2004-2016 Honda TRX500FM1FM2FM5FM6FM7, TRX500FE1FE2 and TRX500FA5FA6FA7 Service Repair Manual Instant Download

1
2004-201s
SERVICE MANUAL
2
CONTENTS GENERAL INFORMATION FRAME/BODY
PANELS/EXHAUST SYSTEM MAINTENANCE PGM-FI SYSTEM
IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM
ENGINE/DRIVE TRAIN AND ELECTRICAL
COOLING SYSTEM
8
LUBRICATION SYSTEM CYLINDER HEADNALVE
CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE (FM/FE
models) DUAL CLUTCH TRANSMISSION (DCT FA models)
SUB-TRANSMISSION (FA models) ALTERNATOR/STARTER
CLUTCH
CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
16
ENGINE REMOVAMINSTALLATION FRONT
WHEEL/SUSPENSION/STEERING
REAR WHEEL/SUSPENSION
19
CHASSIS
20
BRAKE SYSTEM
FRONT DRIVING MECHANISM REAR DRIVING MECHANISM
BATTERY/CHARGING SYSTEM
FRAME ELECTRICAL
LIGHTS/METERS/SWITCHES
24
ELECTRIC SHIFT PROGRAM (ESP FE models) ELECTRIC
POWER STEERING (EPS FM2/FM6/FM7/FE2/FA6/FA7) WIRI
NG DIAGRAMS INDEX
3
(No Transcript)
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com
5
1. GENERAL INFORMATION
SERVICE RULES -- MODEL IDENTIFICATION SPECIFICATI
ONS - TORQUE VALUES --
- -- 1-2 ----------- 1-3
LUBRICATION SEAL POINTS ----- CABLE HARNESS
ROUTING - - EMISSION CONTROL SYSTEMS ---
TECHNICAL FEATURE -- - --
1-22
1-26
' - -- - - 1-5 ------ - 1-13
1-48
1-50
1-1
6

• GENERAL INFORMATION
• SERVICE RULES
• Use Honda Genuine or Honda-recommended parts and
  lubricanls or thetr equivaTenls Paris that don't
  meet Honda's design specifications may cause
  damage to îhe vehicle
• Use Ille special tools designed for this produit
  (0 avoid damage anÖ incorrect assemUly
• 3 Use only metric tools when servicing the
  vehcte. Metric bolts, nuts and screws are not
  interchanqeable with English fasteners
• InstaII new gaskets, 0-rings. catter pin9, and
  fock plates when reassembling.
• When tightentng bolts or nuls, begin with the
  larger diameter or inner bols first Then tighten
  lo the specfied torque diagonaily in
  incrementat steps un\ess a particuîar sequence s
  specified
• Clean parts in cleaning solvent upon disassembly.
  Lubncate any sliding surfaces before raassembly.
• ? After raassembly. check all parts for praper
  installation and operat on
• 8. Route all eleclrical wires as shown in the
  Cable Harness Routing (page 1-26j
• 9 Oo not bend or twist contrat cables. Damaged
  conVol cables wII not operaîe smoothly and may
  stick or btnd 10.Do not tow your ATV behind a car
  or other vehicle.
• ABBREVIATION
• Throughout this manual, lhe following
  abbreviation are used to identify the respective
  parts or systems.

Abbrev. term Full term

2WD
2 Wheel Drive 4 Wheel Drive
4\MD " CkP sensor
Cra sha os ion sensor
DCT ÒÏC DTC ECÚI(FM models) ECT sensor ECU
EÉPROM "EPS ESP jACV SAT sensor "LCD" MAP sensor
ÏvICS MIL PCM (FE/FA models) PGM-FI SCS servica
connector TP sensor VS sensor
I Dual Clutch Transmission Oata Link
Connector Oiagnostic Trouble Code Engine Controi
Module

EngineCoülaÑt Temperature sensor

Electric Control Unit
ETectrically Erasabie Programmable Read Only
Memory
E1ectnc Pôwer Ëteering Electnc ShiR
Prôram IdIe Ar Control Valve
Intake Air ÏemperaÏure sensor
" Lquid Crystal Display
Manifold A_at_sôlute Pressure sensor
ÑloÏôrcycle Communication System
"MaÏfunctÏon"Indicator Lamp PowertÄinContrôÏ
Module Programmad Fuel Injection SeÑice Check
Short service connector Throttle Position
sensor " " I" Vehicle Speed sensoi


DESTINATION CODE Throughout (his manual, lhe
following codes are used to idenlify individual
types for each region
DESTINATION CODE
REGION U"SA
1-2
7

• GENERAL INFORMATION
• MODEL IDENTIFICATION
• This manual covers 1.0 types of TRX?00 models
• FM1 Left loo! operated gaarshiR
• FM2 Lift foot.operatedgearahift/Electric Power
  Steering (EPS) FMS Left. foot operated
  gearshifMndesndent rear suspension
• FM6 Left foot operated gearshffl/Efectrfc Power
  Steering (EPS/Independent rear suspenslon
• FM7 L6ft footoperated gearshifVElectric.Power
  Steering (EPS\lndependentrear suspension/ATuminum
  wheel program (ESP)
• FE2 Electric shift program (ESP)/Electric Power
  Steering (EPS)
• FA5 Dual clutch trerismission (DCT)/Independent
  rear suspension
• FA6 Dual clutch transmission (DCT)/Electric
  Power teering (EPS)/Independent fear suspension
• FA7 DUa clutch transmission (DGTgElectric
  Power Stashing (EPS/Independent rear
  suspension/Aluminum whael
• Be sura to refer to the procedure that pertains
  to the appropriate version of tha TRX500.
• 14 model shown

