2001-2003 Honda Rubicon 500 Repair Manual TRX500FA

A Few Words About Safety Ser\lice Information The servite and repair information tontained in this manual is intended fOI use by qualified, professiorlal tochrl,eisns. Anempt irlg service 01 lepairs without Ihe proper \rllirlirlg, lools. and equipment could cause injury TO yOtJ or othe r S. I! cotJld also damage the vehicle or ~reale an unsafe condition. This mantJal describes the proper m elhods and procedures fat pcrformirl9 servi ce, mainlenance, and repairs. Some proce- dtJres require the tJS'" of speciall y designed tool s and dedicated equipment. Any person who imends to use a replacemenl part, servi ce procedure Or a tooll hal is rlot recommerlded by Honda, must detormine Ihe risks to thei r persorlal safely and the safe opelation of the vehicle. If you need to repl ace a part, tJ se ge nuirl e Honda Pllrts with the co .. o<:t part num ber or an equival ent part . We strongly l ee- ommend that you do nOt tJse replacement pails of inferior quality. ForVour Customer's Safety Proper service and maintenance are essential 10 the customer 's sa/e- ty and the reliability of the vehicle. Any error or oversight while ser· v,cing "vehicle Clln resul! in faulty operation, damage 10 the vehiCle. 01 i niury to othels. For Vour Safety 8ecause Ihis manua l is intended for tile plofessional selv ice techn;- cian, we do not provide wamings about many basic sh op safety prac- ticas le.g., Hot pans - wear gloves!. 1/ you have not l ueived shOp safety tl aif'ling or do no! feel confident about your ~ now ledge 01 S li fe servicing praclioos, we recommend thlll vou dO nOI anempl to per - fOlm the plocedu 'es descr ibed in this manual. Some of the mOSI im portant general service safety precautions ale g iven bel ow_ However, we cannot warn yotJ of every conceivable hazard Ihat ca n ari se in performi ng service and repllir procedures_ Only you ca n decide whet her or not you shoul d perform a given tas k. Important Safety Precautions A WARNING Improper service or repairs can Cleale an unsafe condit ion thaI carl cause your customer or others to be seri ously Il"rt or kill ed. Foll ow the procedures and precautions in t his manual and ot her service materialS c/lle /ully. cautions can cause you 10 be seriously hurt 01 ~ill ed_ F ollow the procedures lind prilcatJ\ions on !;his manua l caref ully_ Make sure you have a cl ear understanding of all basic shop sa f ety practices and that you are wearing apPlopl iate cl o thing end using safelY equipment . When perform ing any service task, be especi ally careful of tile followin g: Read all of the in structi ons before you begin. lind ma ke sur", vou have the too ls. the replacement or re pair parts, li nd the sk ill s required to perform the taskS sa/ely end completely_ Proteci your eves bv using proper safelY glasses, goggles or lace sh ieldS any lime you hammer . drill, grind, pry or work arotJnd pressurized air or liquids. and springs or other stored-enel gy components . If there is any doubt, p ul on eye prate<:· 11011. Use other protective wear when necessary. fOI example gloves 01 safety shoes. HlIndli ng hot Ot sharp pans can cause sever~ btJrns Or cuts. Before you grab somet hing that looks like it can hull you, st op and put on gloves_ Prolecl yourself and others whenever you have Ihe vehicle up in til e air. Any lime you lilt the vehicle, eil h er wi lh e h oist or '\ a iack, make sure thaI il i$ al wllys securely stJpported. Use iack siand s. J M"l<e Sure Ihe engine i~ o ff before vou begin My servici ng procedures, unless th e i nstruction tells you 10 do otherwise . This will h elp eliminate several pot ential Ilazard~: Carbon moooxide poisoni ng from engi ne exllaust. Be sure there is adequate vent i latioo whenever you rtJ n the engine Burns from hot p ail s or coolant. Let the eogine and exhaust syS1em cool before working in those aleas. Injury /Iom moving parts. 1/ the inslr uct ionlells you to ItJn the engine , be sure yOtJr hands. finge rs and ClOthing are Out of Ihe way. Gasoline vapors and hydrogen gases from ba rt ~ries ~'" ""pt osive. To r"due" Ihe possi bility of a fire Or explosion, be careful when working lIround gasoline or bafteries. Use only a no f'lli ammable So lvent, not gasoline, 10 clean pans . Never drain or store g~soline in an open container. Keep all cigarefteS, sparks and flames away from the banery and all fu el-re taled parts.

