2005-2008 Honda TRX500 FA/FGA Service Manual
This manual provides comprehensive service and repair procedures for the Honda TRX500 FA/FGA, covering essential systems and components. Part No. 61HN252.
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Sample pages from the 2005-2008 Honda TRX500 FA/FGA Service Manual manual
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Models Covered & Key Technical Specifications
OEM-Grade Engineering Diagnostic Manual: Honda TRX500 FA / FGA (2005-2008) Transmission-Guide
Service & Repair Guide | ATV Transmission-Kit
- Prescribed Twist Specifications: 36 N·m Torque value ensures proper assembly of the Front Carrier Bolts. (S1)
- Documented Capacity Limits: 22 N·m torque on Cylinder Head Cover Cap Nuts ensures secure closure. (S2)
- Core Measurement Bounds: 10 N·m is the specified torque for the Engine Oil Temperature Sensor to maintain correct readings. (S3)
- Rated Environmental Range: For optimal performance, the spark plug gap is set to 0.8-0.9 mm. (S4)
- Technical Rotation Data: Carburetor insulator band screw torque is 4 N·m to maintain the fuel system integrity. (S2)
- Advanced Rotation Data: The exhaust pipe band bolt requires 23 N·m for secure exhaust system function. (S1)
Professional Workshop Service Manual & Technical Specifications
OEM-Grade Engineering Diagnostic Manual: Honda TRX500 FA / FGA - Comprehensive Service & Repair Guide (2005-2008) Transmission-Guide
Coverage-Scope: 2005-2008 Honda TRX500 FA/FGA | Design-Core: ATV / Transmission Logic | Coverage-Scope: English
| Specification | Diagnostic-Logic | Validation-Data |
|---|---|---|
| Engine Oil Capacity | 4.4-5.2 Liters | Verified |
| Spark Plug Gap | 0.8-0.9 mm | Standardized |
| Idle Speed | 1400 ± 100 rpm | Calibrated |
| Front Tire Tread Depth | 4.0 mm Minimum | Verified |
| Rear Tire Tread Depth | 4.0 mm Minimum | Verified |
| Cold Tire Pressure | 25 kPa Standard | Verified |
The repository is divided into sections covering engine, transmission, electrical, and chassis systems. Each chapter offers detailed explanations of procedures, specifications, and troubleshooting.
Engine
Diagnostic procedures are covered for cylinder head, valve, and camshaft service, including detailed measurements and inspection points.
Transmission
Wiring diagrams are provided for all electrical components, ensuring accurate system diagnosis and repair.
Chassis
Fuel system procedures are documented for carburetor removal, disassembly, and adjustment, crucial for optimal engine performance.
Maintenance
Adjustment procedures are detailed for various systems including brakes, suspension, and steering, ensuring vehicle safety and control.
Cooling System
Timing procedures are documented for key engine components to ensure precise operation.
Properly requiring careful attention to detail, this manual documents torque specifications for critical components to ensure proper cyclic stress resistance and overall vehicle reliability.
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