Pull the seat and body panels tonight, and by the hour's end you'll be reading the same 446-page Honda TRX500FE, TRX500FM, TRX500TM service manual PDF the dealer tech works from, covering all three ATV variants across the TM, FM and FE driveline layouts. Wiring diagrams sit at the back with a separate sheet per model, tracing the regulator/rectifier, starter relay and combination meter circuits through the 30 A main fuse. Carburetor teardown, crankcase separation and the Electric Shift Program diagnostics each get a full chapter, with ESP fault charts that walk you from symptom to the angle sensor or control motor. Torque the cylinder head cap nuts to 39 N-m (29 lbf-ft) with oil on the threads and seating face; pack the outboard CV joint with 40 to 60 g of grease. Guessing costs a driveshaft boot or a second teardown. Text is searchable, bookmarks run chapter by chapter, and it stays yours for as long as you own the machine.
What's Inside This Honda TRX500FE, TRX500FM, TRX500TM Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 3-41 | Service Rules, General Specifications |
| Technical Features | 42-43 | Integrated Engine Control Module |
| Frame/Body Panels/Exhaust System | 44-58 | Body Panel Locations, Seat, Exhaust System |
| Maintenance | 59-80 | Maintenance Schedule, Throttle Operation, Air Cleaner |
| Lubrication System | 81-90 | Lubrication System Diagram, Cooling Fan, Oil Pump |
| Fuel System | 91-112 | Carburetor Removal, Carburetor Disassembly, Carburetor Assembly |
| Engine Removal/Installation | 113-124 | Engine Removal, Engine Installation |
| Cylinder Head/Valve | 125-149 | Cylinder Head Removal, Cylinder Head Disassembly, Cylinder Head Assembly |
| Cylinder/Piston | 150-158 | Cylinder/Piston Removal, Inspection, Cylinder/Piston Installation |
| Clutch/Gearshift Linkage | 159-183 | Centrifugal Clutch, Change Clutch, Gearshift Linkage |
| Alternator/Starter Clutch | 184-197 | Recoil Starter, Alternator Stator, Flywheel/Starter Clutch |
| Crankcase/Transmission/Crankshaft/Balancer | 198-228 | Crankcase Separation, Transmission, Crankshaft/Balancer |
| Front Wheel/Suspension/Steering | 229-259 | Handlebar, Wheel Hub and Knuckle, Suspension Arm |
| Rear Wheel/Suspension | 260-271 | Rear Axle Removal, Swingarm |
| Brake System | 272-291 | Brake Fluid Replacement, Front Brake Caliper, Rear Brake Drum/Shoes |
| Front Driving Mechanism (FM/FE Models) | 292-324 | Front Drive Shaft, Front Final Drive Removal, Front Final Gear Assembly |
| Rear Driving Mechanism | 325-351 | Rear Axle Removal, Rear Final Drive Removal, Rear Final Gear Assembly |
| Battery/Charging System | 352-359 | Battery, Charging System Inspection, Regulator/Rectifier |
| Ignition System | 360-366 | Ignition System Inspection, Ignition Coil |
| Electric Starter | 367-379 | Starter Motor, Starter Relay Switch, Diode |
| Lights/Meters/Switches | 380-400 | Headlight, Brake Light Switch, Combination Meter |
| Electric Shift Program (ESP: FE Model) | 401-422 | Diagnostic Troubleshooting, Angle Sensor, Control Motor and Reduction Gears |
| Selectable 4WD System (FM/FE Models) | 423-432 | Troubleshooting Chart |
| Wiring Diagrams | 433-438 | A/CM-Type TM Model, FM Model, FE Model |
| Troubleshooting | 439-444 | Engine Does Not Start, Engine Lacks Power, Poor Performance |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head cap nut | 39 N·m (4.0 kgf-m, 29 lbf-ft) | p. 128 |
| Cylinder head cap nuts torque | 39 N·m (4.0 kgf·m, 29 lbf·ft) | p. 142 |
| Outboard joint grease capacity | 40 - 60 g | p. 301 |
| Inboard joint grease capacity | 55 - 75 g | p. 301 |
| Main fuse | 30 A | p. 353 |
| Main fuse (TM/FM) | 30 A | p. 382 |
| Throttle position sensor spacer screw torque | 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) | p. 382 |
| Throttle position sensor screw torque | 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) | p. 399 |
| Angle sensor bolt torque | 6 N·m (0.6 kgf·m, 4.4 lbf·ft) | p. 402 |
| Reverse shift switch torque | 13 N·m (1.3 kgf·m, 10 lbf·ft) | p. 402 |
| Engine oil capacity (after draining) | 2.4 liters | p. 60 |
| Engine oil capacity (after draining/filter change) | 2.5 liters | p. 60 |
Honda TRX500FE, TRX500FM, TRX500TM Common Problems This Manual Covers
Honda TRX500FE 4x4 will not engage, front driveline stays dead with indicator blinking
Check the main fuse block first. Verify the 30 A main fuse and the 10 A ignition fuse on page 424 are intact before condemning the sensor. Unplug the front vehicle speed sensor connector, clean the corroded pins, and confirm 4.7 to 5.3 V input. Repack joints with 40 to 60 g grease if opened.
