🏷️ Basic Information Identification Make: Honda Model: TRX500 Fourtrax Foreman Model Variants: TRX500FE, TRX500FPE, TRX500FM, TRX500FPM, TRX500TM Model Years Covered: 2005, 2006, 2007, 2008, 2009, 2010, 2011 Codes Engine Code Series: Likely variations of the Honda TRX500 series engine, specific codes would be detailed within the manual Chassis Code Series: Likely variations of the Honda TRX500 chassis, specific codes would be detailed within the manual 👋 Introduction Market Position Target Audience: Professional mechanics, ATV technicians, and experienced DIY owners undertaking major repairs and maintenance on the specified Honda Fourtrax Foreman models. Competitive Analysis Value Proposition: Offers the most complete service and repair information available, replicating the resources used by factory-trained technicians, thus enabling cost-effective and accurate repairs. Key Features Completeness: Covers all aspects of service, repair, maintenance, and troubleshooting for the entire model range and specified years. Usability: PDF format with clickable chapters and high-quality diagrams enhances ease of use for quick information retrieval. 📋 Manual Details Coverage Areas Scope: Comprehensive service and repair information for all specified Honda TRX500 Fourtrax Foreman models and years. Page Count Number Of Pages: 550 Manual Type Type: Repair Service Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (including cylinder head, valve, cylinder, piston, crankshaft, balancer), Clutch, Gearshift Linkage, Fuel System, Lubrication System, Alternator/Starter Clutch, Crankcase, Transmission. Chassis And Body: Frame, Body Panels, Exhaust System, Front Wheel/Suspension/Steering, Rear Wheel/Suspension, Brake System. Electrical: Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Electric Shift Program (ESP - for FE/FPE models), Selectable 4WD System (except TM model), Electric Power Steering (EPS). Drivetrain: Front Driving Mechanism (Except TM Models), Rear Driving Mechanism. Procedures Included Diagnostic: Troubleshooting section, diagnosis of common issues. Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements, general upkeep. Repair And Rebuild: Complete tear down and rebuild procedures for all major components and systems. Installation: Engine removal/installation, component installation. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to advanced diagnostics and complete engine/transmission rebuilds. Suitable for professional mechanics and experienced DIY technicians. 📊 Manual Specifications File Format Quality: High quality PDF. File Size: 80 MB Navigability: Clickable chapters for easy navigation. Print Quality Print Permissions: No restrictions on printing or saving/burning to disc. Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper: Not Applicable (Digital PDF) Content Type Visuals: Includes pictures and part diagrams. ⚙️ Engine Specifications Primary Engine Type: Likely a 475cc to 500cc class liquid-cooled, 4-stroke, OHV, semi-dry sump, single-cylinder engine (specific displacement detailed in manual). Engine Layout: Longitudinal engine orientation. Valve Train: Overhead Valve (OHV) with 2 valves per cylinder, operated by a single camshaft. Performance Horsepower: Specific figures will vary by model year and tune, but generally in the range of 30-35 HP (detailed in manual). Torque: Specific figures will vary, but generally in the range of 25-30 lb-ft (detailed in manual). Fuel System Induction: Likely fuel injection (PGM-FI) for most models, potentially carbureted on earlier or specific variants (manual will specify). Fuel Type: Unleaded gasoline (refer to manual for octane rating). Lubrication System Oil Type: Specific Honda GN4 4-stroke motorcycle oil or equivalent SAE 10W-40, API SG or higher (refer to manual for exact specification and viscosity). Oil Capacity: Approx. 3.0 US qt (2.8 L) for engine oil and transmission oil combined (refer to manual for exact capacity and separate drain procedures). Ignition System Type: CDI (Capacitor Discharge Ignition) with electronic advance. Cooling System Type: Liquid-cooled. 🔧 Transmission Standard Type: TRX500FE/FPE: 5-speed automatic clutch with Electric Shift Program (ESP). TRX500FM/FPM: 5-speed manual clutch with foot shifter. TRX500TM: 5-speed manual clutch with foot shifter. Optional Optional Features: ESP for automatic shifting, electric power steering (EPS) on FPE/FPM models. Features Drive System: Shaft drive. 2WD (TM model) or 4WD (FE/FPE/FM/FPM models) with selectable 4WD system. Sub-transmission with Hi/Lo range on some models. Fluid Specification Transmission Oil Type: Honda ATV SHA Plus or equivalent SAE 10W-40 API SG or higher (integrated with engine oil sump, refer to manual for specific fill procedures). 📐 Dimensions Exterior Length: Approx. 82.2 inches (2088 mm) (Varies slightly by model variant, consult manual for exact figures). Width: Approx. 45.1 inches (1145 mm) (Varies slightly by model variant, consult manual for exact figures). Height: Approx. 46.9 inches (1191 mm) (Varies slightly by model variant, consult manual for exact figures). Weights Curb Weight: Approx. 593 lbs (269 kg) for 4x4 models (Varies by model variant, consult manual for exact figures). Towing Capacity: Typically 850 lbs (385 kg) (Refer to manual for precise specifications and limitations). Rack Capacity: Front: 99 lbs (45 kg), Rear: 198 lbs (90 kg) (Refer to manual for exact specifications). 🛡️ Safety Features Ratings Atv Safety Standards: Compliant with ANSI/SVIA standards (Specific certifications would be detailed in owner's manual or associated documentation). Active Features Braking System: Hydraulic disc brakes front and rear, often with combined braking system activated by...
