify the correct fluid capacities, operating clearances, and bolt-tightening specs. Additional reference tables provide valve clearances, cylinder and piston wear limits, spark plug gaps, and sensor resistances. Engine oil quantities distinguish draining, filter replacement, and engine disassembly.

Illustrated references include the PGM-FI System Diagram, ESP and EPS system diagrams, the Cooling System Flow Pattern, and the Lubrication System Diagram. The model-specific wiring diagrams include wire colors, connector identification, and switch-continuity tables.

Service cautions flag severe engine damage from a reversed oil filter and throttle-body damage from cleaning its internal passages with wire.

Working on ATVs carries inherent risks; always verify torque sequences and utilize proper lifting equipment before beginning any major teardown.