SERIAL NUMBERS/LABELS The Vehlcle Identification
Number(VIN)1isstamped on lhe front side of the
frame through the front fender.
The throtiie body identification number1 is
stamped on the ower sida of the throttle body.
1-3
8
GENERAL INFORMATION
FMFE models The engine serial number 1 is siampec! on the left side of the rear crankcase. FA models The engine serial number 1 is stamped on the upper side of the rear crankcase.
FM1 FM2.. FE1. FE2 The certification label 1 (U.S.A. type) oi snfely certification label 2 fCanada type) is attached on the left front frame down pipe FM5/FM6/FM7.FA5/FA6/FA7! The certification label 1 (U S.A. type) or safety certification label 2 (Canada type) is attached on the left front frame pipe
1/2
The color label 1 is attached on lhe left front frame down pipe. Wh..n ordering color-coded parts, nlways specify the designated colur code The vehicle emission control information label 1 is attached on the leh front frame pipe U S A and Canadn type 1 Canada 1ype 2) U S A. and Canada type
1-4
9
GENERAL INFORMATION
SPECIFICATIONS GENERAL SPECIFICATIONS
ITEM
SPECIFICATIONS
DIMENSIONS
FM1/FM2/FE 1/FE2
Overall length
2,103 mm (82.8 in) I 2ÏÏ47 mm (84.5 in)
1,2Ö5 mm (47.4 in) 1,21a mm (48 0
in)
FM5/FM6/FM7/FA5/FA6/FA7
" FM1/FM2/FE1/FE2
Overail width Overail height Wheelbase
FM5/Fht6/ÈM7/FA5/FA6/FA7 1,235 mm 48.6 in)
FM Ï/FM2/FE 1.'FE2 1Ï2 8"mm (49.9 in)
FM5/FÏvI6/FM7/FA5.FA6/FA7 1,292 mm (50.9 in)
Front tread
FM1/FMZ/FE 1/FE2 910 mm (35 8 inj
FTU/FMbÏFh\7/FA5/FA6/FA7 920 mm (36.2 in)
Rear tread FM1/FÜl2/FE1/FE2 920 mm (36.2 in)
FM5/FÜl6/FM7/FA5/FA6/FA7 936 mm 3fi.9 in)
Seat height " FM1/FM2/FE1/FE2 , 869 mm (34.2 in)
FM5 FÑf6/FM7/FAS/FA6ÏFA7 909 mm (35.8 in)
FM1/FM2/FE f/FE2 358 mm 14.1 in)
Footpeq height Ground
FM5/FMG/FM7/FA5/FA6/FA7' 377 mm ( 14.8 in)

FMT/FM2/FE1 FE3 190 mm (7.5 in
clearance Fus rM6 FM7/FAñIFA IFA7 239 mm 9.4
tn)
Curb weigh FM1
AC 286 kg 1631 iis) CM 287 kg 633 iDs j FE1
AC 286 kg (631 lbs FM2 AC 292 kg (644
Ibs)" " CM 293 kg (646 Ils) " AC 293 kg (646
lDs) CM 294 kg (G48 Ibs) "
FE2
FMI " AC 307 kg (677 lbs) CM 308 kg (679 Ïbs) FM6 AC 313 kg (690 Ibs) "
CII 314 kg t692 lbs/ FM7 AC. 309 kg (681 Abs)
CM 311 kg (686 lbs i
FA5 AC 319 kg (703 fbs)
-A6 AÖ 326 kg (719 Ibs)
CM. 327 kg (721 Ibs)
FA7 ÂC 323 kg (712 Ibs)
CMŸ25 kg (716 Ibs)
Maximum FMI/FM2/FE1/FE2 250 kg (551 lDs)
w g ht FM5ÎFM6/FM7/FA5/FA6/FA7 26ô kg (573 Ibs)
ä ä
1-5
10
GENERAL INFORMAT)ON SPECIF!CATIONS
FRAME

Frame type From suspension Front wheel travel
Front damper
Doubie cradle Double wishbone 15 mm (7,3
in) Double tube Swingarm ftrailing typej
Doubls wishbone

Rear FM1/FM2FE/FE2
suspension Fkt5/FM6/Fkl7ñFA5/FA6/FA7 Rear
wheel " FM1/FM2FE1/FE2
85 mm (73 in)
travel
rM5/FM6/FM7/FAS/FA6/FA7
2 hmm 8.5 ink" Double tube
Rear damper

