Honda TRX500FM Service Manual

2WD/4WD SELECT SYSTEM ·· ............................ ····· 3-19
4WD SELECT SWITCH ············ ............. ·······22-17
ACCESSORY SOCKET ···
........ . .............. "' 22-10
AIR CLEANER ...................... -.- ···································· 3-5
AIR CLEANER HOUSING ................................. ·········7-19
AIR
CLEANER HOUSING DRAIN TUBE· ·······················3-7
ALTERNATOR CHARGING COIL ······························21-10
ALTERNATQRSTATOR ................................... ... 13-6
ASSIST HEADLIGHT······ .. · .. ·· .... ····· .. ··· ...... ··· .. · .. · .... ·· ,,, 22.-4
BANK ANGLE SENSOR ···· .. ············· .. ············ .. ·········· .. 4-33
BATIERy ············· ...................................................... '· 21-8
BODY
PANEl LOCATIONS ...................................... "' 2-3
BRAKE FLUiD· ····· ... ..... ....................... ... ................ ···· 3-20
BRAKE FLUID REPLACEMENT/AIR BLEEDING .... "' 18 -7
BRAKE LIGHT SWITCH ···············································3- 21
BRAKE PAD/DISC ,... .......................... ·· ·· ······ ,8-8
BRAKE PADS WEAR ······················,····························3-21
BRAKE SHOES WEAR ··' ........... - .. ········· ·_ -_············· 3-21
BRAKE SYSTEM ........................ ································ 3-22
BRAKEIT AILLlGHT· .... ... .... -........................................ 22-6
CABLE
& HARNESS ROUTING ··································· 1-23
CAMSHAFT INSTALLATION ······································ 10-23
CAMSHAFT
REMOVAL .. .. ............... . ........ 10-20
CENTRIFUGAL CLUTCH ·············································
,2-8
CHANGE CLUTCH ············································ .. ··· ···· 12· 13
CHARGING SYSTEM INSPECTION ····························21-9
CLUTCH
SySTEM ····· ···· ············ ·· ············· · ·· ··· ···3- 24
CO MBINATION METER ... ······22-6
COMPONENT LOCATION
BATTERY/CHARGING SYSTEM " ................... ······ 21-2
ELECTRIC POWER STEERING (EPS ) ···················24-2
ELECTRIC SHIFT PROGRAM (ESP) ······················23
-2
ELECTRIC STARTER .......... , ......................... "' 6-2
IGNITION
SyS TEM ········ ....................... ··················· 5-2
LIGHTS/METERS/SWITCHES
................................. 22-2
PGM-FI SYSTEM
...................................................... '4-2
CONDENSER (Canada type) ········································· 5-8
CONNECTOR LOCATION
ElECTRIC POWER STEERING (EPS) ··········· 24-5
ELECTRIC SHIFT PROGRAM (ESP)······················23-7
PGM-FI SYSTEM ,,,
..................................... ············· 4 -7
COOLANT REPLACEMENT ............................... ··-········ 8-6
COOLING
FAN · .... ........... ........ . .......... ········ 22-15
COOLING SySTEM ······················· ·········· 3-16
COOLING SYSTEM FLOW PATTERN
.. ·························8-2
COOLING SYSTEM TESTING ·······································8-5
CRANKCASE ASSEMBLY ···············-························· 14·21
CRANKCASE BEARING ·······
.................. ··················14-18
CRANKCASE SEPARATION ··················· ········,· 14-7
CRANKSHAFTIBALANCER
.................... . ........ 14·15
CYLINDER COMPRESSiON ···· ·· ············· ..... ........ 10-7
CYLINDER
HEAD ASSEMBL Y··································· ,0-14
CYLINDER HEAD COVER ASSEMBL YI
INSTALLATION
··· ............................................... ········ ,0 - 17
CYLINDER HEAD COVER REMOVAU
DISASSEMBLY .......................................................... , 10-7
CYLINDER HEAD DiSASSEMBLy···· ························ 10-10
CYLINDER HEAD INSTALLATION .......................... ' 10-16
CYLINDER HEAD REMOVAL .............. ····················10-9
CYLINDER/PISTON INSTALLATION
........ ................. " 11-6
CYLINDER/PISTON REMOVAL ························· .. ········ 11-4
DIODE···························
............................. ······ 6-10
DRIVE TRAIN BOOTS
....... . ...... . . .............. ········3-17
DTCINDEX
ELECTRIC POWER STEERING (EPS)
......... ·······24 -16
ELECTRIC SHIFT PROGRAM (ESP) ····················23-13
PGM-FI SYSTEM
......... ················ 4-13
DTC TROUBLESHOOTING
ELECTRIC POWER STEERING (EPS) '
.... ··········24· 16
INDEX
ELECTRIC SHIFT PROGRAM (ESP)····· .. ············· 23-14
PGM-FI···································· .............. ················· 4-14
ECT SENSOR
.......................................... ················· 4-32
EMISSION CONTROL SYSTEMS
............. ················ 1-44
ENGINE GUARD ···········-····························
