Honda 2005-06 TRX500FE FM TM Fourtrax Foreman Service Manual 448 Pages

The 2005-2006 Honda Service Manual for TRX500 models provides detailed instructions for professional technicians on servicing, maintenance, and repairs. It emphasizes safety, using genuine parts, and following specified procedures. The manual includes sections on engine, transmission, electrical systems, and troubleshooting.

•    Safety Precautions: Use proper tools, training, and genuine Honda parts to avoid injury and damage.

•    Service Manual Usage: Intended for qualified technicians; follow maintenance schedules and service procedures.

•    Model Information: Covers TRX500 models with specific features and specifications.

•    Service Rules: Use Honda parts, metric tools, and follow torque specifications for assembly.

•    Maintenance and Safety: Proper maintenance ensures safety and vehicle reliability; avoid inferior parts.

•    Troubleshooting: Detailed troubleshooting for clutch, gearshift linkage, and transmission issues.

•    Lubrication and Fuel Systems: Specifications for engine oil, fuel system, and cylinder/piston details.

•    Drive and Electrical Systems: Clutch, gear ratios, ignition, and starting systems detailed.

•    Selectable 4WD System: Components and troubleshooting for 4WD system in FM/FE models.

•    Component Locations: Diagrams for lights, meters, switches, and 4WD components.

•    General Specifications: Dimensions, weight, and engine details for TRX500 models.

•    Service Tools: Specific tools listed for clutch and transmission maintenance.

•    Index and Content Structure: Sections for various vehicle systems, troubleshooting, and maintenance.

•    The document is a service manual for Honda TRX500 models, covering detailed procedures for maintenance and repair.

•    It provides safety precautions and emphasizes the importance of using genuine Honda parts and proper tools to avoid unsafe conditions.

•    The manual includes detailed specifications for various components such as the engine, transmission, and electrical systems.

•    Troubleshooting guides are provided for common issues like clutch slipping, transmission problems, and excessive engine noise.

•    Safety messages are highlighted with symbols and signal words like DANGER, WARNING, and CAUTION.

•    Maintenance schedules and procedures for the first scheduled maintenance are emphasized as crucial for optimal vehicle performance.

•    Detailed instructions for component removal and installation are included, such as for the crankcase, transmission, and clutch systems.

•    The manual contains wiring diagrams and information on the selectable 4WD system for specific models.

The index and content structure of the service manual for the Honda TRX500 models includes the following sections:

•    General Information: Includes service rules, model identification, and specifications for various systems such as lubrication, fuel, cylinder head/valve, and more.

•    Maintenance: Contains maintenance schedules and procedures to ensure optimal vehicle performance.

•    Lubrication System: Details on lubrication specifications and seal points.

•    Fuel System: Specifications and details for maintaining the fuel system.

•    Cylinder Head/Valve System: Specifications and service information for the cylinder head and valve.

•    Cylinder/Piston System: Information on cylinder and piston specifications and service procedures.

•    Clutch/Gearshift Linkage: Specifications and service information for the clutch and gearshift linkage.

•    Brake System: Specifications and maintenance procedures for the brake system.
•    Driving Mechanisms: Specifications for both front and rear driving mechanisms, including 4WD systems for FM/FE models.

•    Battery/Charging System: Specifications and maintenance for the battery and charging system.

•    Ignition and Electric Starter Systems: Specifications and service information for the ignition system and electric starter.

•    Lights/Meters/Switches: Specifications for lights, meters, and switches.

•    Torque Values: Standard torque values for various components.

•    Cable & Harness Routing: Detailed routing for cables and harnesses.

•    Emission Control Systems: Information on emission control systems.

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