ATZ5 x 8-12
Front tire sexe Rear tire"s\ze Front rim stze
Rear rim site
AT25x 10-12 "

t2 x 6 0 AT 12 x 7.5 AT

Front tire
" FM1/FM2/FE1/FE2
M975 (MAXXIS I i MU25 (MAXXfS)
brand Rear tire brand
FM5/FM6/FM7/FAS/FA6/FA7 FM1/FM2/FE1/FE2
FM5/FM6/FM7/FA5/FA6/FA7
M978(MAXXIS) i MU26 (MAXXIS)
Hydaulic disc brake
Frontbrake Rear brake
FM1/FM2/FÉ1/FE2" FM5/FM6'FM7/FA5/FA6/FA7
FM1/FM2/FE1/ÉÉ1 FM5/FM6/FM7/FA5ïÉA6/FA7
Mechanical drum brake Hydralic disc brake
Casier angie

2 1 6.0 mm (0.24 in) 1.0 mm (0.04 in) '
0 0.1"

FM1/FM2/FE1/FEJ FM5/FM6/FM7/FA5/FA6/FA7
Front
camber angle Rear camber angle
Fuei Ïank capacity Fuel tank reserve capacity
14 7 liters (3.88 US gai, 3.23 Imp gal)
4.9 îiters (1.28 US gal, 1.08 Imp gal) Single
Eytinder. longitudinally instalied
ENGINE
CyÏinder arrangement Bose and sfroke DispTacement
Compression ratia Vatve"train InÏake
" 92.0 x 71 5 mm (3.62x 2.81 in)
475 cm (29.0 Cu-in)
"9"5. t OÉÏV
' 'BTDC
valve at Jim
!
odFEs


(0.04 in) lift
FA moduts ""
5"BTDC
46 ABDC
closes. at 1 mm
FM/FE models FA nodets " FM/FE , models
50 ABDC
(0 04 tn) Tift opens! at 1 mm (0.04 in)
lift closes.
46 BBOC

y FA models
42º BBDC 4º ATDC

' FM/FE
at 1 mm models
(0 04 in) lift FA modats
8 ATDC Forced pressure anü wetsump Trôchoid

Lubrlcatian system Oil pump lype
Coofing system Air filtration Liquid œoled I Oiled double urethane foam
Engine dry vveight FÑI1/FM2 514kg (113,3 Ibs)
FÈ1/FE2 FMI/FM6/ 524 kç/ (115.5 lbs) AC "51.4 kg (112.3 lbs)
FM7 CM 52 5 kg T11É.7 lbs)
ÈA5 62.1 kg (136.8 Ïbs)
FA6/FA7 AC 62/1 kg 136.9 lbs)
CM"63.2 kg (139.3Ïbs)"
FUEL DELIVERY Type PGM-FI
SYSTEM Throttle bore 36 mm (1.4 in)
1-6
11
GENERAL INFORMATION

DRIVE TRAIN ITEM Clutch system SPECIFICATIONS Centrifugal and multi-piate, wet
(FM/FE models) Clutch operation sysrem Transfnission Automatic Constant mesh, 5-speeds with reverse
Primary reduction 2.103 (61/29)
Secondary reduction 1.875 (30/16)
Final reduction Front 3.231 (42/13)
Rear " 3. 1S4 (41/13)
Gear ratio 1st 4.230 (55/13)
2nd 3rd 2.388 (43/18j "1 608 37/23j "
4Ih 1.178 33/28
5Ih 0.848 î28/33)
Reverse Pattern FM modeIs FE models
5.743 (48/13 x 28/18)
Gearshih pattern
R N 1 2 3 4 S Left foot operated
reiurn system
EIectric shift (left hand operated) return system
Centrifugal and 2 múlti-plate wet c1utches
Automatic Automatic. 5-speeds with reverse
DRIVE TRAIN (FA modelsl
Clutch system Clutch operation system
Transmission Primary reduction Secondary
reduction Fnai reduction
2.680 (67/25) 1.520 (38/25 3.230 (42/13) 3. 153
(41113) 3.058 (52/17) 2.157 (41/1Û-) 1.588
(27/17) 1.181 (26/22) 0.848 (28/33)
From Rear 1sl 3nd 3rd 4th 5th
Transmission gear ratio

Reverse 3.996 (45/1ó x 27/19) R N 1 2
3 4 5 Automatic and Efectric shift (left hand
operated)
Transmission gearshift pattern

relum system 2.187 (35/16) 1.5Z0 (38/25) L
D Lever operated system Fill transistorized
ignition Eleclric starter motor
Sub lransmission gear ralio
L D
Sub transmission gearshift payern
ELECTRICAL
Ignition system Starting sysfem
AC CM
""E lectric starter motor and emergency recoii
stater Triple phase output alternator FET
shorted. triple phase full wave rectifiCation
Charging system Regulator/rect er Lighting
system
"Bat t ery
PGM-FI SYSTEM SPECIFICATIONS
SPECIFICATIONS 2 2 2.7 kCl I .0 1.3 kCl 11. 1
123 ID
ITEM
IAT sensor resistance (40C. 104F) ECT sensor
resistance (20C/6BF) Fuel injector
resÏstanca (20C/68F)
IGNITION SYSTEM SPECIFICATIONS
ITEM
SPECIFiCATIONS BKR5E11 (NGK), K16PR-U1 1
(DENSO " 1 0 1. 1 mm (0.039 0.043 in ) 100
V minimum 0.7 V minimum 1ß BTDC at ictÏe
Spark plug Spark plug gap
Ignition coil primary peak voltage Ignition
pulse generator peak voltage Ignition liming (
F" markj
1-7
12
GENERAL INFORMATION FUEL SYSTEM SPECIFICATIONS
ITEM Throttle body identification number Idée
speed

SPEClFICATtONS GO3QA 1.400 1 10Òrgm 3 - 8 mm
(0.1- 0.3 in)


Throttfe lever freeplay Fuel pressure at idle
Fuel pump flow (at 12 V)

331 - 367 kPa (3.4 3.7 kgfcm'. 48 53 psi) 3É6
cm (12.0 US oz. 12.5 Imp oz) minimum/10"seconds
COOLING SYSTEM SPECIFICATIONS
ITEM Radiator and engine Resrve tank
SPEÖÎFICATIONS

Coolant capacity
1.54 liters (1 63 US ql, 1.36 IM
9!)