'- HOWTO USE THIS MANUAL Tn., .. ",ioe m.~u. ' " .. <rib .. ,h, "'VI .' Procedures ,,,, Ihe TAX5OOFA., follow I~. "'.ift,.~.nc. S<:I>.dul. I$ oc tlcn 31 , ,",ommo nd.,,on. to ' '''Ut. th., 'ho ",,";': 10 i. in pM. ",>.".U,,!! «><1" ;';"0 and 'h' _ ;"'on 10 ... . 1 • .,. WI '!>'" the .,.M.,d, ..,. b, ,h. C. I,'o.n;O Ai, A •• ou .... 8"",d !'.rf"'mln~ 'ho J~ .. <coodu •• d m. ;n1<n.nce ..... . 'Y '",~~.nL I, <-om- 1>01'1""" f". , ... ;M I" "' ••• lMI o>cGu" dw i nll ,11. elut-In period. Sec,;"". \ OM 3 'PC'" 10 to. who le ... 0,,;.:10. Soo,ion 2 ;I ~!f.j •• ~,o- oedu,,,, k .. ,.""",.If,,, ... , •• ,,,,,, of <;Qml'O'l 0 n" 'hot mo, 1M! reQUirod '0 p.co1<>rm ... """" dose ri b6d in lfIel"",,wlns 5eCfIOM_ s..,;" n. 4 ,"'ough:1l dHe Mo 1>"'" 01 "" .... "'<Ie. grouped . """,di n; to k>t.a"on, F'M tllo ..."ien 'I'<IU w Ont on ,M pa~, 'n on '", n 10 ,h. lObi. 0' ,,,n- l e"'.M ,,,.. ~'" p..o~" '" ,no ,000ion. Mo .. 'O<liMO .,.n w~" on .... mb IV "f ."""'" iii". " •• ;.,., .•• rvice ;nfo"" .. ;oo ..,d "_' •• ~';"~ Ie< 'he .. etl~".TM . ..... "'1lI.,,' 1>&\1" g;~ d .. ai led Pfoeodu,u If V<lu d",,', k ".w '00 ..,,,,e. ~f ,M. 1foubioo. go ,. ~<tlon a, T '''" .'" ,,~'" i ng. Vou, .. f . ... ono "'~ .. f orvo' ",o o r<, to ... 'Y I",<,Mann~ "~\J> you mo~. 1~1'"m''' d""",one wo hove """, i ded •• • .." me .... g .. ono o,h. , . nlo'ma' ..... ''',ougho" . ,,, .. mOM._. O' eou' .... ~ i. no. 0'"'" I,e.ol ~' po,,'.' o [0 _, n V<lu .boUI .,1 1 11.0 h.,.,d, ..... d. ''''' w~h .. ",., In; 'hi •• o,.;cl • . V ... mull utO ""U' own pood judll<mon' ¥ou w; !t fiod i ... ",,"~nt " 'e .. ,,,I,,,,,,.,,,,,, '" a ""n." of lo'm. ' '''' 'ud;ng: . S.'.tvL.be ls- on,h.~hl~l • . S. , .tv M ..... ga. _ ~I..,.dod bV ' .. f.ry.I. ~ ' Vmbol ~ oodon. of ,h,.., "gn.' ,",on:!>, OA.NGEA. WARN ING. 0' CAUTION. Th . ..... ~o., _,d. ",un. ri·f.MMi' nWWilM You WILL b. ~ ll lED 01 SEA IOUSlV HUAT il vou don', f oil"", i ... ',LIO"" ..... Voo CA.N be KILLED '" S EAI OUSl¥ HUf\'1" If ¥OIl oon~ foil"", I O"~IMS. "MiliI.if' :;:,~~~~: HUFIl" ,fy ou don', fOllOw '",""otions ~ hw.o " .... '0. ,MI, Wl n .. ,. """oellv .nO .. r.,V· ... ~ ,,, •• ", .. nu ol , yO<.J will fo nd ;"fo, mo,ion ,ho'" 01&< .... 0 1>" ol!:!Q!!f!J 'Vmbol. Th. ~ U_ of ,hi. m ... . ..... .. '" hlp I""..-.n' domag. ,. \'<lu, Vilh;CI •. e lM, P,O ... .....", 0' I ..... nvl~",,',,"t. w Z '" iii CONTENTS GENERAL INFORMATION FRAME/BODV PANELS/ EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUE L SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CVLlNDER HEAD/VALVE CYLINDER / PISTON CENTRIFUGAL CLUTCH ALTERNATOR / STARTER CLUTCH SUB·TRANSMISSION CRANKSHAFTfAUTOMATICTRANSMISSION FRONTWHEEl/SUSPENSION/STEERING REARWH EElfSUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM REAR DRIVING MECHANISM BATTERVf CHAAGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LlGHTSf METERSf SWITCHES HONOAMATIC WIRING DIAGRAMS TECHNICAL FEATURES TROUBLESHOOTING INDEX

