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TRX500FM
Honda TRX500FM Service Manual
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GENERAL
INFORMATION
HANDLEBAR
SWITCH
WIRE
REAR
BRAKE
LIGHT
SWITCH
WIRE
(
lever
side
)
1·24
Front
t
FUEL
TANK
B
R
E
A
T
H
E
R
H
OSE
IGNITION
SW
IT
C
H
B3
Ol,--!{I
GRAY
TAPE
HAN
DLEBAR
SW
ITCH
WIRE
(To
front
brake/light
switch)
Front
t
FRONT
BRAKE
I
NHIBIT
OR
SWITCH
BRAKE
LIGHT
SWITCH
I
j
29
31
Table of Contents
How to Use this Manual
2
Symbols
4
Table of Contents
5
General Information
7
Service Rules
8
Abbreviations
8
Model Identification
9
Serial Numbers
9
Labels
10
General Specifications
12
GFM-FI System Specifications
13
Ignition System Specifications
13
Electric Starter Specifications
13
Fuel System Specifications
13
Cooling System Specifications
14
Lubrication System Specifications
14
Cylinder Head/Valve Specifications
14
Cylinder/Piston Specifications
15
Clutch/Gearshift Linkage Specifications
15
Alternator/Starter Clutch Specifications
15
Crankcase/Transmission/Crankshaft/Balancer Specifications
16
Engine Removal/Installation Specifications
16
Front Wheel/Suspension/Steering Specificatons
16
Rear Wheel/Suspension Specifications
17
Brake System Specifications
17
Front Driving Mechanism Specifications
17
Rear Driving Mechanism Specifications
17
Battery/Charging System Specifications
18
Lights/Meters/Switches Specifications
18
Torque Values
19
General Information
20
Lubrication & Seal Points - Engine
25
Lubrication & Seal Points - Frame
27
Cable & Harness Routing
29
Emission Control Systems
50
Exhaust Emission Control System
50
Crankcase Emission Control System
50
Prohibited Actions
50
Noise Emission Control System
51
Fuel Permeation Emission Control System
51
Rebuilt Engine
51
Frame/Body Panels/Exhaust System
53
Frame/Body Panels/Exhaust System Service Information
54
Frame/Body Panels/Exhaust System Torque Values
54
Frame/Body Panels/Exhaust System Troubleshooting
54
Body Panel Locations
55
Seat Removal
56
Seat Installation
56
Side Cover
56
Fuel Tank Side Cover
57
Mudguards
58
Engine Guard
59
Front Grille
59
Front Fender/Carrier Removal/Installation
60
Front Fender/Carrier Disassembly/Assembly
61
Rear Fender Cover
61
Tool Box Lid
62
Rear Fender/Carrier
63
Mudguard Bracket
65
Exhaust System Removal
66
Exhaust System Installation
66
Exhaust Pipe Stud Bolt Replacement
67
Exhaust System Disassembly/Assembly
67
Maintenance
69
Maintenance - Torque Values
70
Maintenance - Tools Needed
70
Maintenance Schedule
71
Fuel Line
72
Throttle Operation
72
Air Cleaner
73
Air Cleaner Housing Drain Tube
75
Spark Plug
76
Valve Clearance
77
Engine Oil Level Check
80
Engine Oil Change
81
Oil Change Indicator Reset
81
Engine Oil Filter
82
Engine Idle Speed Inspection
83
Radiator Coolant
83
Cooling System Maintenance
84
Drive Train Boots
85
Rear Final Gear Case Oil and Differential Oil
85
Final Gear Case Oil Level Check
85
Final Gear Case Oil Change
86
Differential Oil Level Check
86
Differential Oil Change
87
2WD/4WD Select System
87
2WD/4WD Selector Cable Adjustment
87
Brake Fluid
88
Brake Shoes Wear
89
Brake Pads Wear
89
Brake Light Switch
89
Brake System Maintenance
90
Front Brake
90
Rear Brake
90
Reverse Lock System
91
Guards
92
Clutch System
92
Suspension Maintenance
93
Spark Arrester
93
Nuts, Bolts, Fasteners
93
Wheels/Tires
93
Tie-Rod and Joint Boots
94
Steering Shaft Holder Bearing
94
Steering System
94
PGM-FI System
97
PGM-FI Component Location
98
PGM-FI System Diagram