0.15 îitet (0. Ï6 US qt. 0.13 Imp qt) 108
137 kPa (1 1 1.4 kg/cm', 16 20 psig
Radialor cap relief pressure
Begin to open Fully open VàÎve lift
80 8ÂC (176- 183F)

Thermostat
95C (203F)
8 mm 0.3 in) minimum at 95C (203F) Pro Honda
HP Coo1ant or an equialent high quaÏify
ethylene glycol antifreeze containing corrosion
protection inhibitors
Racommended antifreeze
Standard coolant concentration

1 1 mixture wth disl tlad water
LUBRICATION SYSTEM SPECIFICATIONS
Unit mm (inj SERVICE LIMIT
IÏEM
STANDARD 2.9 liters (3.1 US qt. 2.6 Imp qt) 3.0
filers (3.2 US ql. 2.6 Imp ql)
Engine oi! capacité
FM/FE models
After draining After draining/filter change Aher
disassembly After draining After
draining/filter change
3.3 liters (3.5 US qt. 2.9 Imp qt) 3.6 liters
(3.8 US qt. 3.2 Imp qt) 3.8 liters (4î0 US qt.
3.3 Imp qt)
FA models
ARer disassemb1y
4.4 liters (4"6US qt. 3.8 Imp qt) Pro HondaGN4
4-stroke oil (U.S.A. and Canada) or equivalent
motorcycle oil API service classification SG or
hi9her (except oils labeled as energy conserving
on the circular API service label) JASO T 903
standard. MA Viscosity SAE 10W-30 510 kPa (5.2
kgf/cm', 74 psi) 0. JS (0_at_0d)
Recommended engne oil
0.20 IO.008
Oil pressure at 5.000 min " (rpm)
(80C/176F) Oil eump Rip c/saranœ
1-8
13
GENERAL INFORMATION
CYLINDER HEAD/VALVE SPECIFICATIONS
Uni mm (inI SERVICE LIMIT
ITEM Cyinder campresson at 450 rpm Valve
cfearance"

STANDARD 680 kPa (6.9"k f/cm', 99 psi j 0.15
"0"02 (0 006 1 0.001) " 0.23 0.02 (0 009 1
0.001)
IN EX IN EX INDEX IN/EX IN/EX Inner Outer IN/EX
IN/EX IN EX IN/Ex IN/EX
Va\ve, valve guide
Valve stem O.D. Valve guide I.D. Valve guide
protection above cylindei head " Vaive seat
widih Free length
5.975 5990 f0. 2352 0.2358) 5.955 5.970
(0.2344 0.2350)
S. 95 0.284 t 5.93 IO.233) 6.C2 (0.227)
6.000 6.01Ü (0.2862 - 0.2367" 14.8 15.0
(0.58 0 59
1.2 0.05) "" 42.94 (t .691) 43.63 1.Y1B)
1 5 0.06 i
Valve spring
42 08 (1.657 I
42 76 (1.683 12.OR (0.474)
Rocker arm
Arm \.D. Shaft O.D Cam lobe heighl
12.000 12.D1B (0.4724 D 4731 )" 11 966
11.984(0 4711 0.4718) 35.9400 36.1800 (1
41496 1 42441)
Camshaft and" " cam follower
ÜS.74 (1.407) "35.48 (1.397) 22 46 (0.ß84j 22.54
t0.887) 0 10 (0.004
35.6811 35.9211 ( 140476 1 4 1421)" 22 467
22.482 (0.8845 0.8851) 23.510 22.526 (0.8862
- B.8868)
Cam follower 0. D. Follower bore i.D
Y inder ñead warpage
CYLINDER/PISTON SPECIFICATIONS
LJf1it. mm (iD ) " SERVICE LIMIT 92.10
(3.626) 0.10 (0.004) 91.g0 (3.618) 19 04 IO
750) B 96 O.746 0.5 IO 02) 0.6 l0.02 \
ITEM
STANDARD 92.000 - 92.Ö10 (3.6220 - 3.6224
Cylinder
I.D
Out-of-round Pislon O.D. at 15 (0.6 from bottom
Piston pin hole I.D."
Piston, piston pin. piston ring
91.9?0 91.99O (3.G200 - 3.6216) 19.002 19.008
l0 7481 - 0.7483) 18.994 19.000 (0.74 78 - 0
7480 0.15 0.30 (0.006 0.012) 0.30
O.45"(Ò"Ò 12 0.01B ) 0.Z0 0"70 \0 008 O
02Bj 0.030 0.D60 (0.00 \ 2 - 0.0024 0.030
0.060 (0.00t 2 - 0.0024j 19/020 "19041 (0.74B8 -
0.7496)
Piston pin O.O. Pis(on ring end 9ä Piston
ring-to-ring
Top Seoond Oil Aside rail i Top
"
0 9 i0 04j Ö.09 \0.004 0.09 (O.004t 19.07 T0 751
)
groove clearance Second
Connecting rod small end I D.
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (FM/FE
models)
mm ein \ SERVICE LIMIT " 1"5O 4 (5 52 t .3 lü
05s 2.84 (0.112 25 7 (1 01 50.7 (2.00 45.3 (1
78j 2,3 (0.09) 0.20 (0,008)
ITEM Drum I D
STANDARD 1500 JSÖ 2 (S 906 - 5.9J 3) 2"0 t0
08) 2.9G"(0. 117)" 24"72 D 973) 52.2 (2.06) 46/8
(1.84) ?.62 2.7B(0.1D3 0.109)
Weight lining thickness
Clutch spring height Clutch weight spring free
length Spring free length"" FM1/FM2 FE
1/FE2 Disc thickness
Change clutch
Plate warpage Outer I.D Outer guide
29.D00 - 2 021 ( 1.1417 I . J426 22.000
22.021 (0.86g1 - 0.867LI 28.959 28.380 1
1401 1. 1409) 1.967 21".9BO (0 8648 - 0.86S4
29.000 29.021 ( ) J417 - f 1426) 28.959 -
28.980 ( 1.1461 1 J409
I.D Ö D.
Mainshaft O.D. al clutch ouier guiöe
29 05 i 1 144l 28 93 i 1.13JI
Primary"drive gear
Gear t 0
crankshaft O.D. at dnve gear
1-9
14
GENERAL INFORMATION DUAL CLUTCH TRANSMISSION
SPECIFICATIONS (FA models)
Unit rrim (in)
STANDARD 140.0 140.Z (5 512 - 5.520 ) 2.0
(0.08)
ITEM Drum I.D. Weight lining thidkness ñiutch
sprirt height "Cluich weight spñng free length "
1 140 4 5.53) 1.3 (0,05) 5.68 (0.145) 25.6
(1.01)
"Centn?ñgal
3460' 970
510 kPa (5. kgf/cm. 7'4 psi) 510"kPa (5.2
kgf/cm. 74 ps) 0 70 0 90 (0 028"- 0.035)"
Oil pressure âi 5,000 m (80'C/176F) " ihte J
h
' Shift cdtch Initial clearance
1st 2nd