SYMBOLS The symbo ls used Ihroughoul Ihis manuill show specific service proclldures. 1/ supplementary informal ion is required ~,. lail'ling 10 Ihese symbols, it would be ex pl 8ined speci fically in lI'>e le~l witho,, ' lhe .. 51! of the symbols. ell Replace th ", panls) with new one(s) belo,,'! assembl y_ - 71 Use recommended engine oil, unless otherwise specified. j Us e molybdenum oil solu tion (mixture of the engine o il arid mo1ybd"'"um grease in ~ ral,o all: H. • .w;;.. Use mulli-purpose grease (Lithium besed multi - purpon gre&se NLGI #2 or equivale nt). Use molybdenum disulfide grease (contain ing more Ihan 3% mol ybd"'num disulfide, NLGI 1/2 or ~ equivalen!l. e""mple: Molykole<Si BR·2 plus manufauured by Dow Corning. U.S.A. Multi-purpose M-2 manufactured by Milsubishi Oil, Japan Use molybdenum di su lfide paste Itontai nill9 more than 40% molybdenum disulfide, NLGI #2 or equivalent). ~ E){smple: MOlY~ OIe$ G·n P~$te. manufactured by Dow Corning. U.S.A. Honda MOly 60 IU .S.A. onl y) Rocol ASP mllnufac\Ured by Rocol Limited. U.K. Aocol Paste manufactured by Sumico Lubricant, Japan .... 61 Use silicone grease. -- ~ Apply 11 locking agent. Usa /I middll! $THlIlgth locking agent unl eU otherwise specified. ,,€Ill! Apply sealant. a Use DOT 3 or DOT 4 br ah flu id. Use lhe rocommended brake fluid lInless oTherwise specified. GI Use For~ or Suspension Fluid.

- 1. GENERAL INFORMATION SERVlCE RULES ,- , LUBRICATION & SEAL POINTS , · 16 MODEL IDENTIFICATION ' -2 CAB LE & HARNESS ROUTING 1-19 SPECIFICATIONS ' -3 EMISSION CONTROL SYSTEMS 1-32 TORQUE VALUES '- '1 EMISSION CONTROL INFORMATION TOOLS 1-14 LABEL IU.S.A. onlvl ' -33 SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants Of their equival':lnls. Parts that don't meet HONDA's design specifications m ~ y cause darn ~ge to the motorcycl e. 2. Use tile s~;allools designed for this produCllo .woid damage and incQrrect assembly. 3. Use o"ly metric tools wh,m servicing the motof!:yde. M(!t";c boilS, nu tS and screws ~re not inTer<:lIangeeble with Engli sll fastene rs. 4. In stall new \Jeskels. O-ring~. coner pins, and loCI< plillllS when reassembling. 5. When l ighten ing boilS or nuts. begin with the larger diamet er or inner bolt fir st.Then lighten 10 the specified torque diag' onally in i ncremental S1~ps unl tlss a particular sequence is specified. 6. Clean oarts in cl ea n ing $olvent upon disassembly. Lubricate any slidir.g surfaces before reasscmbly. 7. After re~$$embly, chcck ail parts for proper il\$Iall81ion Md operat ion. S. Routa an eleclricat wire~ as shown (In pages 1-19 I hrough 1-31, Cable & HEl rness Routing. 1-1

GENERAL INFORMATION MODEL IDENTIFICATION The vehIcle Identlf.c.,(lon number NIN) IS slemped on th e Ironl side ollhe Ir~ms. The carbur etor identification n umber is s t ampec on the lelt side 01 the carbure to r body, 1·2 MODEL IDENTIFICATION LA8E L The IDOdel it\en\if\cil\ion label is lotaled on the left side frame down tube. The eng ine se(li~1 number 1$ stamped (In the right SIde 01 the tt 3nkC.!lse. The co lo. label IS ana~h"'d on The flghl SIde 01 th" hame under the seet. When order ing color-coded parts . a !waV $ specify Ihe designated COlor code.

