Honda TRX500 Rubicon 2001-2004 Service & Repair Manual (Clymer M210)

Honda TRX500 Rubicon 2001-2004 Service & Repair Manual (Clymer M210)
Brand:Clymer
Product Code:Clymer M210
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CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

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 and FIVE / ENGINE
Exhaust system / Cylinder head cover, rocker arms and push rods / Cylinder head / Valves and components / Camshaft / Camshaft chain tensioner / Cylinder / Piston and ring / Removal 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 / 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 TRX500FA TRX500 FA TRX 500 Rubicon
2004 TRX500FGA TRX500 TRX 500 FGA Rubicon

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