0 65"-095 (0026 - 0037)
Disc thickess 1t88 2.00 (0.074 - 0.079) "
Plaie th ckness 1.55 165(0.06 - 0.065) _
Primary dnve Gear I.D_ 29.000 29.02t (1.1417 t .1426)
gear Crankshaft O.D. al drlye gear 28.959 28.980 (1.1401 1.1409)
SUB-TRANSMISSION SPECIFICATiONS (FA models)
Unit mm (in) SERVICE LIMIT
ITEM
Shin fork Claw thickness
Low, dip "Low drive Law dne " at Low, drive
Tran ssion
t Gear UD. Gear bushingCl D. " Gesr bushing l,D,
23/000 23.021 9055- 0.9063) 22.959 22.980
(0.9039 0.9047)
S b mision " h
18/959 19.980 (0.7858 0.786)
"
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
Unit mm (n) SERVICE-- LIM--.T.
fTEM
r
D.D. " ITD. " "
Starter driven sar bass
"31 85 (1.2?4) CRAXkCASE/TRANSMISSION/CRANKSHAFT/
BALANCER SPECIFICATIONS FM/FE models
Unit mm (ink SERVICE LIMIT
ITEII
STANDARD " 2 4 (0.1 0.2)" 1?.000 13.021
(0.5118 0.5126) 13.000 13.018 (0.5116 -
0.5125)
Ie 7 seIectr l'v fr'eplay
Font, rear Cente

Claw thickness ShaC 0. D. Gâar I.D.
5 129 40.6Ï 9 0.5112)
_ Transmission
' 42.
25.üoo 25èüi to.9u3 - o.ss51
M3 M5 C1, C2, C4. CR Reverse die M3 UM"
" C2 C1. C4, CR
20.000 20.021 0.7874 0.7B82) 28.020
28.041(1.1031 1 1040) 13.000 13.021 (0.5118
0.5126)a 24.959 34.980 (0.9826 - 0.9835) t9.966
19. "(0.7861 0.7868) 27.984 28.005 (1.1017
I.1026 I 27.979 38.000 (1 1015 11024 22.000
Z2.020.8661 0.B670) 17.016 17.034 (0.6699
0.6706) 25.000 25021 (0.9843 0.9851) 21.959
21.980(0.8645 0 8654) 16.976 16.087 (0.6683
0.668B)
year bushing O.D.
!
Cear bushing I.D. i M3 M5

MâinshaR ONO.
ai M3 " at M5
" Cranshaft
"Reverse idIeshaRO.D.
12.966 12.984 (0.5105 0.5112)
0 i5 (0.006) 0.8 I0.03) _ 0.05 (0.002)
B 'end side clearance

