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TRX500FM
Service manual
Honda TRX500FM Service Manual
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:
Owner's manual
(258 pages)
,
Owner's manual
(256 pages)
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Owner's manual
(258 pages)
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Table Of Contents
565
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565
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
How to Use this Manual
Symbols
Table of Contents
General Information
Service Rules
Abbreviations
Model Identification
Serial Numbers
Labels
General Specifications
GFM-FI System Specifications
Ignition System Specifications
Electric Starter Specifications
Fuel System Specifications
Cooling System Specifications
Lubrication System Specifications
Cylinder Head/Valve Specifications
Cylinder/Piston Specifications
Clutch/Gearshift Linkage Specifications
Alternator/Starter Clutch Specifications
Crankcase/Transmission/Crankshaft/Balancer Specifications
Engine Removal/Installation Specifications
Front Wheel/Suspension/Steering Specificatons
Rear Wheel/Suspension Specifications
Brake System Specifications
Front Driving Mechanism Specifications
Rear Driving Mechanism Specifications
Battery/Charging System Specifications
Lights/Meters/Switches Specifications
Torque Values
General Information
Lubrication & Seal Points - Engine
Lubrication & Seal Points - Frame
Cable & Harness Routing
Emission Control Systems
Exhaust Emission Control System
Crankcase Emission Control System
Prohibited Actions
Noise Emission Control System
Fuel Permeation Emission Control System
Rebuilt Engine
Frame/Body Panels/Exhaust System
Frame/Body Panels/Exhaust System Service Information
Frame/Body Panels/Exhaust System Torque Values
Frame/Body Panels/Exhaust System Troubleshooting
Body Panel Locations
Seat Removal
Seat Installation
Side Cover
Fuel Tank Side Cover
Mudguards
Engine Guard
Front Grille
Front Fender/Carrier Removal/Installation
Front Fender/Carrier Disassembly/Assembly
Rear Fender Cover
Tool Box Lid
Rear Fender/Carrier
Mudguard Bracket
Exhaust System Removal
Exhaust System Installation
Exhaust Pipe Stud Bolt Replacement
Exhaust System Disassembly/Assembly
Maintenance
Maintenance - Torque Values
Maintenance - Tools Needed
Maintenance Schedule
Fuel Line
Throttle Operation
Air Cleaner
Air Cleaner Housing Drain Tube
Spark Plug
Valve Clearance
Engine Oil Level Check
Engine Oil Change
Oil Change Indicator Reset
Engine Oil Filter
Engine Idle Speed Inspection
Radiator Coolant
Cooling System Maintenance
Drive Train Boots
Rear Final Gear Case Oil and Differential Oil
Final Gear Case Oil Level Check
Final Gear Case Oil Change
Differential Oil Level Check
Differential Oil Change
2WD/4WD Select System
2WD/4WD Selector Cable Adjustment
Brake Fluid
Brake Shoes Wear
Brake Pads Wear
Brake Light Switch
Brake System Maintenance
Front Brake
Rear Brake
Reverse Lock System
Guards
Clutch System
Suspension Maintenance
Spark Arrester
Nuts, Bolts, Fasteners
Wheels/Tires
Tie-Rod and Joint Boots
Steering Shaft Holder Bearing
Steering System
PGM-FI System
PGM-FI Component Location
PGM-FI System Diagram
PGM-FI System Service Information
PGM-FI System Torque Values
PGM-FI System Specifications
PGM-FI System - Tools Needed
PGM-FI System Symptom Troubleshooting
PGM-FI Connector Location
PGM-FI - General Troubleshooting
System Description
HDS Pocket Tester Information
DTC Readout
MIL Blink Pattern
Erasing DTC
Circuit Inspection
Inspection at PCM/ECM Connector
Reading DTC with the MIL
PGM-FI DTC Index
DTC Troubleshooting
DTC 1-1 (MAP Sensor Low Voltage)
DTC 1-2 (MAP Sensor High Voltage)
DTC 7-1 (ECT Sensor Low Voltage)
DTC 7-2 (ECT Sensor High Voltage)
DTC 8-1 (TP Sensor Low Voltage)
DTC 8-2 (TP Sensor High Voltage)
DTC 9-1 (IAT Sensor Low Voltage)
DTC 9-2 (IAT Sensor High Voltage)
DTC 12-1 (Fuel Injector)
Dtc 29-1 (Iacv)
Dtc 33-2 (Eeprom)
DTC 54-1 (Bank Angle Sensor Low Voltage)
DTC 54-2 (Bank Angle Sensor High Voltage)
MIL Circuit Inspection
Fuel Pump Relay Inspection
Sensor Unit (MAP/TP Sensor) Removal/Installation
TP Sensor Reset Procedure
ECT Sensor Removal/Installation
ECT Sensor Inspection
Bank Angle Sensor Removal/Installation
Bank Angle Sensor Operation Inspection
Bank Angle Sensor Inspection with HDS Pocket Tester
PCM/ECM Removal/Installation
Power/Ground Line Inspection
Engine Stop Switch Line Inspection
Ignition System
Ignition System Component Location
Ignition System Diagram
Ignition System Service Information
Ignition System - Specifications
Ignition System Torque Values
Ignition System - Tools Needed
Ignition System Troubleshooting
No Spark at Spark Plug
Ignition System Inspection
Ignition Coil Primary Peak Voltage
CKP Sensor Peak Voltage
Ignition Coil Removal/Installation
Ignition Timing
Condenser (Canada Type) Removal/Installation
Condenser (Canada Type) Inspection
Rectifier (Canada Type) Removal/Installation
Rectifier (Canada Type) Inspection
Electric Starter
Electric Starter - Component Location
Electric Starter - System Diagram
Electric Starter - Service Information
Electric Starter Torque Values
