Honda 2006 FOURTRAX FOREMAN TRX500 FM Manuals

Manuals and User Guides for Honda 2006 FOURTRAX FOREMAN TRX500 FM. We have 1 Honda 2006 FOURTRAX FOREMAN TRX500 FM manual available for free PDF download: Service Manual

Honda 2006 FOURTRAX FOREMAN TRX500 FM Service Manual

Honda 2006 FOURTRAX FOREMAN TRX500 FM Service Manual (448 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 51 MB

Table of Contents

1. General Information

5
3. Frame/Body Panels/Exhaust System

46
- Service Information
  47
- Troubleshooting
  47
- Body Panel Locations
  48
- Recoil Starter Cover
  49
- Seat
  49
- Side Cover
  49
- Fuel Tank Cover
  50
- Center Mud Guard
  51
- Front Mud Guard
  52
- Inner Fender
  52
- Front Carrier/Carry Pipe
  53
- Front Fender- •3-9
  54
- Rear Carrier
  55
- Rear Fender •3-11
  56
- Engine Air Guide- •3-12
  57
- Engine Guard
  57
- Exhaust System
  58
4. Maintenance

61
- Service Information
  62
- Maintenance Schedule
  63
- Fuel Line
  65
- Throttle Operation
  65
- Carburetor Choke
  66
- Air Cleaner
  67
- Air Cleaner Housing Drain Hose
  69
- Spark Plug
  69
- Valve Clearance
  70
- Engine Oil
  71
- Engine Idle Speed
  73
- Engine Oil Filter
  73
- DRIVE SHAFT BOOTS (FM/FE Models)
  74
- Rear Final Gear Case Oil and Differential Oil
  74
- Brake Fluid
  76
- Brake Light Switch
  77
- Brake Pads Wear
  77
- Brake Shoes Wear
  77
- Brake System
  78
- Clutch System
  79
- Reverse Lock System
  79
- Skid Plate, Engine Guard
  79
- Spark Arrester
  80
- Suspension
  80
- Nuts, Bolts, Fasteners
  81
- Steering Shaft Holder Bearing
  81
- Wheels/Tires
  81
- Steering System
  82
6. Fuel System

93
- System Components
  94
- Service Information
  95
- Troubleshooting
  96
- Air Cleaner Housing
  97
- Carburetor Removal
  98
- Carburetor Disassembly/ Inspection
  99
- Carburetor Assembly
  104
- Carburetor Installation
  109
- Pilot Screw Adjustment
  111
- High Altitude Adjustment
  112
- Fuel Tank
  114
8. Cylinder Head/Valve

127
- System Components
  128
- Service Information
  130
- Troubleshooting
  132
- Cylinder Compression
  133
- Cylinder Head Cover Removal/ Disassembly
  133
- Cylinder Head Removal
  135
- Cylinder Head Disassembly
  136
- Valve Guide Replacement
  138
- Valve Seat Inspection/Refacing
  139
- Cylinder Head Assembly
  142
- Cylinder Head Cover Assembly/ Installation
  144
- Cylinder Head Installation
  144
- Camshaft Removal
  146
- Camshaft Installation
  149
10. Clutch/Gearshift Linkage

161
- System Components
  162
- Service Information
  163
- Troubleshooting
  165
- Front Crankcase Cover Removal
  166
- Centrifugal Clutch
  168
- Change Clutch
  173
- Gearshift Linkage
  180
- Front Crankcase Cover Installation
  183
12. Crankcase/Transmission/Crankshaft/Balancer

200
- System Components
  201
- Service Information
  203
  - Crankshaft/Balancer
    219
- Crankcase Bearing
  223
- Crankcase Assembly
  226
13. Front Wheel/Suspension/Steering

231
- System Components
  232
- Service Information
  233
- Troubleshooting
  235
- Handlebar
  236
- Throttle Housing
  239
- Front Wheel
  240
- Tires- •13-11
  242
- Wheel Hub and Knuckle
  244
- Suspension Arm
  250
- Front Shock Absorber
  254
- Steering Shaft
  255
- Tie-Rod
  260
15. Brake System

274
- System Components
  275
- Service Information
  276
- Troubleshooting
  277
- Brake Fluid Replacement/Air Bleeding
  278
- Brake Pad/Disc
  279
- Front Master Cylinder
  281
- Front Brake Caliper
  284
- Rear Brake Drum/Shoes
  288
- Rear Brake Pedal
  292
16. Front Driving Mechanism (Fm/Fe Models)

294
- System Components
  295
- Service Information
  296
- Troubleshooting
  299
- Front Drive Shaft
  300
- Front Final Drive Removal
  305
- Front Final Gear Disassembly/ Inspection
  308
- Front Final Gear Case Bearing Replacement
  315
- Front Final Drive Installation
  323
17. Rear Driving Mechanism

327
- System Components
  328
- Service Information
  329
- Troubleshooting
  332
- Rear Axle Removal
  333
- Rear Final Drive Removal
  336
- Rear Final Gear Disassembly/ Inspection
  338
- Rear Final Gear Case Bearing Replacement
  343
- Rear Final Gear Assembly
  346
- Rear Final Drive Installation
  349
- Rear Axle Installation
  351
18. Battery/Charging System

354
- Battery
  355
- Component Location
  355
- System Diagram
  355
- Charging System Inspection
  360
- Alternator Charging Coil
  361
- Troubleshooting
  365
21. Lights/Meters/Switches

382
- Component Location
  383
- Service Information
  384
- Assist Headlight
  385
- Headlight
  386
- Taillight
  386
- Accessory Socket
  387
- Ignition Switch
  388
- Handlebar Switch
  389
- Brake Light Switch
  390
- Front Brake Switch
  391
- Gear Position Switch
  391
- Carburetor Heater/Carburetor Heater Switch
  392
- COMBINATION METER (Except A/CM Type TM Model)
  393
- FUEL GAUGE/FUEL LEVEL SENSOR (Except A/CM Type TM Model)
  394
- Oil Cooling System
  396
- Temperature Indicator
  398
- Throttle Position (Tp) Sensor
  400
- HORN (U Type Only)
  402
22. Electric Shift Program (Esp: Fe Model)

403
- Component Location
  404
- System Diagram
  404
- Service Information
  405
- Before Troubleshooting
  406
- Diagnostic Troubleshooting
  408
- Angle Sensor
  420
- Control Motor and Reduction Gears
  421
- Gearshift Switch
  423
- Reverse Shift Switch
  424

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