Big end radial clearance
0.006 0.I?18 (0.0002 - 0.0007)
1-10
15
GENERAL INFORMATION
FA models-
UnJj mm in l " SERVICE LIHIT
ITEM"
STANOARO
RBverse selector 1ever freeplay
2 -4 (0.1" 0.2j
Shift fork
I.D Claw thickness "

13.000 13.018 (0.511B 0.5125 5.93
6.00_(0.233 - 0.236) J2.966 11.984 (0.5105 -
0.5112)
Shaft O D. "
Transmission Gear I.D. ñJ1 M3 C2 CA. CR 20.000 20.021 (0.7874 - 0.7882) 25.000 25.021 (0.9843 - 0.9_at_51) 28.0 0 Ž8.041 (1.1031 - 1.1040) 20.000 20.021 (0.7874 - 0.7882) 25.000 25.021 (0.9843 - 0.9_at_51) 28.0 0 Ž8.041 (1.1031 - 1.1040)
Gear bushing C5 Reverse idle M1 31 000 31 025 (1 2205 1.221 ) 13 000 13 0 8 (0.51 \8 - 0 5?2Š) 19,966 19 984 10 786 T - 0 7C68) 31 000 31 025 (1 2205 1.221 ) 13 000 13 0 8 (0.51 \8 - 0 5?2Š) 19,966 19 984 10 786 T - 0 7C68)
0 D M3 Z4. _at_59 24.980 (0.9826 0.98Š5) Z4. _at_59 24.980 (0.9826 0.98Š5)
C2/CR C4 27.979 8. 000 (1.1015 J .1024) 27 98 28.005 (1.1017 1.1026) 27.979 8. 000 (1.1015 J .1024) 27 98 28.005 (1.1017 1.1026)
CS 30.950 0.975 (1 2185 1 2195j 30.950 0.975 (1 2185 1 2195j
Gear bushing I.D. "' M1 M3 C2/CR C5 Gear bushing I.D. "' M1 M3 C2/CR C5 17 000 17 018 (0.6692 0.6700) 22.000 22.021 (0.8661 0 8670) 25 000 25.013 10.0843 0.9848I 2B.DD0 28.021 (1 1024 1.10 Ž)
Mainshaft Q.D. at M 16.976 16.987 l0.6683 0.66_at_8) 16.976 16.987 l0.6683 0.66_at_8)
at M3 21.959 - 21"980 f0.8605 0.86a) 21.959 - 21"980 f0.8605 0.86a)
Countefshaft O D. at C2/CR 24.959 24 980 ID 5826 0.9835i 24.959 24 980 ID 5826 0.9835i
at C5 27 959 27 980 (1 1D07 1 1016) 27 959 27 980 (1 1D07 1 1016)
Reverse idle shaft O.D.
t 2.966 12.984 0.51LI5 0.5112j
Cankshaft Runout
0.15 (0.006 0.8 (0.03) 0.05 (0.002)
Big end side clearance"
1.05 0.6s (0.002 O O2G) 0.006 0.018 (0.O002
- 0.0007)
' Big end radial clearance
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit. mm (in ) SERVICE LIMIT
ITENI
STANDARO 30 kPa (0.30 kgf/cm , 4.4 psi I 30 hPa
0.30 kgf/cm, 4 4 psi)
Cold rire pressufe
Standard " With cargo FM/FE models FA models
Tie-rod distance beiween the ball OintS Toa
387, g ( 15.27) 388 4 (15.29) Toe-out 25 -t
IN (1.0 z 0.6)
REAR WHEEL/SUSPENSION SPECIFICATIONS
ITEM
" STANDARD 30 kPa 0.30 kgf/cm . 4.4 psi
SERvlCE LIMIT
Cold tire prelude
Standard With cargo
1-11
16
GENERAL INFORMATION BRAKE SYSTEM
SPECIFICATIONS Unit mm in) STANDARD SERVICÉ
LIMIT
Honda DÕT 4 brake fluid 3.3 3"7 (D 13 0 15)
RecomTeMded"brake fluid Disc ihickness Desc
runout Masler cylinder l.D Master pis on O.O.
Caliper cylinder I.D. Caliper psron O.D
Front brake
3.0 \0. 2 .. 0.30 (0.0z2 I
. J4.000 14.043 (0 5512 0.552S) 3.857
13.984 \0.5495 0.5506) 32.030 32.D80 (1.2610
1.2630 31.948 31 998 (1.2578 1.2598) 15 -
20 (0.6 0.8) l 5 20t0.6 0.8)


!
Reat (parking) bra?e levBr freeplay
Rear brake (ÇM1IN-M2l

Real brake pedal freeplay
FE 5FE2) Rear brake îFM5/FM6/ FM7/FA5/FA6/ Rear bake drum l.D Rear (parking) brake lever Recommended bake fluid Disc lhickness " freepfay " t60.0 -"160.2 (6.30 6 31) 25 30 ( 1D 1.2) Honda DOT 4 brake fluirÎ 7.3 - 7.7 (0.29- 0.30/ lxl 0 (b b) 6.0 (0.24)
FA7) Disc runout 0.30 (0.012)
Master cylinder I.D. Master piston O D 15.870 15.913 (0.6248 D.6265) 15.827 - 15.854 0.62310.6242) _
Calipercylindei I.D" Caliper pistonÕ.Õ. 30 230 30 280 (1 1902 \ 1921j 30.165 30 198 (1.1876 1.1889) -
FRONT DRIVING MECHANISM SPECIFICATIONS
Unit mm (In) SERVICE LIMIT
STANOARÕ
ITEM Oil capacity
After draining After disassembly
Front final drive
325 cm' ti1.0 US oz, 11".4"Imp õz) 370 cm' ( 12.5
US oz, 13 0 ImpOZ) Hond shaft drive oil or
equivalent hypoid gear oil, SAE 80W90 0.05
0.25 (0.002 0.010)
Gear Dakash Backlash difference Slip torque
0.4(Õ02) 0.2 (0.01) 12 N m (1.2 kgf m, 9 bf
R) 3.3 t0.13) 6.55(0.2Ÿ8 26 (0 0)