.. ·················· 2-7
ENGINE IDLE SPEED······ ················
·· ·· ························ 3-15
ENGINE INSTALLATION · .................................. ····· ··,5-9
ENGINE OIL '" .................... ····························3-12
ENGINE OIL FILTER ···············
................................... 3-14
ENGINE REMOVAL .................................................. 15-4
EPS ECU ................................................................... 24-35
EPS INDICATOR CIRCUIT INSPECTION ................. 24-32
ESP BEFORE TROUBLESHOOTING· ······ . .. 23-5
EXHAUST SySTEM ·········································· .. ········· 2-14
FL YWHEEUST ARTER CLUTCH .......................... -.... 13-11
FRONT BRAKE CALiPER ·········································· 18-12
FRONT BRAKE
SWiTCH ·······································,··· 22-12
FRONT
CRANKCASE COVER INSTALLATION··· .. ··· 12-23
FRONT
CRANKCASE COVER REMOVAL········ ...... 12-6
FRONT
DRIVE SHAFT··············· .. ································ 19· 7
FRONT FENDER/CARRIER ··········································2-8
FRONT FINAL CLUTCH .. ····································· ···· 19-16
FRONT FINAL DRIVE INSTALLATION '" .................. 19-37
FRONT
FINAL DRIVE REMOVAL·· .. ·························· 19-12
FRONT
FINAL GEAR ASSEMBLY························-··· 19-33
FRONT
FINAL GEAR CASE BEARING
REPLACEMENT ...
.. .................................................... 19-30
FRONT FINAL
GEAR DISASSEMBL YI
INSPECTION
......... ......... ··································· 19-22
FRONT GRILLE······························································ 2-7
FRONT MASTER
CYLINDER ···································· 16-10
FRONT PROPELLER SHAFT········_······· ··_··············· 19-14
FRONT SHOCK ABSORBER ................ ··············16-26
FRONT WHEEL······························ ·· ·························· ,6-13
FUEL GAGEiFUEL LEVEL SENSOR .. ·········· .. ··········· 22-16
FUEL INJECTOR································ ........................ 7-25
FUEL LINE .................... ··········, ································ ·· ·· 3-4
FUEL
LINE INSPECTION···· ................................... ···· · 7-6
FUEL PUMP
RELAY ......................................... ·········· 4-29
FUEL TANK ·································································· 7-18
FUEL
TANK COVER ······················································ 2-5
FUEL
TANK SIDE COVER············································· 2-5
GEAR
POSITION SWITCH ..................................... 22-14
GEARSHIFT LINKAGE···· .................. .. ..................... 12-19
GEARSHIFT SWITCH ............... , .......................... ···· 23-29
GUARDS
.................................................................... 3-24
HANDLEBAR············· ..............•............... .................. 16-8
HANDLEBAR SWiTCH ······ ·· ................... ······· 22-11
HEADLIGHT ................................ ............. ··················22-5
IACV
.................................................................... ····· 7-24
IGNITION COIL
.............................. -........................... 5-7
IGNITION SWiTCH·····················,·······························22-11
IGNITION SYSTEM INSPECTION
.............................. 5-5
IGNITION TIMING .......................................................... 5--8
LUBRICATION & SEAL POINTS .. ······"""""""""""""1-19
LUBRICATION SYSTEM DIAGRAM .............................. 9-2
MAINTENANCE SCHEDULE ...... ······························· ··3-3
Mil CIRCUIT INSPECTION ................... ····················· 4-29
MODEL IDENTIFICATION ............................................. 1-3
MUDGUARD··································································· 2-6
MUDGUARD
BRACKET .......... .................................... 2-13
NUTS, BOLTS . FASTENERS" ................................ ··· 3-25
Oil PUMP ' ..................................................................... 9-4
PCMlECM ··········
.. ·· .. ···· .. ························•··· • .......... ······· 4-34
POWER
RELAY (Canada type)············ ·· ···················· 21-11
RADIATOR COOLANT····· ············ · ·· ········ ......... - ... ······3- 15
RADIATOR RESERVE TANK ...................................... 8-1 1
RADIATORlCOOUNG FAN ... ....................................... 8-9
REAR AXLE
INSTALLATION ........... ····················· .. ·· 20-24

Honda TRX500FM Specifications

General

Brand	Honda
Model	TRX500FM
Category	Offroad Vehicle
Language	English