Likely variations of the Honda TRX500 series engine, specific codes would be detailed within the manual
Chassis Code Series:
Likely variations of the Honda TRX500 chassis, specific codes would be detailed within the manual
👋 Introduction
Market Position
Target Audience:
Professional mechanics, ATV technicians, and experienced DIY owners undertaking major repairs and maintenance on the specified Honda Fourtrax Foreman models.
Competitive Analysis
Value Proposition:
Offers the most complete service and repair information available, replicating the resources used by factory-trained technicians, thus enabling cost-effective and accurate repairs.
Key Features
Completeness:
Covers all aspects of service, repair, maintenance, and troubleshooting for the entire model range and specified years.
Usability:
PDF format with clickable chapters and high-quality diagrams enhances ease of use for quick information retrieval.
📋 Manual Details
Coverage Areas
Scope:
Comprehensive service and repair information for all specified Honda TRX500 Fourtrax Foreman models and years.
Frame, Body Panels, Exhaust System, Front Wheel/Suspension/Steering, Rear Wheel/Suspension, Brake System.
Electrical:
Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Electric Shift Program (ESP - for FE/FPE models), Selectable 4WD System (except TM model), Electric Power Steering (EPS).
Drivetrain:
Front Driving Mechanism (Except TM Models), Rear Driving Mechanism.
Procedures Included
Diagnostic:
Troubleshooting section, diagnosis of common issues.
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, general upkeep.
Repair And Rebuild:
Complete tear down and rebuild procedures for all major components and systems.
Comprehensive, covering everything from basic maintenance to advanced diagnostics and complete engine/transmission rebuilds. Suitable for professional mechanics and experienced DIY technicians.
📊 Manual Specifications
File Format
Quality:
High quality PDF.
File Size:
80 MB
Navigability:
Clickable chapters for easy navigation.
Print Quality
Print Permissions:
No restrictions on printing or saving/burning to disc.
Binding Type
Binding:
Not Applicable (Digital PDF)
Paper Type
Paper:
Not Applicable (Digital PDF)
Content Type
Visuals:
Includes pictures and part diagrams.
⚙️ Engine Specifications
Primary Engine
Type:
Likely a 475cc to 500cc class liquid-cooled, 4-stroke, OHV, semi-dry sump, single-cylinder engine (specific displacement detailed in manual).
Engine Layout:
Longitudinal engine orientation.
Valve Train:
Overhead Valve (OHV) with 2 valves per cylinder, operated by a single camshaft.
Performance
Horsepower:
Specific figures will vary by model year and tune, but generally in the range of 30-35 HP (detailed in manual).
Torque:
Specific figures will vary, but generally in the range of 25-30 lb-ft (detailed in manual).
Fuel System
Induction:
Likely fuel injection (PGM-FI) for most models, potentially carbureted on earlier or specific variants (manual will specify).
Fuel Type:
Unleaded gasoline (refer to manual for octane rating).
Lubrication System
Oil Type:
Specific Honda GN4 4-stroke motorcycle oil or equivalent SAE 10W-40, API SG or higher (refer to manual for exact specification and viscosity).
Oil Capacity:
Approx. 3.0 US qt (2.8 L) for engine oil and transmission oil combined (refer to manual for exact capacity and separate drain procedures).
Ignition System
Type:
CDI (Capacitor Discharge Ignition) with electronic advance.
Cooling System
Type:
Liquid-cooled.
🔧 Transmission
Standard
Type:
TRX500FE/FPE: 5-speed automatic clutch with Electric Shift Program (ESP). TRX500FM/FPM: 5-speed manual clutch with foot shifter. TRX500TM: 5-speed manual clutch with foot shifter.
Optional
Optional Features:
ESP for automatic shifting, electric power steering (EPS) on FPE/FPM models.
