1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
Table of Contents
- 2. How to use this manual
- 4. Symbols
- 5. Table of Contents
- 7. General information
- 8. Service rules
- 9. Model identification
- 10. Labels
- 12. General specifications
- 13. GFM-FI system specifications
- 14. Cooling system specifications
- 15. Cylinder/piston specifications
- 16. Crankcase/transmission/crankshaft/balanc...
- 17. Rear wheel/suspension specifications
- 18. Battery/charging system specifications
- 19. Torque values
- 20. GENERAL INFORMATION
- 25. Lubrication & seal points - engine
- 27. Lubrication & seal points - frame
- 29. Cable & harness routing
- 50. Emission control systems
- 51. Noise emission control system
- 53. Frame/body panels/exhaust system
- 54. Frame/body panels/exhaust system service...
- 55. Body panel locations
- 56. Seat removal
- 57. Fuel tank side cover
- 58. Mudguards
- 59. Engine guard
- 60. Front fender/carrier removal/installatio...
- 61. Front fender/carrier disassembly/assembl...
- 62. Tool box lid
- 63. Rear fender/carrier
- 65. Mudguard bracket
- 66. Exhaust system removal
- 67. Exhaust pipe stud bolt replacement
- 69. Maintenance
- 70. Maintenance - torque values
- 71. Maintenance schedule
- 72. Fuel line
- 73. Air cleaner
- 75. Air cleaner housing drain tube
- 76. Spark plug
- 77. Valve clearance
- 80. Engine oil level check
- 81. Engine oil change
- 82. Engine oil filter
- 83. Engine idle speed inspection
- 84. Cooling system maintenance
- 85. Drive train boots
- 86. Final gear case oil change
- 87. Differential oil change
- 88. Brake fluid
- 89. Brake shoes wear
- 90. Brake system maintenance
- 91. Reverse lock system
- 92. Guards
- 93. Suspension maintenance
- 94. Tie-rod and joint boots
- 97. PGM-FI system
- 98. PGM-FI component location
- 99. PGM-FI system diagram
- 100. PGM-FI system service information
- 101. PGM-FI system symptom troubleshooting
- 103. PGM-FI connector location
- 106. PGM-FI - general troubleshooting
- 107. HDS pocket tester information
- 108. Erasing DTC
- 109. PGM-FI DTC index
- 110. DTC troubleshooting
- 111. DTC 1-2 (MAP sensor high voltage)
- 112. DTC 7-1 (ECT sensor low voltage)
- 113. DTC 7-2 (ECT sensor high voltage)
- 114. DTC 8-1 (TP sensor low voltage)
- 115. DTC 8-2 (TP sensor high voltage)
- 117. DTC 9-1 (IAT sensor low voltage)
- 118. DTC 9-2 (IAT sensor high voltage)
- 119. DTC 12-1 (fuel injector)
- 120. DTC 29-1 (IACV)
- 121. DTC 33-2 (EEPROM)
- 122. DTC 54-1 (bank angle sensor low voltage)
- 123. DTC 54-2 (bank angle sensor high voltage...
- 125. MIL circuit inspection
- 126. Sensor unit (MAP/TP sensor) removal/inst...
- 127. TP sensor reset procedure
- 128. ECT sensor removal/installation
- 129. Bank angle sensor removal/installation
- 130. Bank angle sensor inspection with HDS po...
- 131. Power/ground line inspection
- 132. Engine stop switch line inspection
- 133. Ignition system
- 134. Ignition system component location
- 135. Ignition system service information
- 136. Ignition system troubleshooting
- 137. Ignition system inspection
- 138. CKP sensor peak voltage
- 139. Ignition coil removal/installation
- 140. Ignition timing
- 141. Condenser (Canada type) inspection
- 142. Rectifier (Canada type) removal/installa...
- 143. Electric starter
- 144. Electric starter - component location
- 145. Electric starter - service information
- 146. Electric starter troubleshooting
- 148. Starter motor removal/installation
- 149. Starter motor inspection
- 150. Starter relay switch - operation inspect...
- 151. Starter relay switch - circuit inspectio...
- 152. Diode removal/installation
- 153. Fuel system
- 154. Fuel system exploded diagram
- 155. Fuel system - service information
- 156. Fuel system - tools needed
- 157. Fuel line troubleshooting
- 158. Fuel line inspection
- 159. Injector side
- 161. Quick connect fitting installation
- 162. Quick connect fitting installation - inj...