Manual Section: Selectable 4WD System (FM/FE Models) p. 424Gear position indicator blinking with problem code display and electric shift acting up
Pull the angle sensor connector and measure resistance across the terminals. Standard is 4 to 6 kilohms at 20 degrees C (68 degrees F) per page 418, with input voltage at 4.7 to 5.3 V. Replace a sensor reading outside that window, then torque the socket bolt to 6 N-m (0.6 kgf-m, 4.4 lbf-ft).
Manual Section: Electric Shift Program (ESP: FE Model) p. 418Engine runs terribly, unstable idle, hogs and stumbles when you crack the throttle
Measure throttle position sensor resistance before touching the carburetor. Page 398 calls for 4 to 6 kilohms at 20 degrees C (68 degrees F); anything outside means a new sensor torqued to 3.4 N-m (0.35 kgf-m, 2.5 lbf-ft). Then reset idle speed to 1,400 plus or minus 100 rpm and set throttle lever free play at 3 to 8 mm.
Manual Section: Lights/Meters/Switches p. 398Won't shift from first to second, transmission jumps out of gear under load
Inspect the gearshift linkage and shift drum stopper arm before tearing into the crankcase. Verify the reverse shift switch is torqued to 13 N-m (1.3 kgf-m, 10 lbf-ft) and its lead is not chafed. Drain and refill engine oil to 2.4 liters (2.5 US qt), since thin or overfull oil makes the change clutch drag.
Manual Section: Clutch/Gearshift Linkage p. 402Engine cranks but won't fire, or starter turns over slowly in cold weather
Clean the battery terminals and load test the battery before blaming the starter. Pull the plug and gap it at 1.0 to 1.1 mm (0.039 to 0.043 in), then torque it to 22 N-m (2.2 kgf-m, 16 lbf-ft). Work the no-spark checks on page 439 if you still have no fire at the plug.
Manual Section: Troubleshooting p. 439Won't go, drive engagement inconsistent, machine sits still with indicators lit
Test the handlebar shift switch for 4.7 to 5.3 V input at the connector, as page 422 specifies. Back-probe the harness, flex it, and watch for voltage drop from corroded pins. Grease the control motor reduction gear journals with 3 to 5 g of specified grease during reassembly.
Manual Section: Electric Shift Program (ESP: FE Model) p. 422Frequently Asked Questions
What are the torque specifications for the cylinder head cap nuts on a Honda TRX500FM?
The cylinder head cap nuts on the TRX500FM should be tightened to 39 N-m (4.0 kgf-m, 29 lbf-ft). When tightening, apply engine oil to the threads and seating surface. p. 128
What is the torque specification for the front wheel nuts on a Honda TRX500FE?
The front wheel nuts on the TRX500FE must be tightened to 64 N-m (6.5 kgf-m, 47 lbf-ft). p. 231
What is the standard intake and exhaust valve clearance on a Honda TRX500FE, TRX500FM, TRX500TM?
The standard valve clearance for both intake and exhaust valves is 0.15 mm (0.006 in) with a tolerance of ± 0.02 mm (0.001 in). This inspection should be performed while the engine is cold (below 35°C/95°F). p. 68
What is the engine oil capacity on a Honda TRX500FE, TRX500FM, TRX500TM after draining and changing the oil filter?
After draining the engine oil and replacing the oil filter, the engine oil capacity is 2.5 liters (2.6 US qt, 2.2 Imp qt). p. 60
What is the standard float level for the carburetor on the TRX500?
The standard float level for the carburetor is 15.9 mm (0.63 in). This measurement is taken with the float valve seated and the float arm just touching the valve. p. 103
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