GENERAL INFORMATION SPECIFICATIONS GENERAL I TEM SPECIFICATIONS DIMENSIONS Overall length 2,072 mm (81.6 in) Ovorall width 1,184 mm (46.6 inl OVllrall Ilei ght 1,194 mm (41.0 in) Wlleelbase 1,281 mm (50. 1 in) Front tread 914 mm 136.0 in) Rear tread 925 mm (36.4 in) Seat Ileighf 862 mm (33.9 in l FOOtpeg hei ght 337 mm 113.3 inl Ground clearance 19B mm lIS jnl Dry weight 273 kg (602 Ibsl Curb weight 2B5 kg 1628 Ibs) Ma~imum weight capacity 220 kg (485 Ibs) FRAME Frame TYPO Doubl('! cr8dle Frol"lt suspension Double wish-bon ... fra Il! """" ... ellrllvol 110 mm /S.7 in) fr ol"lt damper Double IlJbe Rear $ lJsp ... nsion Swing"rm Rea r wheel travel 110 mm (6.7 in) Rea r damp"" Dou bl!,! tube from tire sile ..0..125)(8-\2 *. RM r l ire size ..0..125)( 10 -12 *. Frol"lt rim sile 12)(6.0 AT I Rear rim Si lll 12)(7.5..o..T Front tire brand DIRT HOO KS 15 (S ,idgestonel Rear tire brand DIRT HOOKS 14 (B ,i dgllstonel Front brake Hydraulic drum bra~e !Dualleadingl Rear brllH Mechanical drum br ake (Leading - Trail ing) Caslor angle 3' Tr ail length 12 mm (0.5 in) Camber angle O· f uelllln~ capacity 14 liters (3.7 US gal, 3.1 Imp gall Fuel tank reserve capllcity 3.8 l it ers (1.00 US gill, 0.84 Imp gall ENGINE Cylinder arrangemel'll Single cylinder. longitudinally installed Bore and stroke 92 ~ 15 mm 0.6 ~ 3.0 in, Displacemllrlt 496.5 cm3 130.'1 cu-inl Compression r31io 9.2 : 1 Valve train QHV Intake lIalVll opons 6· BlOC (at 1 m m litU closes 35· ..o..SDC lat 1 mm liftl Exhaust V llive opens 40· BBDC (at 1 mm liftl close~ 5" ATOC {ell mm liftl Lubrication system forc ed pressure (dry sump) Oil pump type Trochoid Cool ing system Liquid cooled Air liltration Oil ei:! urethane foam Engine dry wei ght 63.2 kg (139.3 Ibs) 1-3

GENERAL INFORMATION GENERAL {CG!\ t'd ) ITEM CARBUREToR1C~rburetO' type I Throttle bore DRIVE TRAIN-+-' Clulctl C "C ,C "C m ---- - T { ftn"m; s,>'CI'I P,imary (ed uction Secondary re du cti on Final reduc ti on Front Raar Automatic lransmissi on .ali o Low-Q,O. Sub-transmission gear ratio Orive ELECTRICAL 1-4 Gea'shift pan~rn Ignil ion system Starting sysTem Charging syslem R@9U1 i\lofll euil iel Li ghTing system Low Reverse SPECIFICATIONS COilSIMU Vacuum (VE type> 36 mm (1.4 in> Cenl. i/ug81. Wilt HONDA"".!>.')C (awornal'c; non·st age speed) with s"b -transmission (conslalll mesh) 2.188 (7O/fil) 2.ClClCl (4(lJ2(lJ 3.231 (42/13) 3.154 (41{13) 0. 84-3 .13 1.583138/241 2.500 (45/1 6) 3.222 (29"8,, 28/1 4) R _ N - 0 - L (Sub-tr ansmission) 0 : 3·mode; Automa t ic 2·pattern ( 01 /02) ", nd Man"., 1 (ESP: 5-speedsl L: 2·mode; Automat ic and M3null( I ESP: S·speeds) R: I-mode (fixed (ow 'aliol OC-COI (Oi'ect current·Capacitor discha.gC igni t ion) Elactric starter malar and e me rgency .e eoil slane' Tr iple phase output alternator SeA short"d. triple phase lun wave r« lilical,on Ban ery