- 163. Fuel pressure increasing
- 164. Fuel flow inspection
- 165. Sub-fuel tank/fuel pump inspection
- 166. Sub-fuel tank/fuel pump removal/installa...
- 167. Fuel pump filter replacement (Type A)
- 169. Fuel pump unit holder removal (Type A)
- 171. Sub-fuel tank/fuel pump assembly
- 172. Fuel tank removal/installation
- 173. Fuel strainer screen cleaning
- 174. Air cleaner housing removal/installation
- 175. Throttle body removal
- 176. Throttle body disassembly/assembly
- 177. Throttle body installation
- 178. IACV inspection
- 179. IACV removal/installation
- 180. Fuel injector inspection
- 181. Fuel injector installation
- 183. Cooling system
- 184. Cooling system flow pattern
- 185. Cooling system service information
- 186. Cooling system - tools needed
- 187. Cooling system testing
- 188. Coolant replacement
- 189. Coolant replacement/air bleeding
- 190. Thermostat removal/installation
- 191. Radiator/cooling fan
- 192. Cooling fan removal/installation
- 193. Radiator reserve tank removal/installati...
- 194. Mechanical seal replacement
- 197. Lubrication system
- 198. Lubrication system diagram
- 199. Lubrication system service information
- 200. Oil pump removal
- 201. Oil pump assembly
- 202. Relief valve disassembly/inspection
- 203. Cylinder head/valve
- 204. Cylinder head/valve - system components ...
- 206. Cylinder head/valve - service informatio...
- 207. Cylinder head/valve - tools needed
- 208. Cylinder head/valve troubleshooting
- 209. Cylinder compression
- 211. Rocker arm/shaft inspection
- 212. Cylinder head disassembly
- 213. Cylinder head inspection
- 214. Valve guide replacement
- 215. Valve seat inspection
- 216. Cylinder head assembly
- 218. Cylinder head installation
- 219. Cylinder head cover assembly/installatio...
- 221. Cylinder head cover installation
- 222. Camshaft removal
- 223. Camshaft inspection
- 224. Cam chain tensioner inspection
- 225. Camshaft installation
- 229. Cylinder/piston
- 230. Cylinder/piston - system components diag...
- 231. Cylinder/piston - service information
- 232. Cylinder/piston removal
- 233. Cylinder inspection
- 234. Piston/piston ring inspection
- 236. Cylinder stud bolt replacement
- 237. Piston installation
- 239. 12. CLUTCH/GEARSHIFT LINKAGE
- 240. Clutch/gearshift linkage - system compon...
- 241. Clutch/gearshift linkage - service infor...
- 242. Clutch/gearshift linkage - tools needed
- 243. Clutch/gearshift linkage troubleshooting
- 244. Front crankcase cover removal
- 245. Crankshaft bearing replacement
- 246. Centrifugal clutch removal
- 247. Clutch drum check
- 248. Clutch spring removal
- 249. Centrifugal clutch assembly
- 250. Centrifugal clutch installation
- 251. Change clutch disassembly
- 253. Clutch lifter inspection
- 254. Clutch disc check
- 255. Clutch outer guide check
- 257. Gearshift linkage removal
- 259. Gearshift linkage installation
- 260. Gearshift spindle A (FM/FPM models only)
- 261. Front crankcase cover installation
- 263. Alternator/starter clutch
- 264. Alternator/starter clutch - system compo...
- 266. Alternator/starter clutch - service info...
- 267. Alternator/starter clutch - tools needed
- 268. Recoil starter (Canada type) removal/ins...
- 270. Stator and CKP sensor removal
- 271. Rear crankcase cover installation
- 273. Flywheel/starter clutch removal
- 274. Starter clutch disassembly
- 275. Starter clutch assembly
- 276. Starter clutch installation
- 278. Starter motor bearing replacement
- 279. Crankshaft/transmission/crankshaft/balan...
- 280. Crankshaft/transmission/crankshaft/balan...
- 281. Crankshaft/transmission/crankshaft/balan...
- 282. Crankshaft/transmission/crankshaft/balan...
- 284. Crankshaft/transmission/crankshaft/balan...
