2005-2011 Honda TRX500 Foreman ATV Clymer Repair
Manual M206
Models
Covered:
- TRX 500 Foreman 2005 - 2011
Every Clymer contains hundreds of original
photographs and illustrations developed from a complete disassembly and assembly
of the motorcycle. This, in addition to extensive research, allows Clymer to
achieve an un-matched level of detail, accuracy & clarity.
The step-by-step instructions and two column text
with large print are user friendly, bold figure numbers make it easy to quickly
match instructions with illustrations and photos. Thumb tabbed chapters,
numbered table of contents and extensive index make it possible to locate the
desired section quickly. This manual includes a Quick Reference Data section
with frequently used specifications.
Table of Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers and
information labels / Fasteners / Shop supplies / Tools / Measuring tools /
Electrical system fundamentals / Service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Starting the engine / Starting difficulty / Poor idle speed performance / Poor
medium and high speed performance / Electric starting system / Charging system /
Ignition system / Cooling system / Combination meter / Fuel system / Engine
overheating / Engine / Engine noises / Cylinder leakdown test / Clutch (engine)
/ Transmission / Drive selector clutch / Drivetrain / Handling / Electric power
steering system / Frame noise / Brake system / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE and TUNE-UP
Pre-ride check list / Tune-up / Tires and wheels / Engine oil / Front
differential gearcase / Rear differential gearcase / Air filter / Control cables
/ Brake system / Fuel system / Spark plug / Valve clearance adjustment /
Ignition timing inspection / Cylinder compression test / Clutch adjustment /
Exhaust system / Suspension / Steering system / Drive system / Electrical system
/ Body / Fasteners / Specifications
CHAPTER FOUR / ENGINE TOP END
Exhaust system / Cylinder head cover, rocker arms / and push rods / Cylinder
head / Valves and valve components / Cylinder / Piston and piston rings /
Camshaft / Specifications
CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine removal installation / Recoil starter /
Driven pulley / Alternator cover / Rear crankcase cover / Flywheel and starter
clutch / Reverse shaft assembly / Lubrication system / Oil pump / Relief valve /
Oil strainer screen / Output shaft and gears / Crankcase / Transmission function
check / Engine break-in / Specifications
CHAPTER SIX / CLUTCH, PRIMARY DRIVE GEAR and ESP GEARS
ESP reduction gears / Front crankcase cover / Clutch lever assembly / Clutch
assemblies / Centrifugal clutch and primary drive gear / Change clutch /
Specifications
CHAPTER SEVEN / TRANSMISSION and SHIFT MECHANISM
External gearshift linkage / Transmission and internal shift mechanism /
Mainshaft / Countershaft / Reverse idler gear assembly / Internal shift
mechanism / Reverse selector cable replacement / Specifications
CHAPTER EIGHT / FUEL SYSTEM
Air intake duct / Air box / Carburetor / Carburetor float level adjustment /
Carburetor adjustments / Carburetor heater / Fuel tank / Fuel valve / Fuel level
system / Throttle housing and cable / Choke cable replacement / Specifications
CHAPTER NINE / ELECTRICAL SYSTEM
Electrical component replacement / Continuity testing / Electrical connectors /
Negative battery terminal / Battery / Charging system / Alternator / Ignition
system / Starting system / Starter relay / Start circuit diode / Electric shift
system / Drive selector clutch system / Electric power steering (EPS) / Lighting
system / Sensors / Cooling fan motor / Combination meter / Switches / Fuses /
Wiring diagrams / Specifications
CHAPTER TEN / FRONT SUSPENSION and STEERING
Front wheel / Tires and wheels / Front hub / Shock absorbers / Tie rods /
Steering knuckle / Control arms / Handlebar / Steering shaft / Electric power
steering / Specifications
CHAPTER ELEVEN / FRONT DRIVE MECHANISM
Front drive axles / Drive shaft / Front final drive and selector clutch /
Specifications
CHAPTER TWELVE / REAR AXLE, SUSPENSION and FINAL DRIVE
Rear wheels / Wheel hub / Shock absorbers / Rear axle / Rear final drive / Swing
arm / Specifications
CHAPTER THIRTEEN / BRAKES
Brake service / Front brake pads / Front brake caliper / Front brake master
cylinder / Brake system draining / Brake bleeding / Rear drum brake / Rear brake
shoes / Brake panel / Front brake hose replacement / Rear brake pedal and cable
/ Rear brake lever/parking brake cable / Specifications
CHAPTER FOURTEEN / OIL COOLER AND COOLING FAN
Oil coolers / Oil hose replacement / Cooling fan / Specifications
CHAPTER FIFTEEN / BODY
Retaining clips / Retaining tabs / Seat / Recoil starter cover / Right side
cover / Left side cover / Fuel tank cover / Front carrier / Front skid plate /
Front bumper cover / Front bumper / Inner front fender / Front fender / Center
mud guards / Front mud guards / Rear fender lid / Taillight grille / Rear corner
outer fender / Storage box / Rear carrier / Rear fender / Engine skidplate /
Rear final drive skidplate / Air guides / Handlebar cover / Specifications
INDEX
COLOR WIRING DIAGRAMS
Specifications:
- Publisher: Clymer
Publications
- Printed Book: Approx. 391 pages
- Dimensions: 10.0 x 7.0 x 0.8 inches
- Part # CM206
- ISBN #: 9781599694108