2012 Honda TRX500FMFPMFEFPE Service Repair Manual Instant Download

1
SERVICE MANUAL
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MEMO
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1. GENERAL INFORMATION
SERVICE RULES
-
1 -2
LUBRICATION SEAL POINTS
1-19
1-3
CABLE HARNESS ROUTING
- - 1-23
MODEL IDENTIFICATION - SP ECIFICATIONS - TORQUE
VALU ES
1-44
-
1 -6
EMISSION CONTROL SYSTEMS
1-13
1-1
6

• GENERAL INFORMATION
• SERVICE RULES
• Use Honda Genuine or Honda-recommended parts and
  lubricants or their equtvalents. Parts that don't
  meet Honda's design specificafions may cause
  damage to the vehicle
• Use the special tools designed for Ihis product
  fo avoid damage and incorrect assembly.
• Use only metric tools when servicing the vehicle.
  Metric bolts, nuts and screws are not
  interchangeable with English fasteners.
• Install new gaskets, O-rings, cotter pins, and
  lock plates when reassembling.
• When tightening bolts or nuts, begin with the
  larger diameter or inner ball first. Then tighten
  to the specified torque diagonally in
  incremental steps unless a partiEular sequence
  is specified.
• Clean parts in cleaning solvent upon disassembly.
  Lubricate any sliding surfaces before reassembly.
• 7 After rsassembly, check all parts for proper
  installation and operation
• Route alt electrical wires as shown in the Cable
  HamesS Routing (page 1-23).
• Do nol bend or twist control cables. Damaged
  control cables will not operates smoothly and may
  st ck or bind.
• Do nol tow your ATV behind a car or other vehicle
• ABBREVIATION
• Throughout this manual, the following
  abbreviation are used la identify tha respective
  parts or systems.

Full term Crankshaft Position sensor Líquid
Crystal Disp1ay Data Link Connectar" Diagnostic
Trouble Code Powertrain Control kÏodule Engine
Control Module Engne Coolant Temperature
sensor Electrically Erasable P'rogrammable Read
Only Memory
Abbrev. ierm " CKP sensor " LCD DLC DTC PCM
(FE/FPE models) " ÉCM (FM/FPM models) ECT
sensor ÉEPROM EPS

Electric Power Steering i Electric Shift
Program EI8CtriC ControÏ Unit Honda
Diagnostic System IdIe Air Control
Vaive Intake Amr Temperature sensor Manfold
Absolute Pressure sensor Malfunction Indicator
Lamp Progfammed Fuel Injection Service Check
Short service connecfor Throttte Position sensor
Vehicle Speed sensor 4 Wheel Drive
" ESP ECU HDS tACV IAT sensor MAP sensor
MCL PGM-FI
SCS service connector
TP sensor VS sensor 4WD

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GENERAL INFORMATION
ITEM
SPECIFICATION\IS
DRIVE TRAIN
I Clutch system
Centrifugal and multi-platewet Automatic
Clutch operation system
Transmission Primary reduction Secondary
reduction Final reduction
Constant mesh, 5-speeds with reverse
2. J03 (61/29) 1.875 (30/J 6) 3.231 (42/13) 2.154
(41/13) 4.230 (55/13) 2.388 (43/18) 1.608
(37/23) 1.178 (33/28) 0.848 (28/33) 5.743 (48/13
x 28/18) R N 1 2 3 4 5 Left foot
operated return system Electric shift (left hand
operated ) return system ransisorized"ignition El
ectric starter motor Electric starter motor and
emergency recoil stater Triple phase output
alternator FET shooted, triple phase full wave
rectification Battery
Front Rear 1st 2nd 3rd 4th Sth Reverse
Gear ratio
Gearshift pattern
FM/FPM FE/FPE
ELECTRICAL
Ignition system Starting system
Jul
U.S.A. Canada
Charging system Regulator/rectifier Lighting
system
PGM-FI SYSTEM SPECIFICATIONS
SPECIFICATIONS 11.6 12.4 G
IGNITION SYSTEM SPECIFICATIONS
iTEM
SPECIFICATIONS BKR5E-11 (NGK) K16PR-U11
(DENSO) 1.0 1.1 mm' (0.039 - 0.043 in) 100 V
minimum
Spark plug Spark plug gap
Ignition coil primary peak voltage Ignition
pulse generator peak voltage
0.7 V minimum
Ignition timing ("F" mark) 10 BTDC at idle
ELECTRIC STARTER SPECIFICATIONS
Unit mm (in)
TEM STAhIDAR SERVICE UNIIT "
Starter motor brush length ' 12 0 ( 47) 6 5 (0 26)
FUEL SYSTEM SPECIFICATIONS
Throttle body identification Idle speed ITEM number I SPECIF CAUNS GQ3RA 1 400 100 rpm
Throttle lever freeplay 3 8 mm (0.1 0.3 in)
Fuel pressure at idle Fuel pump flow (at 12 V) 316 387 kPa (3.2 3.9 kgt/cm, 46 56 psi) 125 cm 4 2 US oz 4 4 mp oz) minimum/10 seconds I
1-7
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GENERAL INFORMATION
CYLINDER/PISTON SPECIFICATIONS
Unit mm (in)
Cylinder
ITEM I l.D. Out-of-round
STANDARD 9ERVICE LÍMIT
I 92.000 - 92.010 (3.6220 3.6224) 92. \0
(3.626)