- 285. Crankcase separation
- 286. Oil strainter cleaning
- 287. Gear/bushing/shaft inspection
- 288. Output shaft/gear
- 289. Shift drum
- 293. Crankshaft/balancer removal
- 294. Crankshaft/balancer installation
- 295. CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANC...
- 296. Crankcase bearing inspection
- 298. Rear crankcase bearing replacement
- 299. Crankcase assembly
- 301. Engine removal/installation
- 302. Engine removal/installation - system com...
- 303. Engine removal/installation - service in...
- 304. Engine removal
- 309. Engine installation
- 315. 16. FRONT WHEEUSUSPENSION/STEERING
- 316. Front wheel/suspension/steering - system...
- 318. Front wheel/suspension/steering - servic...
- 319. Front wheel/suspension/steering - torque...
- 320. Front wheel/suspension/steering - tools ...
- 321. Front wheel/suspension/steering troubles...
- 322. Handlebar removal
- 323. Handlebar installation
- 325. Throttle housing disassembly
- 326. Throttle housing assembly
- 327. Front wheel removal
- 328. Tire repair
- 330. Tire assembly
- 333. Wheel hub and knuckle inspection
- 335. Ball joint replacement
- 336. Ball joint installation
- 337. Suspension arm removal
- 338. Suspension arm inspection
- 339. Suspension arm installation
- 340. Front shock absorber removal
- 341. Front shock absorber installation
- 343. Shaft bushing inspection
- 344. Steering shaft assembly
- 346. Steering shaft/EPS unit (FPM/FPE models)...
- 348. Steering shaft check
- 349. Shaft bushing check
- 350. Steering shaft/EPS unit (FPM/FPE models)...
- 354. Tie-rod removal
- 355. Tie-rod inspection
- 357. Rear wheel/suspension
- 358. Rear wheel/suspension - system component...
- 359. Rear wheel/suspension - service informat...
- 360. Rear wheel/suspension - tools needed
- 361. Rear wheel/suspension - troubleshooting
- 362. Rear wheel removal
- 363. Rear shock absorber inspection
- 364. Swingarm removal
- 365. Swingarm bearing replacement
- 366. Swingarm installation
- 367. Brake system
- 368. Brake system components diagram
- 370. Brake system components - service inform...
- 371. Brake system components torque values
- 372. Brake system components troubleshooting
- 373. Brake fluid replacement/air bleeding
- 374. Brake pad/disc
- 375. Brake disc inspection
- 376. Front master cylinder removal
- 377. Front master cylinder inspection
- 378. Front brake caliper disassemlby
- 379. Front brake caliper inspection
- 382. Rear brake drum/shoes
- 383. Brake drum disassembly
- 385. Brake drum installation
- 386. Rear brake pedal removal
- 389. 19. FRONT DRIVING MECHANISM
- 390. Front driving mechanism - system compone...
- 391. Front driving mechanism - service inform...
- 392. Front driving mechanism - tools needed
- 394. Front driving mechanism - troubleshootin...
- 395. Front drive shaft removal
- 397. Front drive shaft assembly
- 399. Front drive shaft installation
- 400. Front final drive removal
- 402. Front propeller shaft disassembly/inspec...
- 403. Front propeller shaft assembly
- 404. Front final clutch disassembly
- 405. Front final clutch inspection
- 407. Front final clutch assembly
- 410. Front final gear assembly/inspection
- 411. Differential removal
- 412. Gear tooth contact pattern check
- 414. Differential inspection
- 415. Differential components inspection
- 416. Side cone spring check
- 417. Pinion ball bearing and shim replacement
- 418. Gear case bearing replacement
- 419. Pinion needle bearing
- 421. Front final gear assembly
- 422. Differential assembly
- 424. Final gear case assembly
- 425. Front final drive installation
- 429. 20. REAR DRIVING MECHANISM
- 430. Rear driving mechanism - system componen...
- 431. Rear driving mechanism - service informa...
- 432. Rear driving mechanism - tools needed
- 434. Rear driving mechanism troubleshooting
- 435. Rear axle removal
- 436. Rear axle inspection
- 437. Rear final drive removal
- 438. Propeller shaft inspection
- 439. Universal bolt check
- 440. Rear final gear disassembly/inspection
- 441. Rear final gear case disassembly
- 443. Removing the pinion gear
- 444. Pinion bearing and shim replacement
- 445. Gear case bearing: replacement
- 447. Rear final gear assembly
- 448. Pinion gear - installation
- 449. Ring gear clearance inspection
- 450. Rear final drive installation
- 452. Rear axle installation
- 455. Battery/charging system
- 456. Battery/charging system - component loca...