14 17 N m î1 45 1.75 kgf m, TO 13 Ibf ft)
3.3 3.7(0,13 0 15)
Face camió-tauing distance Differential ring gear
depth Cone spnng free height
6.55 6.65 (0.258 0.2621
2.8 (0.11)
REAR DRIVING MECHANISM SPECIFICATIONS
Unit mm (in) SERVICE LIHIT 3.0 (0.12)
SÏAtJDARD
ÏTËM Axle runout (FM \/FM2/FE 1/ËE2)

After disassembly
10ß cm (3.4 ÜS ozs 3.5 Imp"oz)
FM1/FM2/ FEI/FE2) Oil capaci? (FM5/FM6/ FM7
FA5/FA6/ FA7 l Recommended oil
After draining After dicassembty
125 cm' (4.2 US oz, 4,4 Imp oz) 145 Cm (4. 9 US
oz, 5.5 Imp oz)
Honda shaft dnve oil of equivaienl hypoid gear
oil. SAE 80W9D 0.05 - 0.25 (0.002
0.010) O206(001002)

(3earbacNash BackÏah difference

Ring gear-to-stop pin clsaance
1-12


17
GENERAL INFORMATION
BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM
SPECIFICATIONS GYZ16H ""I2 V 16 Ah (10 HR )/12
V 16.8Ah (20 HR) 1 mA max . 0.3 mA max
Battery
Type Capaciiy Current leakage
FM1/FM2/FE1/FE2 "FM5/FM6/FM7/FA5/ FA6/FA7 Fully
charged NeedSchargin9 Normal -oick FM/FE models
FA models
Voltage (20C/68 F) Charging current Capacity
13.0 13"2 V Beiow 12.4 V 1.6 A x 5 - 10 h 8.0
A x 1.0 h 0.481 kW/5,000 rpm 0.595 kW/5.000 rpm 0
1 1._at_
Alternator
Charging coil resistance i20 C/68'F i

LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM
"SPECIFICATIONS 12 V - 35/35 W x 2 12 V - 45W 12
V 50 W
Bulbs Headlight (high/low beam)

Assist headlight
FM1/FM2/FE FE2 FM5/FM6/FM7 FA5/FA6/FA7
8rake/taillight Neutral indicator Reverse indical High"coolant temperature indicator LED LED LED LED
MiL LED
Meter light LED
EPS indicator (FM2/FM6/FM7/FE2 FA6/FA7 j LED
Differential lock Indicator LED
Fuse Main fuse Sub-fuse FM1/FM"Z/FMS FE/FA models FM6/FLJ7 40 A 20 A x 4, UA x 2 30 A x 1, 20 A x 2, 10 A x 2 20 A x 3. 10 A x 2
EPS fuse FM2/FE2/FM6/ FM7/FAG/FAX 40 A
TORQUE VALUES STANDARD TORQUE VALUES
TORQUE N-m (kgfm, Ibfft) 4 2 (0.4 31) 9 (0 9,
6.6j 12 (1.2. 9) 27 (2.8. 20) 39 (4.0 29)
TORQUE N m (kgf m, Ibf-ft) 5.2 0.5, 3.8 10
y0. 7j 22 (2.2. 16) 34 (3 ?. 25) 54 (5.5. 40)
FASTENER TYPE 5 mm screw 6 mm screw 6 mm flange
bolt and nut (Include 8 mm head. large flange
bolt) 8 mm flange bolt and nui 10 mm flange
bolt and nut
FASTENER TYPE
5 mm bolt and nut
6 mm bit and nul (Include SH flange bolt) 8 mm
bolt and nul 10 mm bolt and nut 12 mm bolt and nul
1-13
18

• GENERAL INFORMATION ENGINE FRAME TORQUE VALUES
• Torque specifications listed below are for
  important fasteners Olhers should be tightened lo
  standard iorque values listed above.
• FRAME/BODY PANELS/EXHAUST SYSTEM
• THREAD TORQUE