99
PGM-FI System Service Information
100
PGM-FI System Torque Values
100
PGM-FI System Specifications
100
PGM-FI System - Tools Needed
100
PGM-FI System Symptom Troubleshooting
101
PGM-FI Connector Location
103
PGM-FI - General Troubleshooting
106
System Description
106
HDS Pocket Tester Information
107
DTC Readout
107
MIL Blink Pattern
107
Erasing DTC
108
Circuit Inspection
108
Inspection at PCM/ECM Connector
108
Reading DTC with the MIL
108
PGM-FI DTC Index
109
DTC Troubleshooting
110
DTC 1-1 (MAP Sensor Low Voltage)
110
DTC 1-2 (MAP Sensor High Voltage)
111
DTC 7-1 (ECT Sensor Low Voltage)
112
DTC 7-2 (ECT Sensor High Voltage)
113
DTC 8-1 (TP Sensor Low Voltage)
114
DTC 8-2 (TP Sensor High Voltage)
115
DTC 9-1 (IAT Sensor Low Voltage)
117
DTC 9-2 (IAT Sensor High Voltage)
118
DTC 12-1 (Fuel Injector)
119
Dtc 29-1 (Iacv)
120
Dtc 33-2 (Eeprom)
121
DTC 54-1 (Bank Angle Sensor Low Voltage)
122
DTC 54-2 (Bank Angle Sensor High Voltage)
123
MIL Circuit Inspection
125
Fuel Pump Relay Inspection
125
Sensor Unit (MAP/TP Sensor) Removal/Installation
126
TP Sensor Reset Procedure
127
ECT Sensor Removal/Installation
128
ECT Sensor Inspection
128
Bank Angle Sensor Removal/Installation
129
Bank Angle Sensor Operation Inspection
129
Bank Angle Sensor Inspection with HDS Pocket Tester
130
PCM/ECM Removal/Installation
130
Power/Ground Line Inspection
131
Engine Stop Switch Line Inspection
132
Ignition System
133
Ignition System Component Location
134
Ignition System Diagram
134
Ignition System Service Information
135
Ignition System - Specifications
135
Ignition System Torque Values
135
Ignition System - Tools Needed
135
Ignition System Troubleshooting
136
No Spark at Spark Plug
136
Ignition System Inspection
137
Ignition Coil Primary Peak Voltage
137
CKP Sensor Peak Voltage
138
Ignition Coil Removal/Installation
139
Ignition Timing
140
Condenser (Canada Type) Removal/Installation
140
Condenser (Canada Type) Inspection
141
Rectifier (Canada Type) Removal/Installation
142
Rectifier (Canada Type) Inspection
142
Electric Starter
143
Electric Starter - Component Location
144
Electric Starter - System Diagram
144
Electric Starter - Service Information
145
Electric Starter Torque Values
145
Electric Starter - Specifications
145
Electric Starter Troubleshooting
146
Starter Motor Removal/Installation
148
Starter Motor Disassembly/Assembly
148
Starter Motor Inspection
149
Starter Relay Switch - Operation Inspection
150
Starter Relay Switch - Circuit Inspection
151
Starter Relay Switch - Continuity Inspection
151
Starter Relay Switch - Removal/Installation
151
Diode Removal/Installation
152
Diode Inspection
152
Fuel System
153
Fuel System Exploded Diagram
154
System Components
154
Fuel System - Service Information
155
Fuel System - Specifications
155
Fuel System Torque Values
155
Fuel System - Tools Needed
156
Fuel Line Troubleshooting
157
Fuel Line Inspection
158
Fuel Pressure Relieving
158
Quick Connect Fitting Removal
158
Injector Side
159
Quick Connect Fitting Installation
161
Fuel Pump Side
161
Quick Connect Fitting Installation - Injector Side
162
Fuel Pressure Increasing
163
Fuel Pressure Inspection
163
Fuel Flow Inspection
164
Sub-Fuel Tank/Fuel Pump Inspection
165
Throttle Body Cover Removal/Installation
165
Sub-Fuel Tank/Fuel Pump Removal/Installation
166
Sub-Fuel Tank/Fuel Pump Disassembly
166
Fuel Pump Filter Replacement (Type A)
167
Fuel Pump Unit Holder Removal (Type A)
169
Fuel Pump Filter Replacement (Type B)
