Honda Foreman Trx500 FE Service manual

Honda Foreman Trx500 FE · service manual · 550 pages

Honda Foreman Trx500 FE
Service manual
550 pages
ATV

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
5mm bolt and nut	5 N·m	0.5 kgf·m · 3.6 ft·lb	p. 20
6mm screw	9 N·m	0.9 kgf·m · 6.5 ft·lb	p. 20
8mm bolt and nut	22 N·m	2.2 kgf·m · 16 ft·lb	p. 20
Spark plug	22 N·m	2.2 kgf·m · 16 ft·lb	p. 20
Valve adjusting lock nut	17 N·m	1.7 kgf·m · 13 ft·lb	p. 20
Valve adjusting hole cap	12 N·m	1.2 kgf·m · 9 ft·lb	p. 20
Timing hole cap	10 N·m	1 kgf·m · 7 ft·lb	p. 20
Engine oil drain bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 20
Engine oil filter cover bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 20
Clutch adjusting screw lock nut	22 N·m	2.2 kgf·m · 16 ft·lb	p. 20
Carburetor insulator band screw	4 N·m	0.4 kgf·m · 3 ft·lb	p. 20
Cylinder head cap nut	39 N·m	4 kgf·m · 29 ft·lb	p. 21
Cam sprocket bolt	20 N·m	2 kgf·m · 15 ft·lb	p. 21
Cam chain tensioner pivot bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 21
Exhaust pipe stud bolt	6 N·m	0.6 kgf·m · 4.4 ft·lb	p. 21
Cylinder stud bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 21
Centrifugal clutch lock nut	118 N·m	12 kgf·m · 87 ft·lb	p. 21
7 wv Change clutch lock nut	108 N·m	11 kgf·m · 80 ft·lb	p. 21
Shift drum stopper arm pivot bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 21
Gearshift cam bolt	16 N·m	1.6 kgf·m · 12 ft·lb	p. 21
Gearshift spindle return spring pin	22 N·m	2.2 kgf·m · 16 ft·lb	p. 21
Starter clutch bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 22
Recoil starter driven pulley bolt	108 N·m	11 kgf·m · 80 ft·lb	p. 22
Alternator stator bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 22
CKP sensor bolt	6 N·m	0.6 kgf·m · 4.4 ft·lb	p. 22
Reverse shift switch	13 N·m	1.3 kgf·m · 10 ft·lb	p. 22
Front carrier bolt 4	37 N·m	3.8 kgf·m · 27 ft·lb	p. 23
Front carry pipe bolt	37 N·m	3.8 kgf·m · 27 ft·lb	p. 23
Rear carrier bolt	37 N·m	3.8 kgf·m · 27 ft·lb	p. 23
Muffler band bolt	23 N·m	2.3 kgf·m · 17 ft·lb	p. 23
Footpeg bracket bolt 4 8s	32 N·m	3.3 kgf·m · 24 ft·lb	p. 23
Front differential oil drain bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 23
Rear final gear case oil check bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 23
Rear final gear case oil filler cap	12 N·m	1.2 kgf·m · 9 ft·lb	p. 23
Rear final gear case oil drain bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 23
Spark arrester bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 23
Tie-rod lock nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 23
Cooling fan motor screw	1.5 N·m	0.15 kgf·m · 1.1 ft·lb	p. 23
Cooling fan nut	2.7 N·m	0.27 kgf·m · 2 ft·lb	p. 23
Lower engine hanger nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 23
Left lower engine hanger bracket bolt	32 N·m	3.3 kgf·m · 24 ft·lb	p. 23
Upper engine hanger nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 23
Upper engine hanger bolt	32 N·m	3.3 kgf·m · 24 ft·lb	p. 23
Gearshift pedal pinch bolt	16 N·m	1.6 kgf·m · 12 ft·lb	p. 23
Rear wheel nut	64 N·m	6.5 kgf·m · 47 ft·lb	p. 24
Shock absorber upper mounting nut	34 N·m	3.5 kgf·m · 25 ft·lb	p. 24
Shock absorber lower mounting bolt	44 N·m	4.5 kgf·m · 32 ft·lb	p. 24
Swingarm left pivot bolt	112 N·m	11.4 kgf·m · 83 ft·lb	p. 24
Brake hose oil bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 24
Front brake caliper bleed valve	5.4 N·m	0.54 kgf·m · 4 ft·lb	p. 24