- 457. Battery/charging system diagram (Canada ...
- 458. Battery/charging system - service inform...
- 459. Battery/charging system - tools needed
- 460. Battery/charging system troubleshooting
- 462. Battery removal/installation
- 463. Current leakage inspection
- 464. Alternator charging coil inspection
- 465. Power relay (Canada type) inspection
- 467. 22. LIGHTS/METERS/SWITCHES
- 468. Lights/meters/switches - component locat...
- 469. Lights/meters/switches - service informa...
- 470. Assist headlight bulb replacement
- 471. Headlight bulb replacement
- 472. Brake/taillight replacement
- 473. Power/ground line - inspection
- 475. Speedometer
- 476. Accessory socket inspection
- 477. Ignition switch inspection
- 478. Front brake switch inspection
- 479. Front brake switch replacement
- 480. Pedal switch inspection
- 481. Cooling fan
- 482. Cooling Fan Operation Inspection
- 483. 4WD SELECT SWITCH
- 484. Fuel gauge/fuel level sensor removal/ins...
- 485. Lights/meters/switches - system inspecti...
- 486. Fuel level sensor inspection
- 487. Electric shift program (ESP: FE/FPE mode...
- 488. ESP component location
- 489. ESP system diagram
- 490. ESP: service information
- 491. ESP troubleshooting
- 492. Electric shift does not operate
- 493. ESP connector location
- 496. ESP troubleshooting information
- 497. HDS pocket tester usage
- 498. To erase DTC
- 499. ESP DTC index
- 500. DTC: troubleshooting
- 501. DTC 21-1 (shift angle sensor low voltage...
- 503. DTC 21-2 (shift angle sensor high voltag...
- 504. DTC 22-1/22-2 (shift angle sensor respon...
- 505. DTC 23-1 (shift angle sensor response: v...
- 506. DTC 24-1 (shift control motor drive circ...
- 507. DTC 32-1 (fail-safe relay circuit)
- 508. DTC 41-1 (gear position switch circuit: ...
- 509. DTC 41-2 (gear position switch circuit: ...
- 511. DTC 42-1 (gearshift switch circuit)
- 513. VS sensor removal/installation
- 514. Shift angle sensor removal
- 515. Gearshift switch - system inspection
- 516. Shift control motor/reduction gears
- 517. Shift control motor/reduction gears inst...
- 519. Electric power steering (EPS: FPM/FPE mo...
- 520. EPS component location
- 521. EPS system diagram
- 522. EPS system - service information
- 523. EPS connector location
- 527. EPS troubleshooting information
- 528. How to troubleshootin EPS DTC
- 529. Erase DTC
- 531. Torque sensor initialization
- 533. Circuit inspection at EPS ECU and PCM/EC...
- 534. EPS DTC index
- 536. Verifying proper connector contact
- 537. DTC 11-02: comparison between vehicle sp...
- 539. DTC 15-01: 2WD/4WD select signal blinkin...
- 540. DTC 15-02: 2WD/4WD select signal input l...
- 541. DTC 16-01, 16-02, 17-01, 17-02, 18-01, 1...
- 542. DTC 18-03: EPS ECU internal circuit (cur...
- 543. DTC 22-01: failure to initialize the tor...
- 544. DTC 23-01: low/high voltage for the torq...
- 546. DTC 23-02: torque sensor (VT3 differenti...
- 547. DTC 24-01: engine speed signal (regular ...
- 548. DTC 31-01: low/high IG1-terminal voltage...
- 549. DTC 32-01: low/high VBU voltage (regular...
- 550. EPS indicator circuit inspection
- 551. EPS indicator does not go off, and no DT...
- 553. EPS ECU removal/installation
- 555. Wiring diagrams
- 556. FM model wiring diagram
- 557. FE model wiring diagram
- 558. FPM model wiring diagram
- 559. FPE model wiring diagram
- 563. Index
Page 1 of 564
Table of Contents
- 2. How to use this manual
- 4. Symbols
- 5. Table of Contents
- 7. General information
- 8. Service rules
- 9. Model identification
- 10. Labels
- 12. General specifications
- 13. GFM-FI system specifications
- 14. Cooling system specifications
- 15. Cylinder/piston specifications
- 16. Crankcase/transmission/crankshaft/balanc...