169
Sub-Fuel Tank/Fuel Pump Assembly
171
Fuel Tank Removal/Installation
172
Fuel Strainer Screen Cleaning
173
Air Cleaner Housing Removal/Installation
174
Throttle Body Removal
175
Throttle Body Disassembly/Assembly
176
Throttle Body Installation
177
IACV Inspection
178
IACV Removal/Installation
179
Fuel Injector Inspection
180
Fuel Injector Removal
180
Fuel Injector Installation
181
Cooling System
183
Cooling System Flow Pattern
184
Cooling System Service Information
185
Cooling System - Specifications
185
Cooling System Torque Values
185
Cooling System - Tools Needed
186
Cooling System Troubleshooting
186
Cooling System Testing
187
Coolant (Hydrometer Test)
187
Coolant Replacement
188
Recommended Antifreeze
188
Radiator Cap/System Pressure Inspection
188
Coolant Replacement/Air Bleeding
189
Thermostat Removal/Installation
190
Radiator/Cooling Fan
191
Radiator Removal/Installation
191
Thermostat Inspection
191
Cooling Fan Removal/Installation
192
Radiator Reserve Tank Removal/Installation
193
Water Pump: Mechanical Seal Inspection
193
Mechanical Seal Replacement
194
Lubrication System
197
Lubrication System Diagram
198
Lubrication System Service Information
199
Lubrication System - Specifications
199
Lubrication System Troubleshooting
199
Oil Pump Removal
200
Oil Pump Disassembly/Inspection
200
Oil Pump Assembly
201
Oil Pump Installation
201
Relief Valve Disassembly/Inspection
202
Relief Valve Assembly
202
Cylinder Head/Valve
203
Cylinder Head/Valve - System Components Diagram
204
Cylinder Head/Valve - Service Information
206
Cylinder Head/Valve - Specifications
206
Cylinder Head/Valve Torque Values
206
Cylinder Head/Valve - Tools Needed
207
Cylinder Head/Valve Troubleshooting
208
Cylinder Compression
209
Cylinder Head Cover Removal/Disassembly
209
Rocker Arm/Shaft Inspection
211
Push Rod Inspection
211
Cylinder Head Disassembly
212
Cylinder Head Inspection
213
Valve Spring Check
213
Valve/Valve Guide Check
213
Valve Guide Replacement
214
Valve Seat Inspection
215
Valve Seat Refacing
215
Cylinder Head Assembly
216
Cylinder Head Installation
218
Cylinder Head Cover Assembly/Installation
219
Cylinder Head Cover Installation
221
Camshaft Removal
222
Camshaft Inspection
223
Cam Chain Tensioner Inspection
224
Cam Follower Inspection
224
Camshaft Installation
225
Cylinder/Piston
229
Cylinder/Piston - System Components Diagram
230
Cylinder/Piston - Service Information
231
Cylinder/Piston - Specifications
231
Cylinder/Piston - Torque Value
231
Cylinder/Piston Troubleshooting
231
Cylinder/Piston Removal
232
Cylinder Removal
232
Piston Removal
232
Cylinder Inspection
233
Piston/Piston Ring Inspection
234
Cylinder Stud Bolt Replacement
236
Cylinder/Piston Installation
236
Piston Ring Installation
236
Piston Installation
237
Cylinder Installation
237
12. Clutch/Gearshift Linkage
239
Clutch/Gearshift Linkage - System Components Diagram
240
Clutch/Gearshift Linkage - Service Information
241
Clutch/Gearshift Linkage - Specifications
241
Clutch/Gearshift Linkage Torque Values
241
Clutch/Gearshift Linkage - Tools Needed
242
Clutch/Gearshift Linkage Troubleshooting
243
Front Crankcase Cover Removal
244
Crankshaft Bearing Replacement
245
Clutch Lifter
245
Centrifugal Clutch Removal
246
Centrifugal Clutch Disassembly/Inspection
246
One-Way Clutch
246
Clutch Drum Check
247
Drive Plate Check
247
Clutch Weight Lining Check
247
Clutch Spring Removal
248
Weight Spring Check
248
Centrifugal Clutch Assembly
249