0.10 (0.004) 0. TO (0.004)
Taper Warpage


0.1Ò (0.004)
Piston, pis-ton pin, piston r1ng
PistonO.D. at IS (0.6) from bottom Piston pin
hole I.D.
91.970 - g1.990 (3.6209 - 3.6"216) 91.90
(3.618)
19.002 - 19.008 (0.7481 - 0.7483) 19.04 (
0.750) 1B.994 19.D00 (0.74?'8 0.7480) 18.96
(0.746)
Piston pin O.D.
Piston-to-piston pin clearance 0.002 - 0.014
(0.0001 0.0006) ó.08 (0.003)
Piston ring end gap
i Top 0.t 5 - 0.30 (0.006 0.012) 0.5 (0.02)

second 0.30 - 0.45 (0.012 0.018) 0.6
(0.02)
Oil (side rail) 0.20 - 0.70 (0.008 0.028)
0.9 (0.04) Piston ring-to-ring Top 0.030
Ò.060 (0.0012 0.0024 ) 0.09 (0.004) groove
clearance Second 0.030 - 0.060 (0.0012 - 0.0024)
0.09 (0.D04) CyItnder-to-piston cearance
0.010 - 0040 (0.0004 - 0.0016) 0.10
(0.004) Connecting rod small end I.D.
19020 - 19.041 (0.7488 - 0.7496)
19.07"(0.751) Connecting rod-to-piston pin
clearance 0.020 - Ò/ó47 (0.0008 - 0.0019)
0.10 (0.0d4) CLUTCH/GEARSHIFT LINKAGE
SPECIFICATIONS
Unit mm (in) SERVICE Llf IT
ITEM STANDARD
Centrifugal clutch
Drum I.O.
150.0 150.2 (5.906 5.913) 150.4 ( 5.92)
Weight lining thickness 2.0(0.Ò8)
1.3 (0.05) 2.84 (0.112) 25.7 T1.01)
Clutch spring height 2.96 (0.117)
Clutch waight spring free langth 24.72 o.g73
50.7 (2.00) 46.3 (1.78) 2.3 (0.09) 0.20
(0.008)
Change clutch Spring free length
FM/FPM FE/FPE
52.2 (2.06) 46.8 (1.84)
Disc thickness 2.62 - 2.78 0.103 0.109)
Plate warpage
Outer I.D. 29.000 -"29021 (1.1417 1.1426)
29.05 (1.144) Outer guide I.D. 22.000 22.021
(0.8661 0.8670) 22.05 (0.868)
28.93 (1.139) 21.93 0.863)
O.D. 28.959 2/\.980 (1.1401 1.1409j
Mainshaft O.D. at clutch outer guide 21.967
21.980 (0.8648 0.8654)
Primary drive gear
Gear I.D. Crankshaft O.D. at drive gear
29.000 29.021 (1.1417 1.1426) 29.05 (1.144)
2B.95e z8.980 (1.1401 1.1409 28.93 (1,139)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
Unit mm (in) SERVICE LIM!T
STANDARD
O.D.
Starter driven gear boss
51.705 51.718 (2Ò356 - 2.0361) 51.69 2.035)
D
31.946 - 31.962 (1.2577 - 1.2É83) 31.90 (1.2Éó)
31.884 31.900 (1.2553 1.2559) 31.85 (1.254j
Crankshaft O.D. at starter driven gear
1-9
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GENERAL INFORMATION CRANKCASE/TRANSMISSION/CRANKS
HAFT/BALANCER SPECIFICATIONS Unot. mni (in
ITEM STANDARD SERVICE LIMIT
Shiíj fork I.D F ron1, rear \ 3 000 I 3.021 (Û.51 J 8 D.5126) i 3 D4 f0.513)
Cen1er 13.000 13 018 (0. 118 D 51251 13.04 l/0, 513
Claw Ihck ess 4 '13 5 0Ô (0 1Û4 0 l'27 4 5 i 0 18
í ransmission Shat O.D Gear iD k13 12.9?G 12.984 \0 5 105 0 5112 I 2c' 000 25.02 \ (0 û643 0 9851 j I 2.96 IO.510 25.0É Ò. 9B6
MS 0.000 20.021 (0.7874 0 7882) 20.0ci t0.78ù I
?1. C2. C4. CR 28.iJ20 "28.041 (1. 10. I 1 1040) 28.Ò7(1. 105)