- 17. Rear wheel/suspension specifications
- 18. Battery/charging system specifications
- 19. Torque values
- 20. GENERAL INFORMATION
- 25. Lubrication & seal points - engine
- 27. Lubrication & seal points - frame
- 29. Cable & harness routing
- 50. Emission control systems
- 51. Noise emission control system
- 53. Frame/body panels/exhaust system
- 54. Frame/body panels/exhaust system service...
- 55. Body panel locations
- 56. Seat removal
- 57. Fuel tank side cover
- 58. Mudguards
- 59. Engine guard
- 60. Front fender/carrier removal/installatio...
- 61. Front fender/carrier disassembly/assembl...
- 62. Tool box lid
- 63. Rear fender/carrier
- 65. Mudguard bracket
- 66. Exhaust system removal
- 67. Exhaust pipe stud bolt replacement
- 69. Maintenance
- 70. Maintenance - torque values
- 71. Maintenance schedule
- 72. Fuel line
- 73. Air cleaner
- 75. Air cleaner housing drain tube
- 76. Spark plug
- 77. Valve clearance
- 80. Engine oil level check
- 81. Engine oil change
- 82. Engine oil filter
- 83. Engine idle speed inspection
- 84. Cooling system maintenance
- 85. Drive train boots
- 86. Final gear case oil change
- 87. Differential oil change
- 88. Brake fluid
- 89. Brake shoes wear
- 90. Brake system maintenance
- 91. Reverse lock system
- 92. Guards
- 93. Suspension maintenance
- 94. Tie-rod and joint boots
- 97. PGM-FI system
- 98. PGM-FI component location
- 99. PGM-FI system diagram
- 100. PGM-FI system service information
- 101. PGM-FI system symptom troubleshooting
- 103. PGM-FI connector location
- 106. PGM-FI - general troubleshooting
- 107. HDS pocket tester information
- 108. Erasing DTC
- 109. PGM-FI DTC index
- 110. DTC troubleshooting
- 111. DTC 1-2 (MAP sensor high voltage)
- 112. DTC 7-1 (ECT sensor low voltage)
- 113. DTC 7-2 (ECT sensor high voltage)
- 114. DTC 8-1 (TP sensor low voltage)
- 115. DTC 8-2 (TP sensor high voltage)
- 117. DTC 9-1 (IAT sensor low voltage)
- 118. DTC 9-2 (IAT sensor high voltage)
- 119. DTC 12-1 (fuel injector)
- 120. DTC 29-1 (IACV)
- 121. DTC 33-2 (EEPROM)
- 122. DTC 54-1 (bank angle sensor low voltage)
- 123. DTC 54-2 (bank angle sensor high voltage...
- 125. MIL circuit inspection
- 126. Sensor unit (MAP/TP sensor) removal/inst...
- 127. TP sensor reset procedure
- 128. ECT sensor removal/installation
- 129. Bank angle sensor removal/installation
- 130. Bank angle sensor inspection with HDS po...
- 131. Power/ground line inspection
- 132. Engine stop switch line inspection
- 133. Ignition system
- 134. Ignition system component location
- 135. Ignition system service information
- 136. Ignition system troubleshooting
- 137. Ignition system inspection
- 138. CKP sensor peak voltage
- 139. Ignition coil removal/installation
- 140. Ignition timing
- 141. Condenser (Canada type) inspection
- 142. Rectifier (Canada type) removal/installa...
- 143. Electric starter
- 144. Electric starter - component location
- 145. Electric starter - service information
- 146. Electric starter troubleshooting
- 148. Starter motor removal/installation
- 149. Starter motor inspection
- 150. Starter relay switch - operation inspect...
- 151. Starter relay switch - circuit inspectio...
- 152. Diode removal/installation
- 153. Fuel system
- 154. Fuel system exploded diagram
- 155. Fuel system - service information
- 156. Fuel system - tools needed
- 157. Fuel line troubleshooting
- 158. Fuel line inspection
- 159. Injector side
- 161. Quick connect fitting installation
- 162. Quick connect fitting installation - inj...
- 163. Fuel pressure increasing
- 164. Fuel flow inspection
- 165. Sub-fuel tank/fuel pump inspection
- 166. Sub-fuel tank/fuel pump removal/installa...