Centrifugal Clutch Installation
250
Change Clutch Disassembly
251
Clutch Lifter Inspection
253
Clutch Disc Check
254
Clutch Plate Check
254
Clutch Center Check
254
Clutch Outer Check
254
Clutch Outer Guide Check
255
Primary Drive Gear Check
255
Mainshaft and Crankshaft Check
255
Change Clutch Assembly
255
Gearshift Linkage Removal
257
Gearshift Linkage Installation
259
Gearshift Spindle a (FM/FPM Models Only)
260
Front Crankcase Cover Installation
261
Alternator/Starter Clutch
263
Alternator/Starter Clutch - System Components Diagram
264
Alternator/Starter Clutch - Service Information
266
Alternator/Starter Clutch - Specifications
266
Alternator/Starter Clutch - Torque Values
266
Alternator/Starter Clutch - Tools Needed
267
Alternator/Starter Clutch Troubleshooting
267
Recoil Starter (Canada Type) Removal/Installation
268
Starter Rope Replacement
268
Alternator Stator
268
Rear Crankcase Cover Removal
268
Stator and CKP Sensor Removal
270
Stator and CKP Sensor Installation
270
Output Shaft Bearing Replacement
270
Rear Crankcase Cover Installation
271
Flywheel/Starter Clutch Removal
273
Starter Clutch Disassembly
274
Starter Clutch Inspection
274
Starter Clutch Assembly
275
Starter Clutch Installation
276
Starter Motor Bearing Replacement
278
Crankshaft/Transmission/Crankshaft/Balancer
279
Crankshaft/Transmission/Crankshaft/Balancer - System Components Diagram
280
Crankshaft/Transmission/Crankshaft/Balancer - Service Information
281
Crankshaft/Transmission/Crankshaft/Balancer - Specifications
281
Crankshaft/Transmission/Crankshaft/Balancer - Torque Value
281
Crankshaft/Transmission/Crankshaft/Balancer - Tools Needed
282
Crankshaft/Transmission/Crankshaft/Balancer Troubleshooting
284
Crankcase Separation
285
Oil Strainter Cleaning
286
Transmission Disassembly
286
Gear/Bushing/Shaft Inspection
287
Output Shaft/Gear
288
Shift Fork/Shaft
288
Shift Drum
289
Transmission Assembly
289
Crankshaft/Balancer Removal
293
Crankshaft/Balancer Inspection
293
Crankshaft/Balancer Installation
294
Crankcase/Transmission/Crankshaft/Balancer
295
Crankcase Bearing Inspection
296
Front Crankcase Bearing Replacement
296
Rear Crankcase Bearing Replacement
298
Crankcase Assembly
299
Engine Removal/Installation
301
Engine Removal/Installation - System Components Diagram
302
Engine Removal/Installation - Service Information
303
Engine Removal/Installation - Specifications
303
Engine Removal/Installation - Torque Values
303
Engine Removal
304
Engine Installation
309
16. Front Wheeususpension/Steering
315
Front Wheel/Suspension/Steering - System Components Diagram
316
Front Wheel/Suspension/Steering - Service Information
318
Front Wheel/Suspension/Steering - Specifications
318
Front Wheel/Suspension/Steering - Torque Values
319
Front Wheel/Suspension/Steering - Tools Needed
320
Front Wheel/Suspension/Steering Troubleshooting
321
Handlebar Removal
322
Handlebar Installation
323
Throttle Housing Disassembly
325
Throttle Housing Assembly
326
Front Wheel Removal
327
Front Wheel Installation
327
Tires Removal
327
Tire Repair
328
Tire Assembly
330
Wheel Hub and Knuckle Removal
330
Wheel Hub and Knuckle Inspection
333
Brake Disc Replacement
333
Bearing Replacement
333
Ball Joint Replacement
335
Ball Joint Installation
336
Suspension Arm Removal
337
Suspension Arm Inspection
338
To Replace the Ball Joint
338
Suspension Arm Installation
339
Front Shock Absorber Removal
340
Fron Shock Absorber Inspection
340
Front Shock Absorber Installation
341
