2005 Honda Foreman 500 TRX500 Full Service Kit H119 Instruction Manual

Introduction

This instruction manual provides detailed guidance for performing a full service on your 2005 Honda Foreman 500 TRX500 using the Genuine Honda OEM Full Service Kit H119. Following these instructions will help ensure proper maintenance and optimal performance of your vehicle. This kit includes all necessary fluids and filters for an engine oil change and shaft drive oil replacement.

Kit Contents

Verify that all the following components are present in your service kit before beginning any work:

• 3 x 10W-40 4-Stroke Pro Honda Oil (Part No. 08C35-A141M01)
• 1 x Honda Oil Filter (Part No. 15412-HM5-A10)
• 1 x Honda O-Ring (Part No. 91302-KF0-003)
• 1 x Honda O-Ring (Part No. 91303-HA0-004)
• 1 x Honda Washer (Part No. 94109-12000)
• 2 x Pro Honda Shaft Drive Oil (Part No. 08208-0080)

Figure 1: Contents of the 2005 Honda Foreman 500 TRX500 Full Service Kit H119.

Safety Information

Always prioritize safety when performing maintenance on your vehicle. Read and understand all instructions before proceeding. Wear appropriate personal protective equipment, including gloves and eye protection. Ensure the vehicle is on a stable, level surface and the engine is cool before starting work. Dispose of used oil and filters responsibly according to local regulations.

Setup and Preparation

1. Park the Honda Foreman 500 on a level surface.
2. Ensure the engine is cool to the touch to prevent burns from hot oil.
3. Gather all necessary tools, including a drain pan, wrenches, and a funnel.
4. Locate the oil drain plug, oil filter, and shaft drive fill/drain plugs on your vehicle. Refer to your vehicle's owner's manual for exact locations if unsure.

Operating Instructions: Engine Oil Change

1. Drain Old Oil: Place a suitable drain pan beneath the engine. Remove the oil drain plug (and washer) and the oil filler cap. Allow all the old engine oil to drain completely.
2. Replace Oil Filter: Remove the old oil filter. Ensure the old O-rings are removed. Install the new Honda Oil Filter (Part No. 15412-HM5-A10) with the new O-rings (Part No. 91302-KF0-003 and 91303-HA0-004). Apply a thin coat of new engine oil to the new O-rings before installation. Tighten the filter to the manufacturer's specifications.
3. Reinstall Drain Plug: Clean the oil drain plug and install the new Honda Washer (Part No. 94109-12000). Reinstall the drain plug and tighten it securely to the manufacturer's torque specifications.
4. Add New Oil: Using a funnel, slowly add the three bottles of 10W-40 4-Stroke Pro Honda Oil (Part No. 08C35-A141M01) into the engine through the oil filler opening.
5. Check Oil Level: Reinstall the oil filler cap. Start the engine and let it idle for a few minutes. Turn off the engine and wait a few minutes for the oil to settle. Check the oil level using the dipstick. Add more oil if necessary to reach the recommended level.
6. Inspect for Leaks: Visually inspect around the oil filter and drain plug for any signs of oil leaks.

Operating Instructions: Shaft Drive Oil Replacement

Refer to your Honda Foreman 500 owner's manual for specific locations of the shaft drive fill and drain plugs.

1. Drain Old Oil: Place a drain pan under the shaft drive unit. Remove the fill plug and then the drain plug. Allow the old shaft drive oil to drain completely.
2. Reinstall Drain Plug: Clean the drain plug and reinstall it, tightening to manufacturer's specifications.
3. Add New Oil: Using a suitable method (e.g., a syringe or pump), add the two bottles of Pro Honda Shaft Drive Oil (Part No. 08208-0080) through the fill opening until the oil level reaches the bottom edge of the fill hole.
4. Reinstall Fill Plug: Reinstall the fill plug and tighten it securely.
5. Inspect for Leaks: Visually inspect around the fill and drain plugs for any signs of oil leaks.

Maintenance Schedule

Regular maintenance is crucial for the longevity and performance of your Honda Foreman 500. Always refer to your vehicle's owner's manual for the recommended service intervals. Typically, engine oil and filter changes are recommended every 100 hours of operation or annually, whichever comes first. Shaft drive oil replacement intervals may vary, so consult your owner's manual.

Troubleshooting

• Oil Leak After Change: If you notice oil leaks after performing the service, recheck the tightness of the oil drain plug, oil filter, and their respective O-rings/washers. Ensure all old gaskets and O-rings were removed and new ones were properly installed.
• Incorrect Oil Level: If the oil level is too high or too low, drain or add oil as necessary. An incorrect oil level can lead to engine damage.
• Unusual Engine Noises: If you hear any unusual noises after an oil change, immediately stop the engine and recheck the oil level and filter installation. Consult a qualified mechanic if the issue persists.

Specifications

Warranty and Support

For specific warranty information regarding genuine Honda parts, please refer to the documentation provided with your purchase or contact an authorized Honda dealer. For technical support or further assistance, consult your vehicle's official owner's manual or contact Honda customer service.