Reverse idle 13.000 13.021 Ï0 511R 0 51C6) 13.04 (Ö.513
Gear bushing kt3 24 9 9 24 980 0 982C 0 9835 24.93 ï0 981)
O D EU 1g 9G6 19.984 0.7üh 1 Û 78691 1.94 (0.7851
2 /7. gß4 28.ß05 1. 1 017 1 1Õ26 27.4 (1 100
C 1. C4. CR 27 Û79 28.0D0 i T. 1G15 1 1024 27 93S1. 100
Gunr-to bLIShir1 MJ 0 02ú 0 Õò2 (0.000ß - 0 0024 0. 10 t0.004)
cIe?rance MS 0.016 0.055 (0.ß00G 0.0022) 0.10 (0004)
2 0.01 0.0ú7 (0.D006 0.0022) 0 t)8 (0.003)
C1. C4, CR u.020 - 0.0Cz \0.000g - 0.0024) () 10 fOOOÀl
Geai Uucltf ing I D kJ3 22 000 22.021 0 86ò1 0 8670j 22.04 0.868
I\'15 17.016 17 024 t0 G699 0 6706 i 17.06 tD.672
Ü.t 25 000 25 021 IO.084J 0 Ò851 i 25.05 tõ.986/
L1ainsnaft O D nt MJ 2 1.950 21.98U l0 .0C45 0.8654) 21 '22 fÖ.863 i
nt MW 16.976 16.98 (0.Gb83 0.6688 16.92 (0.667)
I'.orïntershaft O D. at C4 24 SSS 24.980 (0.9ft2G 0.Ó835) 24.'22(0.981)
Reverse idle shaft Q D 1 2 966 1 2 984 (0 51DS 0 5112/ 12.94 (0.509j
B?ishing-to-shall h13 0 íJ20 0.062 (0.0000 0 0ÒZ4 0.10 f0.004
r.-Year a Ice M5 U.029 0.Õ58 i0.0U11 D 0023 0. 10 i"0.004
C4 0 020 0 Ö62 i 0.0008 - 0 002t Ú 10 t0 0ú4
Reverse idlegeai-to-shaft ciearance Reverse idlegeai-to-shaft ciearance Reverse idlegeai-to-shaft ciearance 0.016 0. Ö55 t0.CD06 0.002s i 0 1Ü 0/004
Crz?nkshaft Runaul Crz?nkshaft Runaul Crz?nkshaft Runaul 0. 15 \Ò.006
Biq end side clearance Biq end side clearance Biq end side clearance ï) 0o 0.US (0 002 U 026) 0.8 (0.02)
Big eJd radial clearance Big eJd radial clearance Big eJd radial clearance 0.0D6 0.D 18 tU.ítlJ02 0 0007) 0.05 (0.002
ENGINE REMOVAL/INSTALLATION
ITEM FM.FPM
SPECIFICATIONS
51.4 kg t11?.J lbs 52.5 /9 (115 7 lbs ) ûž 3 kg
(115.2 lbs ) ú3 4 kg 11 7 7 lbs j 2 S liters t3 1
US rel 2 6 lmp ql û 0 liters ï z 2 US qI, 2 6
Insp qt) 3 3 liters t3. o US qi, 2.9 Imp qt 1.5
liters (1.6 US qI, 1.3 Imp qt 2 4 mm (0. 1 -
0.2 in
E fogine dry weight
USA Canada U SA Cnoda
FE.FPE
Enae oil capac its
After training After drainng..'fiIter change
After disassen fly
i oIant capacity (ra1ialoi and engine) Reverse
seIeclor lever free Play
FRONT WHEEL/SUSPENSION/STEERING
SPECIFICATIONS ITEM STANDARD
SERVCE LIMIT 4.0 (0 16
KÆnuni tve mead depth CId ture EfQSÑLJ
FE The-rod distance between the ball joints Tc
Sandad Wilh rarqo
JO kPa (0.30 kgf/cm , 4 4 psi) 30 kPa TO.30
kgf/cm , 4 4 psi) 383a 0508) Toe.out 28 15 G D5
1-10
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GENERAL INFORMATION
REAR WHEEL/SUSPENSION SPECIFICATIONS
Unit mm (Any SERVICE LIMIT 4.0 (0 16)
ITEM
STANDARD
Standard With cargo
30 kPa (0.30 kgf/cm, 4.4 psi) 30 kPa (0.30
kgf/cm', 4.4 psi)
BRAfE SYSTEM SPECIFICATIONS
Unit mm in) SERVICE LIMIT
ITEM
STANDARD