Steering Shaft (FM/FE Models) Removal
341
Shaft Bushing Inspection
343
Steering Shaft Inspection
343
Steering Shaft Bearing Inspection
343
Steering Shaft Assembly
344
Steering Shaft/Eps Unit (FPM/FPE Models) Removal
346
Steering Shaft Check
348
Shaft Bushing Check
349
EPS Unit Check
349
Steering Shaft Bearing Check
349
Steering Shaft Bearing Replacement
349
Steering Shaft/Eps Unit (FPM/FPE Models) Installation
350
Tie-Rod Removal
354
Tie-Rod Inspection
355
Tie-Rod Disassembly/Assembly
355
Rear Wheel/Suspension
357
Rear Wheel/Suspension - System Components Diagram
358
Rear Wheel/Suspension - Service Information
359
Rear Wheel/Suspension - Specifications
359
Rear Wheel/Suspension - Torque Values
359
Rear Wheel/Suspension - Tools Needed
360
Rear Wheel/Suspension - Troubleshooting
361
Rear Wheel Removal
362
Rear Wheel Installation
362
Rear Shock Absorber Removal
362
Rear Shock Absorber Inspection
363
Rear Shock Absorber Installation
363
Swingarm Removal
364
Swingarm Bearing Replacement
365
Swingarm Installation
366
Brake System
367
Brake System Components Diagram
368
Brake System Components - Service Information
370
Brake System Components Specifications
370
Brake System Components Torque Values
371
Brake System Components - Tools Needed
371
Brake System Components Troubleshooting
372
Brake Fluid Replacement/Air Bleeding
373
Brake Fluid Draining
373
Brake Fluid Filling/Bleeding
373
Brake Pad/Disc
374
Brake Pad Replacement
374
Brake Disc Inspection
375
Front Master Cylinder Removal
376
Front Master Cylinder Disassembly/Assembly
376
Front Master Cylinder Inspection
377
Front Master Cylinder Installation
377
Front Brake Caliper Disassemlby
378
Front Brake Caliper Inspection
379
Front Brake Caliper Assemlby
379
Rear Brake Drum/Shoes
382
Brake Drum Removal
382
Brake Drum Inspection
382
Brake Drum Disassembly
383
Brake Drum Assembly
383
Brake Drum Installation
385
Rear Brake Pedal Removal
386
Rear Brake Pedal Installation
386
19. Front Driving Mechanism
389
Front Driving Mechanism - System Components Diagram
390
Front Driving Mechanism - Service Information
391
Front Driving Mechanism - Specifications
391
Front Driving Mechanism - Torque Values
391
Front Driving Mechanism - Tools Needed
392
Front Driving Mechanism - Troubleshooting
394
Front Drive Shaft Removal
395
Front Drive Shaft Disassembly/Inspection
395
Front Drive Shaft Assembly
397
Front Drive Shaft Installation
399
Front Final Drive Removal
400
Front Propeller Shaft Disassembly/Inspection
402
Front Final Drive Operation Check
402
Front Propeller Shaft Assembly
403
Front Final Clutch Disassembly
404
Front Final Clutch Inspection
405
Pinion Joint Ball Bearing Replacement
405
Front Final Clutch Assembly
407
Front Final Gear Assembly/Inspection
410
Backlash Inspection
410
Front Final Gear Disassemblyi
410
Differential Removal
411
Gear Tooth Contact Pattern Check
412
Differential Inspection
414
Differential Disassembly
414
Differential Components Inspection
415
Ring Gear Check
415
Differential Housing/Face Cam/Cam Follower Check
415
Side Cone Spring Check
416
Pinion Gear Removal
416
Pinion Ball Bearing and Shim Replacement
417
Gear Case Bearing Replacement
418
Pinion Joint Needle Bearing Replacement
418
Differential Bearing
418
Pinion Needle Bearing
419
Front Final Gear Assembly
421
Pinion Gear Installation
421
Differential Assembly
422
Final Gear Case Assembly
424
Front Final Drive Installation
425
20. Rear Driving Mechanism
429