- 167. Fuel pump filter replacement (Type A)
- 169. Fuel pump unit holder removal (Type A)
- 171. Sub-fuel tank/fuel pump assembly
- 172. Fuel tank removal/installation
- 173. Fuel strainer screen cleaning
- 174. Air cleaner housing removal/installation
- 175. Throttle body removal
- 176. Throttle body disassembly/assembly
- 177. Throttle body installation
- 178. IACV inspection
- 179. IACV removal/installation
- 180. Fuel injector inspection
- 181. Fuel injector installation
- 183. Cooling system
- 184. Cooling system flow pattern
- 185. Cooling system service information
- 186. Cooling system - tools needed
- 187. Cooling system testing
- 188. Coolant replacement
- 189. Coolant replacement/air bleeding
- 190. Thermostat removal/installation
- 191. Radiator/cooling fan
- 192. Cooling fan removal/installation
- 193. Radiator reserve tank removal/installati...
- 194. Mechanical seal replacement
- 197. Lubrication system
- 198. Lubrication system diagram
- 199. Lubrication system service information
- 200. Oil pump removal
- 201. Oil pump assembly
- 202. Relief valve disassembly/inspection
- 203. Cylinder head/valve
- 204. Cylinder head/valve - system components ...
- 206. Cylinder head/valve - service informatio...
- 207. Cylinder head/valve - tools needed
- 208. Cylinder head/valve troubleshooting
- 209. Cylinder compression
- 211. Rocker arm/shaft inspection
- 212. Cylinder head disassembly
- 213. Cylinder head inspection
- 214. Valve guide replacement
- 215. Valve seat inspection
- 216. Cylinder head assembly
- 218. Cylinder head installation
- 219. Cylinder head cover assembly/installatio...
- 221. Cylinder head cover installation
- 222. Camshaft removal
- 223. Camshaft inspection
- 224. Cam chain tensioner inspection
- 225. Camshaft installation
- 229. Cylinder/piston
- 230. Cylinder/piston - system components diag...
- 231. Cylinder/piston - service information
- 232. Cylinder/piston removal
- 233. Cylinder inspection
- 234. Piston/piston ring inspection
- 236. Cylinder stud bolt replacement
- 237. Piston installation
- 239. 12. CLUTCH/GEARSHIFT LINKAGE
- 240. Clutch/gearshift linkage - system compon...
- 241. Clutch/gearshift linkage - service infor...
- 242. Clutch/gearshift linkage - tools needed
- 243. Clutch/gearshift linkage troubleshooting
- 244. Front crankcase cover removal
- 245. Crankshaft bearing replacement
- 246. Centrifugal clutch removal
- 247. Clutch drum check
- 248. Clutch spring removal
- 249. Centrifugal clutch assembly
- 250. Centrifugal clutch installation
- 251. Change clutch disassembly
- 253. Clutch lifter inspection
- 254. Clutch disc check
- 255. Clutch outer guide check
- 257. Gearshift linkage removal
- 259. Gearshift linkage installation
- 260. Gearshift spindle A (FM/FPM models only)
- 261. Front crankcase cover installation
- 263. Alternator/starter clutch
- 264. Alternator/starter clutch - system compo...
- 266. Alternator/starter clutch - service info...
- 267. Alternator/starter clutch - tools needed
- 268. Recoil starter (Canada type) removal/ins...
- 270. Stator and CKP sensor removal
- 271. Rear crankcase cover installation
- 273. Flywheel/starter clutch removal
- 274. Starter clutch disassembly
- 275. Starter clutch assembly
- 276. Starter clutch installation
- 278. Starter motor bearing replacement
- 279. Crankshaft/transmission/crankshaft/balan...
- 280. Crankshaft/transmission/crankshaft/balan...
- 281. Crankshaft/transmission/crankshaft/balan...
- 282. Crankshaft/transmission/crankshaft/balan...
- 284. Crankshaft/transmission/crankshaft/balan...
- 285. Crankcase separation
- 286. Oil strainter cleaning
- 287. Gear/bushing/shaft inspection
- 288. Output shaft/gear
- 289. Shift drum
- 293. Crankshaft/balancer removal
- 294. Crankshaft/balancer installation
- 295. CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANC...
- 296. Crankcase bearing inspection
- 298. Rear crankcase bearing replacement
- 299. Crankcase assembly
- 301. Engine removal/installation
- 302. Engine removal/installation - system com...
