Honda TRX500FA and TRX500FGA manual.
Includes Color Wiring Diagrams.
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Printed Manual 2001-2004
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Online Manual 2001-2004
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Models Covered|Contents|Online Detail|Videos|Large Image

This Honda Rubicon TRX500 Manual is 392 pages.
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 / Specifications
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 / Battery / Periodic lubrication / Engine oil and filter change / Front and rear differential gearcase oil change / Control cable lubrication / Periodic maintenance / Air filter / Spark arrestor / Toe adjustment / Tune-up / Valve clearance check adjustment / Cylinder compression check / Spark plug / Specifications
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 / Specifications
CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine removal and installation / 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 / Specifications
CHAPTER SIX / CLUTCH AND PRIMARY DRIVE GEAR
Clutch cover / Centrifugal clutch and primary drive gear / Specifications
CHAPTER SEVEN / TRANSMISSIONS AND SHIFT MECHANISM
Shift mechanism / Sub-transmission / Automatic transmission / Specifications
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 / Specifications
CHAPTER NINE / ELECTRICAL SYSTEM
Resistance and peak voltage testing / 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 / Specifications
CHAPTER TEN / COOLING SYSTEM
Coolant / Coolant reserve tank / Radiator / Cooling fan / Thermostat / Water pump / Oil cooler / Thermosensors / Specifications
CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Wheel / Tires and wheels / Hub / Shock absorbers / Tie rods / Steering knuckle / Control arms / Handlebar / Steering shaft / Specifications
CHAPTER TWELVE / FRONT DRIVE MECHANISM
Front drive axles / Driveshaft / Front differential
CHAPTER THIRTEEN / REAR AXLE, SUSPENSION AND FINAL DRIVE
Wheels / Shock absorbers / Rear axle / Final drive unit / Swing arm / Specifications
CHAPTER FOURTEEN / BRAKES
Front brake drum / Front brake shoe / Front brake panel / Wheel cylinders / Front master cylinder / Brake fluid draining / Brake bleeding / Rear drum brake / Rear brake shoe / Brake panel / Front brake hose replacement / Rear brake pedal and cable / Rear brake lever parking brake cable / Specifications
CHAPTER FIFTEEN / BODY
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 / Specifications
INDEX
COLOR WIRING DIAGRAMS
Models covered:
2001 2002 2003 2004 Honda TRX500FA TRX500 FA TRX 500 Rubicon
2004 Honda TRX500FGA TRX500 TRX 500 FGA Rubicon
Clymer Manuals Honda Rubicon TRX500 Manual
Clymer Manuals Honda Rubicon TRX500FA Manual
Clymer Manuals Honda Rubicon TRX500FGA Manual
Clymer Manuals Honda Rubicon TRX500 Online Manual
Clymer Manuals Honda Rubicon TRX500FA Online Manual
Clymer Manuals Honda Rubicon TRX500FGA Online Manual
TRX500FA Rubicon (2001-2004)
TRX500FGA(2004)

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