Rear Driving Mechanism - System Components Diagram
430
Rear Driving Mechanism - Service Information
431
Rear Driving Mechanism - Specifications
431
Rear Driving Mechanism - Torque Values
431
Rear Driving Mechanism - Tools Needed
432
Rear Driving Mechanism Troubleshooting
434
Rear Axle Removal
435
Rear Axle Inspection
436
Rear Axle Bearing Check
436
Rear Axle Bearing Replacement
436
Axle Housing
436
Rear Final Drive Removal
437
Propeller Shaft Inspection
438
Universal Bolt Check
439
Propeller Shaft Operation Check
439
Joint Boot Replacement
439
Rear Final Gear Disassembly/Inspection
440
To Inspect the Backlash
440
Rear Final Gear Case Disassembly
441
Checking Gear Tooth Contact Pattern
441
Removing the Pinion Gear
443
Pinion Bearing and Shim Replacement
444
Gear Case Bearing
444
Gear Case Bearing: Replacement
445
Ring Gear Bearing
445
Rear Final Gear Assembly
447
Pinion Gear - Installation
448
Ring Gear Clearance Inspection
449
Rear Final Drive Installation
450
Rear Axle Installation
452
Battery/Charging System
455
Battery/Charging System - Component Location Diagram
456
Battery/Charging System Diagram
456
Battery/Charging System Diagram (Canada Type)
457
Battery/Charging System - Service Information
458
Battery Charging and Testing
458
Battery/Charging System - Specifications
458
Battery/Charging System - Tools Needed
459
Battery/Charging System Troubleshooting
460
Battery Removal/Installation
462
Voltage Inspection
462
Battery Testing
462
Battery Charging (USA Only)
462
Current Leakage Inspection
463
Charging Voltage Inspection
463
Alternator Charging Coil Inspection
464
Regulator/Rectifier Removal/Installation
464
Wire Harness Inspection
464
Power Relay (Canada Type) Inspection
465
22. Lights/Meters/Switches
467
Lights/Meters/Switches - Component Location Diagram
468
Lights/Meters/Switches - Service Information
469
Lights/Meters/Switches - Specifications
469
Lights/Meters/Switches - Torque Values
469
Lights/Meters/Switches - Tool Needed
469
Assist Headlight Bulb Replacement
470
Assist Headlight Removal/Installation
470
Headlight Bulb Replacement
471
Headlight Removal/Installation
471
Brake/Taillight Replacement
472
Combination Meter Removal/Installation
472
Brakeft AILLIGHT
472
Power/Ground Line - Inspection
473
Serial Communication Line
473
Speedometer
475
Accessory Socket Inspection
476
Accessory Socket Replacement
476
Ignition Switch Inspection
477
Ignition Switch Replacement
477
Handlebar Switch Inspection
477
Front Brake Switch Inspection
478
Front Brake Switch Replacement
479
Rear Brake Light Switch
479
Lever Switch Inspection
479
Lever Switch Replacement
479
Pedal Switch Inspection
480
Gear Position Switch Inspection
480
Gear Position Switch Replacement
480
Cooling Fan
481
Fuse Inspection
481
PGM-FI System OTC Inspection
481
Ground Line Inspection
481
Cooling Fan Operation Inspection
482
Cooling Fan Ground Line Inspection
482
Cooling Fan Power Input Line Inspection
482
4Wd Select Switch
483
Fuel Gauge/Fuel Level Sensor Removal/Installation
484
Lights/Meters/Switches - System Inspection
485
Fuel Level Sensor Inspection
486
Electric Shift Program (ESP: FE/FPE Models)
487
ESP Component Location
488
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE Models)
488
ESP System Diagram
489
ESP: Service Information
490
ESP Torque Value
490
ESP - Tools Needed
490
ESP Troubleshooting
491
Electric Shift Does Not Operate
492
Shifting Operation Check
492
Gearshift Switch Inspection at PCM Connecto
492
Gearshift Switch Inspection