Front master cylinder reservoir cap screw	2 N·m	0.2 kgf·m · 1.5 ft·lb	p. 24
Front brake light switch screw	1.2 N·m	0.12 kgf·m · 0.9 ft·lb	p. 24
Front brake lever pivot bolt	1 N·m	0.1 kgf·m · 0.7 ft·lb	p. 24
Front brake lever pivot nut	5.9 N·m	0.6 kgf·m · 4.4 ft·lb	p. 24
Front master cylinder holder bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 24
Front brake caliper mounting bolt	44 N·m	4.5 kgf·m · 32 ft·lb	p. 24
Caliper pin bolt	23 N·m	2.3 kgf·m · 17 ft·lb	p. 24
Brake pipe joint (green surface) 2	17 N·m	1.7 kgf·m · 13 ft·lb	p. 24
Rear brake arm pinch bolt/nut	20 N·m	2 kgf·m · 15 ft·lb	p. 24
Assist headlight/meter bracket nut	49 N·m	5 kgf·m · 36 ft·lb	p. 25
Muffler band bolts	23 N·m	2.3 kgf·m · 17 ft·lb	p. 78
Front differential oil filler cap	12 N·m	1.2 kgf·m · 9 ft·lb	p. 81
Sealing washer	25 N·m	2.5 kgf·m · 18 ft·lb	p. 91
Filler cap groove	12 N·m	1.2 kgf·m · 9 ft·lb	p. 94
Cap screws	2 N·m	0.2 kgf·m · 1.5 ft·lb	p. 95
Ball joint studs	54 N·m	5.5 kgf·m · 40 ft·lb	p. 102
Relief valve cap	19 N·m	1.9 kgf·m · 14 ft·lb	p. 106
Cooling fan shroud tapping screw	1.5 N·m	0.15 kgf·m · 1.1 ft·lb	p. 106
Carburetor insulator band screw	4.1 N·m	3 ft·lb	p. 119
Insulator band screw as shown	4 N·m	0.4 kgf·m · 3 ft·lb	p. 133
SE valve nut	2.3 N·m	0.23 kgf·m · 1.7 ft·lb	p. 134
Engine hanger nuts and bolts	54 N·m	5.5 kgf·m · 40 ft·lb	p. 147
Head bolts securely	22 N·m	2.2 kgf·m · 16 ft·lb	p. 168
Engine hanger fasteners	54 N·m	5.5 kgf·m · 40 ft·lb	p. 168
Engine hanger fasteners	32 N·m	3.3 kgf·m · 24 ft·lb	p. 168
Change clutch lock nut	108 N·m	11 kgf·m · 80 ft·lb	p. 189
Change clutch lock nut	12 N·m	1.2 kgf·m · 9 ft·lb	p. 189
Nator cover	10 N·m	1 kgf·m · 7 ft·lb	p. 221
EPS motor flange bolt	39 N·m	4 kgf·m · 29 ft·lb	p. 263
EPS motor flange bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 263
EPS motor flange bolt	1.5 N·m	1.1 ft·lb	p. 263
Cotter pin hole	29 N·m	3 kgf·m · 21 ft·lb	p. 280
Lower arm pivot nuts	44 N·m	4.5 kgf·m · 32 ft·lb	p. 284
Holder bolts	32 N·m	3.3 kgf·m · 24 ft·lb	p. 291
EPS unit mounting bolts and nuts	22 N·m	2.2 kgf·m · 16 ft·lb	p. 299
Ball joint stud flat surfaces	54 N·m	5.5 kgf·m · 40 ft·lb	p. 302
Ww Swingarm left pivot bolt	112 N·m	11.4 kgf·m · 83 ft·lb	p. 305
Swingarm right pivot lock nut	112 N·m	11.4 kgf·m · 83 ft·lb	p. 305
Right pivot bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 316
Right pivot bolt	3.9 N·m	0.4 kgf·m · 2.9 ft·lb	p. 316
Valve threads, seal	5.4 N·m	0.54 kgf·m · 4 ft·lb	p. 323
Gm PIVOT BOLT SCREW	1 N·m	0.1 kgf·m · 0.7 ft·lb	p. 328
Caliper pin bolts	23 N·m	2.3 kgf·m · 17 ft·lb	p. 332
Cotter pin hole	137 N·m	14 kgf·m · 101 ft·lb	p. 337
Front final clutch cover bolt	49 N·m	5 kgf·m · 36 ft·lb	p. 341
Mounting bolt and nut	44 N·m	4.5 kgf·m · 32 ft·lb	p. 369
Mounting bolt and nut	22 N·m	2.2 kgf·m · 16 ft·lb	p. 369
Rear final gear pinion bearing lock nut	46.5 N·m	4.7 kgf·m · 34 ft·lb	p. 375
Rear wheel hub nut	98 N·m	10 kgf·m · 72 ft·lb	p. 375
Rear wheel hub nut	49 N·m	5 kgf·m · 36 ft·lb	p. 375
Gear shimistoo steps	49 N·m	5 kgf·m	p. 395
Axle housing mounting nuts	44 N·m	4.5 kgf·m · 32 ft·lb	p. 397
Angle sensor bolt	6 N·m	0.6 kgf·m · 4.4 ft·lb	p. 458
J washer	13 N·m	1.3 kgf·m · 10 ft·lb	p. 479

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	PDF page
K16PR-U11	1–1.1 mm	p. 19
O00	—	p. 537
S19	—	p. 538
S28	—	p. 540
O1L	—	p. 549

Service intervals

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Engine oil change	600 miles		p. 82

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