Honda TRX500 Rubicon Repair Manual 2001-2004

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This repair and service manual covers Honda Rubicon TRX500 including TRX500FA 2001-2004 and TRX500FGA 2004.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION

Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Basic tools | Precision measuring tools | Electrical system fundamentals | Basic service methods | Storage

CHAPTER TWO: TROUBLESHOOTING
Engine operating requirements | Starting the engine | Starting difficulty | Poor idle speed performance | Poor medium and high speed performance | Electric starting system | Charging system | Ignition system | Lighting system | Cooling system | Combination meter | Fuel system | Engine overheating | Engine | Engine noises | Cylinder leakdown test | Engine oil pressure test | Clutch | Sub-transmission | Main (automatic) transmission | Global positioning system (GPS) | Drivetrain troubleshooting | Handling | Frame noise | Brakes

CHAPTER THREE: LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride check list | Maintenance schedule | Tires and wheels | Battery | Periodic lubrication | Unscheduled lubrication | Periodic maintenance | Cooling system | Engine tune-up | Storage

CHAPTER FOUR: ENGINE TOP END
Cleanliness | Exhaust system | Cylinder head cover, rocker arms | and push rods | Cylinder head | Valves and valve components | Camshaft | Camshaft chain tensioner | Cylinder | Piston and piston ring

CHAPTER FIVE: ENGINE LOWER END
Servicing engine in frame | Engine | Recoil starter | Driven pulley | Alternator cover | Starter reduction gears | Rear crankcase cover | Flywheel and starter clutch | Crankcase and crankshaft | Lubrication system | Oil strainer screens | Oil tank | Oil pump | Engine break-in

CHAPTER SIX: CLUTCH AND PRIMARY DRIVE GEAR
Clutch cover | Centrifugal clutch and primary drive gear

CHAPTER SEVEN: TRANSMISSIONS AND SHIFT MECHANISM
Shift mechanism | Sub-transmission | Automatic transmission

CHAPTER EIGHT: FUEL SYSTEM
Carburetor | Carburetor float level adjustment | Carburetor adjustments | Carburetor heater | Throttle housing and cable | Fuel tank | Fuel valve | Air box | Air intake duct | Air intake guide plate | Choke cable replacement

CHAPTER NINE: ELECTRICAL SYSTEM
Resistance and peak voltage testing | Electrical component replacement | Electrical connectors | Charging system | Alternator | Ignition system | Electric starting system | Starter relay switch | Start circuit diode | Automatic transmission (Hondamatic) | Lighting system | Combination meter | Switches | Throttle position sensor | Oil thermosensor | Coolant thermosensor | Coolant fan motor | Speed sensor unit | Fuses | GPS | Wiring diagrams

CHAPTER TEN: COOLING SYSTEM
Coolant | Cooling system inspection | Hoses and hose clamps | Coolant reserve tank | Radiator | Cooling fan | Thermostat | Water pump | Oil cooler | Thermosensors

CHAPTER ELEVEN: FRONT SUSPENSION AND STEERING
Front wheel | Tires and wheels | Front hub | Shock absorbers | Tie rods | Steering knuckle | Control arms | Handlebar | Steering shaft

CHAPTER TWELVE: FRONT DRIVE MECHANISM
Front drive axles | Driveshaft | Front differential

CHAPTER THIRTEEN: REAR AXLE, SUSPENSION AND FINAL DRIVE
Rear wheels | Shock absorbers | Rear axle | Final drive unit | Swing arm

CHAPTER FOURTEEN: BRAKES
Brake service | Front brake drum | Front brake shoe replacement | Front brake panel | Wheel cylinders | Front master cylinder | Brake fluid draining | Brake bleeding | Rear drum brake | Rear brake shoe replacement | Brake panel | Front brake hose replacement | Rear brake pedal and cable | Rear brake lever/parking brake cable

CHAPTER FIFTEEN: BODY
Retaining clips | Retaining tabs | Seat | Recoil starter cover | Right side cover | Left side cover | Fuel tank cover | Front carrier | Front bumper | Center mud guards | Front mud guards | Inner front fender | Front fender | Headlight grill | Rear carrier | Rear fender | Tool box | Handlebar cover

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and illustrations guide you through every job, from basic maintenance and troubleshooting, to complete teardown and rebuild.

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