492
ESP Connector Location
493
ESP Troubleshooting Information
496
Indicator Blinking Pattern
496
Current Dtc/Stored DTC
496
HDS Pocket Tester Usage
497
How to Connect the HDS Pocket Tester
497
Reading DTC with the Gear Position Indicator
497
To Erase DTC
498
Inspection at PCM Connector
498
ESP DTC Index
499
DTC: Troubleshooting
500
Verify Proper Connector Contact
500
DTC 11-1 (VS Sensor no Signal)
500
DTC 21-1 (Shift Angle Sensor Low Voltage)
501
DTC 21-2 (Shift Angle Sensor High Voltage)
503
DTC 22-1/22-2 (Shift Angle Sensor Response: Control Motor Lock/Stuck)
504
DTC 23-1 (Shift Angle Sensor Response: Voltage Variation)
505
DTC 24-1 (Shift Control Motor Drive Circuit)
506
DTC 32-1 (Fail-Safe Relay Circuit)
507
DTC 41-1 (Gear Position Switch Circuit: Short)
508
DTC 41-2 (Gear Position Switch Circuit: Open)
509
DTC 42-1 (Gearshift Switch Circuit)
511
VS Sensor Removal/Installation
513
Shift Angle Sensor Inspection
513
Shift Angle Sensor Removal
514
Shift Angle Sensor Installation
514
Gearshift Switch - System Inspection
515
Shift Control Motor/Reduction Gears
516
Control Motor Removal
516
Reduction Gears Removal
516
Shift Control Motor/Reduction Gears Installation
517
Electric Power Steering (EPS: FPM/FPE Models)
519
EPS Component Location
520
EPS System Diagram
521
EPS System - Service Information
522
EPS System - Tools Needed
522
EPS System - Symptom Troubleshooting
522
EPS Connector Location
523
EPS Troubleshooting Information
527
Restriction on Power Assist Operation
527
Torque Sensor Neutral Position (Torque Sensor Initialization)
527
How to Troubleshootin EPS DTC
528
HDS Pocket Tester Application
528
On DTC Readout
528
Erase DTC
529
Torque Sensor Initialization
531
Circuit Inspection at EPS ECU and PCM/ECM Connector
533
EPS DTC Index
534
Verifying Proper Connector Contact
536
DTC 11-1: Excessive Change of Vehicle Speed Signal (Regular Diagnosis)
536
Dtc Troubleshooting
536
DTC 11-02: Comparison between Vehicle Speed and Engine Speed Signal (Regular Diagnosis)
537
DTC 13-01: EPS ECU Internal Circuit (Lower FET Stuck On) (Initial Diagnosis)
537
DTC 15-01: 2WD/4WD Select Signal Blinking (Regular Diagnosis)
539
DTC 15-02: 2WD/4WD Select Signal Input Line (Regular Diagnosis)
540
DTC 16-01, 16-02, 17-01, 17-02, 18-01, 18-02, 18-05, 18-06, 33-02,3 5-01 , 35-03, or 35-04: EPS ECU Internal Circuit
541
DTC 18-03: EPS ECU Internal Circuit (Current Sensor Stuck Low) (Initial Diagnosis)
542
DTC 22-01: Failure to Initialize the Torque Sensor (Initial Diagnosis)
543
DTC 23-01: Low/High Voltage for the Torque Sensor (VT1 and VT2) (Regular Diagnosis)
544
DTC 23-02: Torque Sensor (VT3 Differential Amplification Function) (Regular Diagnosis)
546
DTC 24-01: Engine Speed Signal (Regular Diagnosis)
547
DTC 31-01: Low/High IG1-Terminal Voltage (Initial Diagnosis)
548
DTC 32-01: Low/High VBU Voltage (Regular Diagnosis)
549
EPS Indicator Circuit Inspection
550
EPS Indicator Does Not Come on
550
EPS Indicator Does Not Go Off, and no Dtcs Are Stored
551
EPS ECU Removal/Installation
553
Wiring Diagrams
555
FM Model Wiring Diagram
556
FE Model Wiring Diagram
557
FPM Model Wiring Diagram
558
FPE Model Wiring Diagram
559
Index
563
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Owner's Manual
258 pages
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Honda TRX500FM Specifications
General
Brand
Honda
Model
TRX500FM
Category
Offroad Vehicle
Language
English
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