Front brake Recommended brake fluid Honda DOT 4 brake fluid Honda DOT 4 brake fluid Honda DOT 4 brake fluid
Osc thickness 3.8 4.2 t0.15 0.17) 3 D T0.12I
Disc runoul 0.30 (0.012)
Master cylinder i D 14.00O 14.043 (0.5512 0.5529 " 14.055 (0. 5533)
Master piston"O.D. 13.957 I 3.984 (0.5495 - 0.5506 13.945 (0.5490)
Caliper cylinder I DC 32.030 32.080 (1.2610 1.2630) 32.090 (1.2634)
Caliper piston O.D 21.984 31 998 (1.2578 1.2598) 31.94 (1 257)
Rear brake Drum I.D. I 80.0 180.2 (7.086 - 7.094) 181.0 (7,13)
Rear (parking Shoe lining thickness brake lever freeplay " 5.3 (0.21) 15 20 mm (0.6 - 0.8 in) To index mark
Rear brake pedal freeptay
T5 20 mm (0.6 0.8 in)
FRONT DRIVING MECHANISM SPECIFICATIONS
Unit. mm (in) SERVICE LIMIT
ITEM Oil capacity
STANDARD 200 cm' (6.8 US oz. 7.0 Ill p oz) 250
cm' (8.5 US oz. 8.8 Imp oz) " Honda shaft drive
oil or equivalent hypoid gear oil. SAE 80 0.US
0.25 (0.002 - 0.010)
Front final drive
After draining After disassembly
Recommended air
Gear backlash Backlash diffrence Slip torque
0.410.02) 0.2(00gtl T2Nm (l24jm 9bT) 8.3(0
13) 655 0258) Z6(0.10)
14 UN m (1.45 1.75 kgf m.
10 13 Ibf ft)
Face cam-to-housing distance Differential ring
gear depth Cone spring free"height
3. 3 "3.7 (0.13 0 15) 6.5 " 6"5 (0.258
0.262J 2.8 (0.11)
REAR DRIVING MECHANISM SPECIFICATIONS
Unii. mm (in) SERVICE LIMIT 0 t0 2j
ITEM
STANOARD
Axle runout Rear final drve
After draining Afterdisassembly
Oii capacity
75 cm (2.5 US oz. 2.6 Imp oz) 100 cm' (3.4 US
oz. 3.5 Amp oz) Honda shaft drive oil or
equivalent hypoid gear oil, SAE 80 0.05 0.25
(0.OO2 - 0.010)
Recommended oil
Gear backlash Backlash difference Ring
gear-to-stop pin claarance
0.4 (0.02) 0.2 (0.01)
0.3 - 0.6 (0.01 - "0.02)
1-11
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GENERAL INFORMATION
BRAKE SYSTEM
ITEM O'TY THREAD DIA. (mm ) TORQUE N'm (kgf m, Ibf'h)
Brake not all bolt 3 0 ?4 3 , 2?
Front brake caliper bleed valve 2 8 5 4 t0.G 4 0 )
Frc/Jt master cylinder re semoir cap screw 2 4 2.0(02. 10
Pad pin 4 10 17 ( 1 7, 1?)
Pad pin plug 4 10 Z4 l0 2. 1 Bl
REMARKS
Front Drake lever pivnf lolt F rent brak lever
pivol nut Frnt brake light inhit ito r switch
scre\v
1 1 1
C
1.0 i 0
. 0.7
Apply Iocknt agent lO the threads
Front master cvlindei holrier bolt Front brake
caliper mounting bolt
ALOC bolt repiace with n nev.' one Apply locking
agent to the threacls
F ronl Drake caliper slide pin
22 2 2, 16)
F rant brake caliper Urackel in Rear brake arm
pinch bnIl.'nil Rear whee! hub nut
2 1
7 1 7. 13) 20 (2 0. 1 o I 13 7 l14 0 1 01 )
20
Rear brake pane! drain boll 1 8 !2l1 2 31
Brake ppe joint bolt 10 14 (1 4 101
FRONT DRIVING MECHANISM
Dt READ! 6D
N.T(OR ,Ebf.ft) 9g f10 0, 72) 49 1 0. 36
REMARKS Locknul repcewih a new oric Smoke
ITEM
Q'TY 1
Fron fnalgearpgton bearing loco nut
8
Diñerential ring gear bolt
Front foal gear case cover bolt 2 10 Applv locking agent ie the thren0s
25 t2 5. 1 g)
FrunI fin al clutCh shift fork fJIt 6 10 ( 1 C 7 ALOC bol rePlace with a new une
From final clutch housing holt 3 8 25 2 5, 10)
Frcnl final gear case mounting nut 10 Lock nail. replace with a new one
4WD select switch 10 1 2 t 1.2, 91
4AD select switch wide claip ball 6 1 ? ( 1.0, 7
Final clutch am cover bolt 6 10 ( 1 0, 7
1-17
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