- 303. Engine removal/installation - service in...
- 304. Engine removal
- 309. Engine installation
- 315. 16. FRONT WHEEUSUSPENSION/STEERING
- 316. Front wheel/suspension/steering - system...
- 318. Front wheel/suspension/steering - servic...
- 319. Front wheel/suspension/steering - torque...
- 320. Front wheel/suspension/steering - tools ...
- 321. Front wheel/suspension/steering troubles...
- 322. Handlebar removal
- 323. Handlebar installation
- 325. Throttle housing disassembly
- 326. Throttle housing assembly
- 327. Front wheel removal
- 328. Tire repair
- 330. Tire assembly
- 333. Wheel hub and knuckle inspection
- 335. Ball joint replacement
- 336. Ball joint installation
- 337. Suspension arm removal
- 338. Suspension arm inspection
- 339. Suspension arm installation
- 340. Front shock absorber removal
- 341. Front shock absorber installation
- 343. Shaft bushing inspection
- 344. Steering shaft assembly
- 346. Steering shaft/EPS unit (FPM/FPE models)...
- 348. Steering shaft check
- 349. Shaft bushing check
- 350. Steering shaft/EPS unit (FPM/FPE models)...
- 354. Tie-rod removal
- 355. Tie-rod inspection
- 357. Rear wheel/suspension
- 358. Rear wheel/suspension - system component...
- 359. Rear wheel/suspension - service informat...
- 360. Rear wheel/suspension - tools needed
- 361. Rear wheel/suspension - troubleshooting
- 362. Rear wheel removal
- 363. Rear shock absorber inspection
- 364. Swingarm removal
- 365. Swingarm bearing replacement
- 366. Swingarm installation
- 367. Brake system
- 368. Brake system components diagram
- 370. Brake system components - service inform...
- 371. Brake system components torque values
- 372. Brake system components troubleshooting
- 373. Brake fluid replacement/air bleeding
- 374. Brake pad/disc
- 375. Brake disc inspection
- 376. Front master cylinder removal
- 377. Front master cylinder inspection
- 378. Front brake caliper disassemlby
- 379. Front brake caliper inspection
- 382. Rear brake drum/shoes
- 383. Brake drum disassembly
- 385. Brake drum installation
- 386. Rear brake pedal removal
- 389. 19. FRONT DRIVING MECHANISM
- 390. Front driving mechanism - system compone...
- 391. Front driving mechanism - service inform...
- 392. Front driving mechanism - tools needed
- 394. Front driving mechanism - troubleshootin...
- 395. Front drive shaft removal
- 397. Front drive shaft assembly
- 399. Front drive shaft installation
- 400. Front final drive removal
- 402. Front propeller shaft disassembly/inspec...
- 403. Front propeller shaft assembly
- 404. Front final clutch disassembly
- 405. Front final clutch inspection
- 407. Front final clutch assembly
- 410. Front final gear assembly/inspection
- 411. Differential removal
- 412. Gear tooth contact pattern check
- 414. Differential inspection
- 415. Differential components inspection
- 416. Side cone spring check
- 417. Pinion ball bearing and shim replacement
- 418. Gear case bearing replacement
- 419. Pinion needle bearing
- 421. Front final gear assembly
- 422. Differential assembly
- 424. Final gear case assembly
- 425. Front final drive installation
- 429. 20. REAR DRIVING MECHANISM
- 430. Rear driving mechanism - system componen...
- 431. Rear driving mechanism - service informa...
- 432. Rear driving mechanism - tools needed
- 434. Rear driving mechanism troubleshooting
- 435. Rear axle removal
- 436. Rear axle inspection
- 437. Rear final drive removal
- 438. Propeller shaft inspection
- 439. Universal bolt check
- 440. Rear final gear disassembly/inspection
- 441. Rear final gear case disassembly
- 443. Removing the pinion gear
- 444. Pinion bearing and shim replacement
- 445. Gear case bearing: replacement
- 447. Rear final gear assembly
- 448. Pinion gear - installation
- 449. Ring gear clearance inspection
- 450. Rear final drive installation
- 452. Rear axle installation
- 455. Battery/charging system
- 456. Battery/charging system - component loca...
- 457. Battery/charging system diagram (Canada ...
- 458. Battery/charging system - service inform...