Features
Drive System:
Shaft drive. 2WD (TM model) or 4WD (FE/FPE/FM/FPM models) with selectable 4WD system. Sub-transmission with Hi/Lo range on some models.
Fluid Specification
Transmission Oil Type:
Honda ATV SHA Plus or equivalent SAE 10W-40 API SG or higher (integrated with engine oil sump, refer to manual for specific fill procedures).
📐 Dimensions
Exterior
Length:
Approx. 82.2 inches (2088 mm) (Varies slightly by model variant, consult manual for exact figures).
Width:
Approx. 45.1 inches (1145 mm) (Varies slightly by model variant, consult manual for exact figures).
Height:
Approx. 46.9 inches (1191 mm) (Varies slightly by model variant, consult manual for exact figures).
Weights
Curb Weight:
Approx. 593 lbs (269 kg) for 4x4 models (Varies by model variant, consult manual for exact figures).
Towing Capacity:
Typically 850 lbs (385 kg) (Refer to manual for precise specifications and limitations).
Rack Capacity:
Front: 99 lbs (45 kg), Rear: 198 lbs (90 kg) (Refer to manual for exact specifications).
🛡️ Safety Features
Ratings
Atv Safety Standards:
Compliant with ANSI/SVIA standards (Specific certifications would be detailed in owner's manual or associated documentation).
Active Features
Braking System:
Hydraulic disc brakes front and rear, often with combined braking system activated by handlebar levers. Parking brake system.
4Wd System:
Selectable 4WD system (except TM model) enhances traction in various terrains.
Passive Features
Lighting:
Dual 30W headlights, 1 x 10W taillight/stoplight.
Instrumentation:
Includes speedometer, odometer, trip meter, 4WD indicator, transmission gear indicator (for ESP models), fuel gauge, clock, and various warning lights.
💡 Technology Features
Infotainment
Features:
Primarily functional instrumentation; no complex infotainment systems typical of automobiles. Focus is on essential operational data.
Driver Assistance
Power Steering:
Electric Power Steering (EPS) available on TRX500FPE and TRX500FPM models, reducing steering effort and providing better control.
Connectivity
Features:
No digital connectivity features in the modern automotive sense. Focus is on mechanical and basic electrical systems.
Electronic Shifting
Esp System:
Electric Shift Program (ESP) on FE/FPE models allows rider to select gears via handlebar-mounted buttons.
4Wd System
Selectable 4Wd:
System allowing the rider to switch between 2WD and 4WD modes, typically operated via a handlebar switch.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Recommended every 600 miles (1000 km) or 6 months, whichever comes first (refer to manual for exact interval and conditions).
Air Filter Cleaning:
Recommended inspection every 600 miles (1000 km), cleaning or replacement as needed (more frequent in dusty conditions).
Spark Plug Replacement:
Recommended every 4,000 miles (6,400 km) or 24 months (refer to manual for specific plug type and gap).
Valve Clearance Check:
Recommended every 4,000 miles (6,400 km) or 24 months (critical for engine performance and longevity).
Fluid Specifications
Coolant Type:
Honda Antifreeze/Coolant (Type 2) or equivalent, pre-mixed 50/50 with distilled water (refer to manual for exact specification and capacity).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for specific type and capacity).
Known Issues
Common Wear Items:
Brake pads, tires, drive belts (if applicable, though this model uses shaft drive), wheel bearings, suspension bushings, and ball joints are common wear items.
Electrical Component Care:
Corrosion on electrical connectors, particularly in wet conditions, can lead to intermittent issues. Regular inspection and dielectric grease application are recommended.
Esp System Maintenance:
For ESP models, ensuring proper battery voltage and clean electrical connections to the shift motor and sensors is crucial for reliable operation.
📚 Vehicle History
Brand Heritage
Atv Development:
Honda has a long and significant history in the ATV market, pioneering many features and establishing a reputation for reliability and innovation in off-road vehicles.
Model Evolution
Foreman Lineage:
The Foreman nameplate has been a staple in Honda's ATV lineup, evolving from earlier models to incorporate advancements like liquid cooling, fuel injection, independent rear suspension (on some models prior to this generation), and electronic shifting/power steering.
Production
Manufacturing Origin:
Typically manufactured in the United States or Japan by Honda Motor Co., Ltd. (specific plant details may be in the manual).
🏆 Awards & Recognition
Recognitions
Industry Reputation:
Honda ATVs, including the Foreman line, are widely recognized for their durability, reliability, and robust performance in agricultural, utility, and recreational applications. Specific model awards would be detailed in separate automotive press or Honda historical archives.
Ratings
Reliability:
Consistently rated highly by owners and industry publications for reliability and build quality.
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