trx500 fm 2010 front diff removal - Honda TRX Forum
 
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post #1 of 4 Old 04-30-2019, 06:13 AM Thread Starter
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trx500 fm 2010 front diff removal

Hi Can anyone tell me the best way to remove the front diff in a trx500 fm 2010. I am wanting to paint front chasis and also do the steering shaft bearing at the same time.
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post #2 of 4 Old 04-30-2019, 01:33 PM
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Are you sure it's a 2010 model? Honda does not list a 2010 TRX500 - it was sold in 2009, 2011 and other years, but not in 2010???

At any rate, here's the text from the 2012 service manual on removing the front final drive (the procedure should be the same for the 2009 and 2011 models)

FRONT FINAL DRIVE REMOVAL
Page 19-12
Remove the following:
- left mudguard (page 2-6)
- engine guard (page 2-7)
- left drive shaft (page 19-7)
Drain the differential oil (page 3-19).
Remove the following from the final gear case:
- breather hose [1]
- select switch connector [2] (disconnect it and remove its wire from the guide [3] and clamp [4])
- cover bolt [1]
- clutch arm cover [2] (by releasing the two tabs [3])
- adjusting nut (1)
- cable retaining plate (2]
- selector cable [3] (remove from the cable holder [4] and joint pin [5])
- cable spring [16]
- joint pin
- base bolts [1]
- arm cover base [2]
- holder bracket [31]
- final gear case mounting nuts and bolts [1]
- two bolts [2] and mounting bracket (3)
Move the gear case assembly [1] forward for maximum clearance between the propeller shaft joint and engine.
NOTE: Turn the handlebar all the way to the right to move the gear case assembly. Put some cloth on the gear case to avoid scratch or damage the lie-rod end [2].
Pull the shaft joint [1] out of the output shaft [2] of the engine.
Remove the boot band [3] and release the propeller shaft boot [4] off the pinion joint [50] of the gear case assembly.
Pull the propeller shaft [6] to force the stopper ring [71] past the groove in the pinion joint to remove the propeller shaft.
Remove the stopper ring from the propeller shaft.
Remove the O-ring (8) from the output shaft.
Loosen the left lower arm pivot nuts and lower the lower arm.
Separate the right drive shaft [1] from the final gear case assembly [21] by tapping the right drive shaft end lightly through the gear case, using a screwdriver or equivalent.
Remove the gear case assembly from the frame.
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post #3 of 4 Old 05-24-2019, 09:47 AM Thread Starter
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Hi
Thanks for that. My trx500 is indeed a 2010 manufactured for the australian market. I live in New Zealand. Thanks for all the information it helped alot. I managed to get it out in one piece without too much cursing.
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post #4 of 4 Old 05-24-2019, 01:41 PM
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Congratulations - I was unaware of your location and there are variations between US models and the machines manufactured in other countries, but all are similar in their assembly.

You may indeed have a 2010 model, there just was not one for the US market. The VIN is the only way to know for sure. The 10th digit indicates the year model. 2010 would have an 'A' for that digit.
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