GENERAL INFORMATI ON LUBRICATION UIl;r mm (in) ITEM STANDARD SERVICE LI MIT Engine oil cepaciry Atle. draining 4.7 lite,s (S.O US qt.. 4 1 Imp qO ;- Ane' d'ainiJlg/1ilter change 4.9 lite. s 15.2 US Qt, 4.3 Imp Cit) i After di sassembly ~ S.5 lite.s (5 .8 US qt, 4.8 Imp qt) Recomme noed engine oil I Honda GN4 4-s((()~e oil oreQu;vdtenf ! moto, oil API selVice dass ific alion SF or SG -- Viscosity: SAE 10W. 40 Oil pr essure At 1,400 rpm Abov(l ISO kPa (1.5 kgflcm 1 • 22 psi) (SO'e/l76"F) At 5,000 rpm Above 800 kPa (8.2 kgl/cm 2 , 116 psi) Oil pump Tip clearance 0. 15 10.0061 0.20 (0.008) Body clearance 0.12----<121 /0.005-(1.0091 0.2510.0JO} Sioe clearance 0.02-0.09 (0.001---0.004) 0. 11 (0.00'1 f UEL SYS TEM ITEM SPECIFICAnONS Carburetor ide"lilic3lion number VEIiAI3 Ma in jet ,,,. -- Slow jet .. S Jet needle Cli p position 2nd groove from top Pilot scr~ w OPfllling See pag e 5-15 Float level 18.5 mm !D. 73 in) Idle speed 1,400 ~ 100 'pm Throttle leYN Irer play 3-8 mm ( 1j8-~11i in) COOLING SYSTEM ~cccc::;~=c.c:--- f; EM ) SPECIFICATIONS Coolant capacity "' R C '~ dC ;, O ,O oc,c.o"~,c,o"c,c ,o"o,----I--------;- , .~" ""C.C"C. C,C8::CU"S~qO,C . ~'~5",CmC,:-:,,", ,------1 Rne"'''' tank 0.40 liter (0.'2 US CIt, 0.35 Imp qll Radialor cap relief pressure Thermos\l1I S.. gin to opc.n F\jll" open Valve lift Recommended antifreele Standard coaJam cMunualion 108-137 ~Pa (1.1 1 .4 ~gfleml. 16--20 psi. 80---S4 ' C n7&----183'F) 95"C (20J'F) 8 mm ~0. 3 in) minimum Pro HOlld~ HP Coolant or an equivalent high qua!ity ethylene glvcol ant i/r€eze contaif1ing silicat e"ree corrosion inhibitors 500/. mirture with distilled water ~--~ 1-5

GENERAL INFORMATION CYLINDER HEAD/VA lVE Unil' mm jin) ITEM STANDARD 'UMIT cornpr~ss ion al ~50 rpm .. , ~PSi ) V"", I ' I ' ° lEX V,~"" , 0,0, IN , 5'<"0"" val ... & guide ~ =* 5,"10,"" , ; clellran~e I IN I 0" IOOOS, '- l ,'''- , 0, "10 0061 V""', ',vl~:J ; I above Ii head , , .Id<h 'N/EX ~O-, I Val ... & spr"'ng I "" Ioo"h I """ ,- I A<m I,D I , '2,OS 10, ~ I ' , "''' 10,'69' I 'IOOO~ , o,oe 100031 ,- '",",' I Com I,", h",hI <om leX , 33,'" C'm " I INiEX , 22, ' 610'''' ~ ,b,," 10, ~ '1""",' , 0' , - 0," 1000<' _ C YLINDER / PISTON Unil' mm l inl ITEM ~ STANDARD SIOAVICE LIMIT CYlind() ~ ' -- 1.0. I 9VO 13,~Z~\ Out of rOllnd 92.000- 92.0 10 (3.6220---.3J'224) 0.10 10.004 1 Taper 0.10 (0.004) Warp8ge 1 0.10 (0.004) Pislon, Pi sl on 0,0. at 15 ( 06) from b otlom 91.965 91.985 (3.6207 3.6214) 9 1. 9013.618) piston pin, ~~on pin hole I ,D. 20.002 20,008 (0.7875-0.7877) 20.04 10.789) piston ' ing 19.994 20 000 10.1872--i1.7874) 1996 \0 . 186\ P'Slon pin 0, 0. Piston- la-piston pin clear8nce 0.002- (LOI4 (O.OOOI--i1 .00Q6) 0,08 (0.003) Piston ring end gap ~ Top 0.15-0.30 (0.006-0.0121 0,510,021 -- I Second 0.JO--{I.45 (0.012--0.01 81 0,1l, \002\ I Oil (side rail) , - 0.20--{1.7010.008--0.0281 ~ P;sto n ring-Io·ring Top/Second 0.030-0,060 (O.OO I2--i1.0024) 0.09 (0.004) I groove cI",aran~", Cyli ndeHo -piston clearance 0.0 15-0.045 10 . 000s-0.00181 0. 10 (0 ,004) Connecting rod sma)) ",nd 1.0 20.02()-Z004 1 (O.7882---().7890) 20.07 (0.790) - ~necting rod -lo'pi sCon pin clearance 0,020-1),047 (0.00(18-000 1 91 1)1 (0 ,00 41 1-6

2001-2003 Honda Rubicon 500 Repair Manual TRX500FA

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