2005-2008 Honda TRX500 FA/FGA Service Manual • P/N 61HN252, published November 2004

Honda TRX500 FA/FGA 2005–2008 Technical Coverage

• Covers 2005–2008 Honda TRX500 FA and FGA Rubicon all-terrain vehicles, featuring the HONDAMATIC transmission and 499cc liquid-cooled engine configurations.
• Official American Honda Motor Co. publication (Form 61HN252, published November 2004) spanning 540 pages across 27 chapters.
• Provides comprehensive reference data for routine maintenance and full vehicle repair planning.
• Delivered as an instant download the moment your payment clears.
• Indexed PDF search covers every chapter and appendix for rapid navigation.
• Stored securely in your account so you can retrieve it after a hard drive loss.

Documented Systems and Workshop Utility

This factory reference serves as the primary technical foundation for the 2005–2008 Rubicon build, encompassing U.S.A., Canada, and international configurations. The content logically segments the ATV into mechanical and electrical sections. Technicians will find detailed parameters ranging from the double-cradle frame and suspension geometry to the intricate transmission assembly. Identification procedures for the engine serial number and chassis VIN are clearly outlined to ensure accurate part sourcing.

Adhering to accurate technical specifications is critical for safe workshop practices; improper torque applications or incorrect fluid levels can lead to catastrophic component failure or compromise rider safety. This document provides the exact factory data for fuel delivery, ignition timing, and filtering systems. Maintenance workflows directly address spark plug standards and drive shaft boot inspections, giving mechanics the necessary numbers for long-term vehicle care.

Specifications and Reference Data

The manual documents precise torque values for critical fasteners, establishing a reliable baseline for any major overhaul or repair assessment. For example, it specifies 36 N·m for front carrier bolts and 53 N·m for cylinder head cover nuts. Electrical system references include triple-phase output alternator data and exact fuse ratings for the control systems.

Fluid capacities are meticulously detailed to prevent guesswork on the shop floor. The coolant system requires 1.7 liters for the radiator and engine, while the engine oil capacity reaches 5.2 liters after full disassembly. The text further outlines critical wear limits for clutch weights and cylinder bore diameters. Intake valve clearance is precisely listed at 0.15 mm, and engine oil pressure must register above 150 kPa at 1,400 rpm.