Electric Starter - Specifications
Electric Starter Troubleshooting
Starter Motor Removal/Installation
Starter Motor Disassembly/Assembly
Starter Motor Inspection
Starter Relay Switch - Operation Inspection
Starter Relay Switch - Circuit Inspection
Starter Relay Switch - Continuity Inspection
Starter Relay Switch - Removal/Installation
Diode Removal/Installation
Diode Inspection
Fuel System
Fuel System Exploded Diagram
System Components
Fuel System - Service Information
Fuel System - Specifications
Fuel System Torque Values
Fuel System - Tools Needed
Fuel Line Troubleshooting
Fuel Line Inspection
Fuel Pressure Relieving
Quick Connect Fitting Removal
Injector Side
Quick Connect Fitting Installation
Fuel Pump Side
Quick Connect Fitting Installation - Injector Side
Fuel Pressure Increasing
Fuel Pressure Inspection
Fuel Flow Inspection
Sub-Fuel Tank/Fuel Pump Inspection
Throttle Body Cover Removal/Installation
Sub-Fuel Tank/Fuel Pump Removal/Installation
Sub-Fuel Tank/Fuel Pump Disassembly
Fuel Pump Filter Replacement (Type A)
Fuel Pump Unit Holder Removal (Type A)
Fuel Pump Filter Replacement (Type B)
Sub-Fuel Tank/Fuel Pump Assembly
Fuel Tank Removal/Installation
Fuel Strainer Screen Cleaning
Air Cleaner Housing Removal/Installation
Throttle Body Removal
Throttle Body Disassembly/Assembly
Throttle Body Installation
IACV Inspection
IACV Removal/Installation
Fuel Injector Inspection
Fuel Injector Removal
Fuel Injector Installation
Cooling System
Cooling System Flow Pattern
Cooling System Service Information
Cooling System - Specifications
Cooling System Torque Values
Cooling System - Tools Needed
Cooling System Troubleshooting
Cooling System Testing
Coolant (Hydrometer Test)
Coolant Replacement
Recommended Antifreeze
Radiator Cap/System Pressure Inspection
Coolant Replacement/Air Bleeding
Thermostat Removal/Installation
Radiator/Cooling Fan
Radiator Removal/Installation
Thermostat Inspection
Cooling Fan Removal/Installation
Radiator Reserve Tank Removal/Installation
Water Pump: Mechanical Seal Inspection
Mechanical Seal Replacement
Lubrication System
Lubrication System Diagram
Lubrication System Service Information
Lubrication System - Specifications
Lubrication System Troubleshooting
Oil Pump Removal
Oil Pump Disassembly/Inspection
Oil Pump Assembly
Oil Pump Installation
Relief Valve Disassembly/Inspection
Relief Valve Assembly
Cylinder Head/Valve
Cylinder Head/Valve - System Components Diagram
Cylinder Head/Valve - Service Information
Cylinder Head/Valve - Specifications
Cylinder Head/Valve Torque Values
Cylinder Head/Valve - Tools Needed
Cylinder Head/Valve Troubleshooting
Cylinder Compression
Cylinder Head Cover Removal/Disassembly
Rocker Arm/Shaft Inspection
Push Rod Inspection
Cylinder Head Disassembly
Cylinder Head Inspection
Valve Spring Check
Valve/Valve Guide Check
Valve Guide Replacement
Valve Seat Inspection
Valve Seat Refacing
Cylinder Head Assembly
Cylinder Head Installation
Cylinder Head Cover Assembly/Installation
Cylinder Head Cover Installation
Camshaft Removal
Camshaft Inspection
Cam Chain Tensioner Inspection
Cam Follower Inspection
Camshaft Installation
Cylinder/Piston
Cylinder/Piston - System Components Diagram
Cylinder/Piston - Service Information
Cylinder/Piston - Specifications
Cylinder/Piston - Torque Value
Cylinder/Piston Troubleshooting
Cylinder/Piston Removal
Cylinder Removal
Piston Removal
Cylinder Inspection
Piston/Piston Ring Inspection
Cylinder Stud Bolt Replacement
Cylinder/Piston Installation
Piston Ring Installation
Piston Installation
Cylinder Installation
12. Clutch/Gearshift Linkage
Clutch/Gearshift Linkage - System Components Diagram
Clutch/Gearshift Linkage - Service Information
Clutch/Gearshift Linkage - Specifications
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Owner's Manual
Table of
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Table of Contents
Troubleshooting
Frame/body panels/exhaust system service information
54
PGM-FI system symptom troubleshooting
101
PGM-FI - general troubleshooting
106
DTC troubleshooting
110
Ignition system troubleshooting
136
Electric starter troubleshooting
146
Fuel line troubleshooting
157
Cooling system - tools needed
186
Lubrication system service information
199
Cylinder head/valve troubleshooting
208
Cylinder/piston - service information
231
Clutch/gearshift linkage troubleshooting
243
Alternator/starter clutch - tools needed
267
Crankshaft/transmission/crankshaft/balancer troubleshooting
284
Front wheel/suspension/steering troubleshooting
321
Rear wheel/suspension - troubleshooting
361
Brake system components troubleshooting
372
Front driving mechanism - troubleshooting
394
Rear driving mechanism troubleshooting
434
Battery/charging system troubleshooting
460
ESP troubleshooting
491
ESP troubleshooting information
496
DTC: troubleshooting
500
EPS system - service information
522
EPS troubleshooting information
527
Verifying proper connector contact
536
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This manual is also suitable for:
Trx500fpm
Trx500fe
Trx500fpe
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