2004 Honda TRX500FE FM TM FourTrax Foreman Repair Service Manual 448 Pages

The document is a Honda service manual for TRX500 models, detailing maintenance, safety precautions, specifications, troubleshooting, and repair procedures. It includes step-by-step instructions for servicing components like the engine, clutch, transmission, and electrical systems, emphasizing the use of genuine parts and proper tools for safety and reliability.

The Honda TRX500 models covered in the service manual include the TRX500TM, TRX500FM, and TRX500FE. These models are part of the 2004 production year as indicated in the manual’s issue date.

The manual covers the following types of TRX500 models:

•    TRX500TM: 2WD with a left foot-operated gearshift.

•    TRX500FM: 4WD with a left foot-operated gearshift.

•    TRX500FE: 4WD with an Electric Shift Program (ESP).
These models are included in the service procedures and specifications outlined in the manual.

General Safety and Maintenance

•    Follow procedures carefully to avoid injury or vehicle damage.

•    Use genuine Honda parts or equivalent for replacements.

•    Wear protective gear like gloves, goggles, and safety shoes during servicing.

•    Ensure proper ventilation when running the engine to avoid carbon monoxide poisoning.
Vehicle Specifications and Features

•    Covers TRX500 models: TM (2WD), FM (4WD), FE (4WD with ESP).

•    Engine: 475.3 cm³ single-cylinder, air-cooled with oil cooler.

•    5-speed transmission with reverse gear; FE model has electric shift.
Maintenance Guidelines

•    Perform scheduled maintenance to ensure reliability and safety.

•    Check and adjust valve clearance, spark plug, and engine oil regularly.

•    Use Pro Honda GN4 or HP4 engine oil; avoid oils with molybdenum additives.
Troubleshooting and Repairs

•    Hard shifting may result from faulty clutch adjustment or damaged gearshift components.

•    Engine starting issues may stem from clogged fuel lines or faulty ignition systems.

•    Inspect bearings, gears, and clutch components for wear or damage during repairs.
Tools and Torque Values

•    Use specialized tools like clutch holders and bearing removers for repairs.

•    Follow torque specifications for bolts to ensure proper assembly.
Electrical and Wiring

•    Battery voltage: Fully charged at 13.0–13.2V; undercharged below 12.3V.

•    Inspect for short circuits or faulty regulator/rectifier in case of charging issues.
Frame and Body Assembly

•    Reinstall body panels, fenders, and exhaust components in reverse order of removal.

•    Tighten bolts to specified torque values for stability and safety.

Troubleshooting Steps for Engine Issues in TRX500 Models:

1.    General Safety and Preparation:
    
•    Ensure the engine is off before servicing unless specified otherwise to avoid hazards like burns or carbon monoxide poisoning. Let the engine cool before working on hot parts.
    
•    Use appropriate safety gear, including gloves and eye protection, when handling sharp or hot parts.

2.    Gearshift and Transmission Troubleshooting:
    
•    If the gears cannot be manually shifted, inspect the transmission or gearshift linkage for faults.
    
•    Verify if the gear position indicator displays the correct gear position during manual gear changes. If not, troubleshoot the gear position switch system.

3.    Electric Shift Program (ESP) System:
    
•    Inspect the electric shift system for issues like incorrect gear position indication or failure to operate. Follow the diagnostic codes displayed on the gear position indicator to identify specific problems.
    
•    Check the continuity and connections of components like the ECM, angle sensor, and gear position switch.

4.    Ignition System:
    
•    Inspect the ignition pulse generator for proper voltage (minimum 0.7V) at both the ECM and alternator connections. Replace faulty components or repair wiring as needed.

5.    Throttle Position (TP) Sensor:
    
•    Measure the resistance and input voltage of the TP sensor to ensure it meets specifications. Check for proper resistance variation during throttle operation. Repair or replace the TP sensor if issues are found.

6.    Angle Sensor:
    
•    Check the resistance and input voltage of the angle sensor. Verify resistance changes during manual gear shifts. Repair wiring or replace the sensor if necessary.

7.    Oil and Lubrication System:
    
•    Inspect the oil strainer and clean it thoroughly to remove accumulated dirt. Replace damaged components to ensure proper lubrication.

8.    System Diagnostics:
    
•    Use the self-diagnostic function of the integrated Engine Control Module (ECM) to identify and troubleshoot system failures. Follow the blinking codes from the gear position indicator or 4WD indicator to pinpoint specific issues.
These steps cover a range of potential engine-related issues in the TRX500 models, helping to identify and resolve faults efficiently.

The TRX500 manual includes the following chapters and sections:

1.    General Information
    
•    Service Rules
    
•    Model Identification
    
•    Specifications (General, Lubrication, Fuel System, Cylinder/Valve, Clutch, Transmission, etc.)
    
•    Safety Guidelines

2.    Maintenance
    
•    Maintenance Schedule
    
•    Inspection, Cleaning, Adjustment, and Replacement Procedures
    
•    Pre-Ride Inspection

3.    Frame/Body Panels/Exhaust System
    
•    Body Panel Locations
    
•    Removal and Installation Procedures
    
•    Exhaust System Maintenance

4.    Engine
    
•    Cylinder Head, Cylinder, and Piston Specifications
    
•    Crankcase, Transmission, and Crankshaft Maintenance
    
•    Lubrication System
    
•    Engine Removal and Installation

5.    Fuel System
    
•    Fuel Line and Tank Maintenance
    
•    Throttle Operation
    
•    Carburetor Inspection and Adjustment

6.    Electrical System
    
•    Battery and Charging System
    
•    Ignition System
    
•    Electric Starter
    
•    Lights, Meters, and Switches

7.    Brakes
    
•    Brake System Specifications
    
•    Brake Pads and Shoes Wear Inspection
    
•    Hydraulic and Mechanical Brake Maintenance

8.    Suspension and Steering
    
•    Front and Rear Suspension Specifications
    
•    Steering System Maintenance

9.    Transmission and Gearshift
    
•    Clutch and Gearshift Linkage
    
•    Transmission Maintenance
    
•    Electric Shift Program (ESP) Diagnostics

10.    Selectable 4WD System (FM/FE Models)
    
•    Troubleshooting and Diagnostics
    
•    Vehicle Speed Sensor Inspection
    
•    Final Drive Maintenance

11.    Torque Values
    
•    Standard Torque Values for Engine and Frame Components

12.    Cable and Harness Routing
    
•    Electrical Wire and Cable Routing Diagrams

13.    Emission Control Systems
    
•    Maintenance and Compliance with EPA and CARB Standards
Each chapter provides detailed instructions, specifications, and troubleshooting steps to ensure proper maintenance and repair of the TRX500 models.

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