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I ran across this thread on another forum, with no replies and figured you guys and gals could help him out, so I referred him here to watch this thread.

His thread reads:
I bought a 2005 Foreman (TM model) last week. I rode it for the first time this past weekend and have a few questions.

Firstly, the foot shift linkage has way too much travel before it engages the gearbox. I wear a size 12 boot (so we're not talking about a dainty foot here) and had to actually lift my leg in order to engage the gearbox. There is so much travel in the linkage that I can't just push up under the shift lever with the toe of my boot to shift gears as on previous Honda ATVs and bikes. Since it was a PITA to shift, I mostly just rode around in too tall of a gear all day. The Foreman didn't complain though as there seemed to be enough torque to tolerate being in too tall a gear.

Question 1: Can the shift linkage be adjusted to shorten the travel? I've done this on my street bikes but never on an ATV.

Secondly, the Foreman seems to be very cold natured. Even though temps were in the 50's all day, any time I had to restart the Foreman after sitting for over 10 minutes I'd have to use the choke and let it warm up a couple of minutes or it'd die. I'm guessing the carbs on new ATVs are set lean to comply with air emission regs.

Question 2: How do I go about adjusting the air/fuel mixture so that the ATV will run a little richer? Again, I've done this on my street bikes but not on ATVs.

Thirdly, starting out in first gear is a waste of time. Like you don't already know that. So I began starting in 2nd gear and missed a shift to 3rd probably 4 or 5 times when I allowed the rpms to get too high. What I noticed was if I let the rpms go past the normal shift point, when I would let off the throttle to upshift, the gearbox would not respond. This usually happened when starting out in 2nd gear and trying to shift to 3rd. I'd then loose speed and engine rpms and have to downshift, but come to almost a complete stop before the gearbox would allow me to shift.

Question 3: Did Honda design it this way, or is it something that needs to be sorted out by the dealer?

Lastly, about the choke. It will not stay out for more than a few seconds before it returns to the off position. For some reason, when I pull the choke out, it immediately starts to slowly recede back to the off position. Since my Foreman takes a few minutes to warm up, if I start out with the choke engaged and then have to come to a stop before the engine warms up, it'll die on me.

Question 4: Is there an adjustment that can be made to choke cable to stop it from turning itself off or is this common to all ATVs?

I apologize if these questions are answered by reading the Owner's Manual, but the Foreman is kept at my brother's farm 4 hours away so I don't have access to the manual right now. Incidentally, the dealer where I purchased the Foreman is also 4 hours away and was closed yesterday when I was up that way so I didn't get a chance to visit with them about these issues. Besides, I'm guessing I'll get a straight answer here and would like to know if other 2005 Foreman owners have had similar issues.

Oh yeah, other than the minor issues above, the Foreman performed beautifully. Lots of torque. Comfortable ride. Even over river rocks in a dry creek bed the ride was not too harsh. Pretty stingy on gas too. The steering is much lighter than our Polaris 4x4s and even the Polaris 2x4. That was much appreciated on the twisting Ozark Mtn. trails we rode Sunday. The design of body panels and fenders really work well as I stayed dry even when running for 50 to 60 feet at full speed through 8 to 10 inches of water. The best part was after checking cattle there was no cow poop on me! Way to go Honda. I guess my only real gripe would be the design of the reverse mechanism. Why does Honda continue to use this design. What a PITA it is. Every time the group had to back up, they were always waiting on me as I was the last ATV in the group!

Thanks for your input.
 

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There is no linkage on the TRX500FE/FM/TE/TM ..If it's new the clutch may not have been adjusted during PDI that would make it shift easier ...This could answer 2 of your questions ..
Yes the Hondas are set lean ,probably because of emissions & fuel mileage ..Honda doesn't have other low speed jets listed for the TRX500TM just the stock #45 ,but if you got the next jet size up then it would idle better in cold weather ..At work we just leave the chokes on till they're warmed up good ..
If you pull on the choke then you see a rubber boot..under the boot is the choke jam-nut ,tighten it a hair with your fingers and this will tighten the choke shaft then it will stay out for you ..
 

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I also have the Foreman 500 TM. I had this issue with my shifter (it was difficult to shift, seemed really tight). I only have about 15 hours on my Foreman (got it 3 weeks ago) and the shifter is great now. It seemed to loosen up after maybe 8-10 hours (probably depends on the amount you shift). I would think yours would do the same.
 

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This is just me im not a mechanic by no means but i wear milking boots when i ride and their size eleven so you know you really cant move your foot or ankle for the matter much and i have no problem shifting it shifts just like any other honda atv ive drove. Their might be something wrong with yours but i dont know. My choke does the same thing i didnt even no that their was anything you could tighten up so that shows how much i know, but mine was also very cold blooded until i put the pipe and jetted it and now it cranks by barely pressin the button.
 

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I wear size 13 rubber boots and never have a problem shifting the ES. Just kidding guys. Although that is one of the perks of the ES.
 
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