- 459. Battery/charging system - tools needed
- 460. Battery/charging system troubleshooting
- 462. Battery removal/installation
- 463. Current leakage inspection
- 464. Alternator charging coil inspection
- 465. Power relay (Canada type) inspection
- 467. 22. LIGHTS/METERS/SWITCHES
- 468. Lights/meters/switches - component locat...
- 469. Lights/meters/switches - service informa...
- 470. Assist headlight bulb replacement
- 471. Headlight bulb replacement
- 472. Brake/taillight replacement
- 473. Power/ground line - inspection
- 475. Speedometer
- 476. Accessory socket inspection
- 477. Ignition switch inspection
- 478. Front brake switch inspection
- 479. Front brake switch replacement
- 480. Pedal switch inspection
- 481. Cooling fan
- 482. Cooling Fan Operation Inspection
- 483. 4WD SELECT SWITCH
- 484. Fuel gauge/fuel level sensor removal/ins...
- 485. Lights/meters/switches - system inspecti...
- 486. Fuel level sensor inspection
- 487. Electric shift program (ESP: FE/FPE mode...
- 488. ESP component location
- 489. ESP system diagram
- 490. ESP: service information
- 491. ESP troubleshooting
- 492. Electric shift does not operate
- 493. ESP connector location
- 496. ESP troubleshooting information
- 497. HDS pocket tester usage
- 498. To erase DTC
- 499. ESP DTC index
- 500. DTC: troubleshooting
- 501. DTC 21-1 (shift angle sensor low voltage...
- 503. DTC 21-2 (shift angle sensor high voltag...
- 504. DTC 22-1/22-2 (shift angle sensor respon...
- 505. DTC 23-1 (shift angle sensor response: v...
- 506. DTC 24-1 (shift control motor drive circ...
- 507. DTC 32-1 (fail-safe relay circuit)
- 508. DTC 41-1 (gear position switch circuit: ...
- 509. DTC 41-2 (gear position switch circuit: ...
- 511. DTC 42-1 (gearshift switch circuit)
- 513. VS sensor removal/installation
- 514. Shift angle sensor removal
- 515. Gearshift switch - system inspection
- 516. Shift control motor/reduction gears
- 517. Shift control motor/reduction gears inst...
- 519. Electric power steering (EPS: FPM/FPE mo...
- 520. EPS component location
- 521. EPS system diagram
- 522. EPS system - service information
- 523. EPS connector location
- 527. EPS troubleshooting information
- 528. How to troubleshootin EPS DTC
- 529. Erase DTC
- 531. Torque sensor initialization
- 533. Circuit inspection at EPS ECU and PCM/EC...
- 534. EPS DTC index
- 536. Verifying proper connector contact
- 537. DTC 11-02: comparison between vehicle sp...
- 539. DTC 15-01: 2WD/4WD select signal blinkin...
- 540. DTC 15-02: 2WD/4WD select signal input l...
- 541. DTC 16-01, 16-02, 17-01, 17-02, 18-01, 1...
- 542. DTC 18-03: EPS ECU internal circuit (cur...
- 543. DTC 22-01: failure to initialize the tor...
- 544. DTC 23-01: low/high voltage for the torq...
- 546. DTC 23-02: torque sensor (VT3 differenti...
- 547. DTC 24-01: engine speed signal (regular ...
- 548. DTC 31-01: low/high IG1-terminal voltage...
- 549. DTC 32-01: low/high VBU voltage (regular...
- 550. EPS indicator circuit inspection
- 551. EPS indicator does not go off, and no DT...
- 553. EPS ECU removal/installation
- 555. Wiring diagrams
- 556. FM model wiring diagram
- 557. FE model wiring diagram
- 558. FPM model wiring diagram
- 559. FPE model wiring diagram
- 563. Index
Also for: TRX500FPM, TRX500FE, TRX500FPE
File size: 84.54 MB
Created: March 10, 2023
Last updated: March 30, 2023
Recommended video
Related Manuals for Honda TRX500FM Service manual
Pages: 258 — Brand: Honda — Category: Offroad Vehicle
Pages: 320 — Brand: Honda — Category: Offroad Vehicle
Pages: 157 — Brand: Polaris — Category: Offroad Vehicle
Pages: 256 — Brand: Honda — Category: Offroad Vehicle
Pages: 235 — Brand: Honda — Category: Offroad Vehicle