ITEM Q'T Q'T Q'T olA. tww\ olA. tww\ olA. tww\ N-m (kgf m, tbf ft) REMARXS REMARXS
Step bracket nut 8 8 8 8 8 8 32 (3.3, 24)
Muffier cover bolt 2 2 2 6 6 6 12 (1.2. 9)
Exhaust pipe cover band screw Exhaust pipe cover band screw 2 2 2.0 (0.2, 1.5)
Exhaustpipe cover rear band screw (FM5/FM6/FM7/FA5/FA6/FA7) Front muffles cover band screw Exhaustpipe cover rear band screw (FM5/FM6/FM7/FA5/FA6/FA7) Front muffles cover band screw 1 1 3.2 (0.3, 2.4) 2.0 (0.2. T 5)
(FM1./FM2/FE1/FE2 (FM1./FM2/FE1/FE2
Front muffles cover band screw (FM5/FM6/FM7/FA5/FA6/FA7) Front muffles cover band screw (FM5/FM6/FM7/FA5/FA6/FA7) 1 1 22(0.3, 24)
Muffles cover band screw Muffles cover band screw 2 2 3.2 (0.3, 2 4)
Exhausi pipe stud bait Exhausi pipe stud bait B 6 (0.6, 4.4) Sea page 2-13
MAINTENANCE
THREAD DIA. (mm)
TOROUE N-m (kgf'm, lbf ft) Z2 (2 2, 16
) 17 (1 7, 13) 12 (1.2, 9) 10 (1 0.
7) 25 (2,5 18) 1 (1.2, 9) t2 (1.2, 9)
\ 2 (1.2, 9) 12 (1.2, 9) 12 (1.2, 9) 26 (2.7,
19)
ITEM
REMARKS
1 14 2 6 2 26 1 14 1 12 1 8
Spark plug Valve adjus(ing screw lock nut Valve
adjusting hoie cap


Timing hole cap

Engine oii drain bolt
Rea final geQr case oil check bolt
(FM1/FMZ/FE1/FE2)


Rear final gear case oil filler cap 1 Rear
fina gear case oil drain bolt 1 1 1 2
30 8 30 8 14

Front final gear case oil filler cap From final
geai case oil drain bolt
R setIect cable Iock"nut (FA5/
FA FA
Front master cylinder reservoir cap
4 8
2.0 (0.2. 1.5) 17 1.7, 13j
Rear brake master cylinder push rod joint lock
nut (FM5/FMd/FM7/FAS/ FA6/FA7) Tie-rod lock nuf
(knuckle side) Tie-rod lock nul (steering arm
sides) PGM-FI SYSTEM
12 12
See page 3-31
" (5 5. 40) 54 (5.5. 40) Left hand
threads. See page 3-31
THREAD DIA. (mm) "3 5 1 10 2 6 1 12
TORQUE
ITEM
Q'TY
REMARKS
N m (kgf'm, Ibf-ft) 3.4 (0.3. 2.5) 12 (1.2. 9)
10 (1.0, 7) 24.5 (2.5. 1B)
Sensor unil torx screw (T25) ECT sensor Bank
angle sensor mounting boll" Oz nsor IGNITION
SYSTEM
THREAD DIA. (mm) 14
TOROUE N'm (kgfm, Ibf'ft) 10 (1.0. 7)
ITEM Timing hole cap
Q'TY
REMARftS
1


1-14
19
GENERAL INFORMATION
ELECTRIC STARTER
THREAD OIA. (mm) 5 5
TORQUE
ITEM
REHARKS
Ibf R) 4.9 (0 5, 3 6) 3.?(0.4,2 7)
Slartermotor case bolt Negaiive brush set
screw FUEL SYSTEM
2 1
"
THREAD
TOAOUf
ITEM Harness clip stay screw ' DIA. (mm) N m (kgf m, Ibf R) 3.4 (0 3. 2 5) REMARKS
Fuel hose clamp stay Screw Insulator bnd screw (Cylinder head side) 3.4 0 3, 2 5) See page 7-21
Insulator band screw (Throttle body side) 1 5 See page 7-22
Throtlle drumcovsr screw
IACV lorx screw (T20 2 4
Fuel injector mounting bolt 2 5
COOLING SYSTEM
R(QD)
TORQUE N m (kgf'm. lbf'R)
Q'TY
ITEM
REMARKS
Waier hose band screw Cooling fan nut Fan motor
bolt Fan motor stay bolt CYLINDER HEAD/VALVE
See page 8-8
5 S
2.7 0.3. 2.0 5.2 (0.5. 3.8)" 8.4 (0.9, 6.2)
Apply locking agent lothe threads
3

THREAD DIA. mm) 10
TORQUE N-m (kgf'm. Ibf'ft 411 (4.9, 35)
REMARKS
ITEM
Q'TY
4 !
Apply engine oil to the threads and seating
surface
Cylinder head nut
1D
63 (ü 4, 46s
benehanger nut
Urpeee
8
32 (3 3, 24)
Upper engine hangar bolt
2
(engine side) Cam chain tensioner pivot bott
1"
12 (1.2. 9)
Apply locking agenf to the threads Coating width
8.0 - 1 0 mm (0.31 0.04 in \ except ZO 1
OmmlD.0B004in
Spark plug " ECT sensor CYLINDER/PISTON
14 10
22 (Ü.2, 16) 12 (1.2, 9)
1
THREAD , DIA. (mm) lÖ
?O?tQUE N'm (kgf'm, Ibf ft) 12 ( 1,2. 9
REMARKS
ITEM
See page 115
CYlinder stud bolt
4
1-15
20
Suggest For more complete manuals. Please go to
the home page. https//www.ebooklibonline.com If
the above button click is invalid. Please
download this document first, and then click the
above link to download the complete manual. Thank
you so much for reading
21
GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE
(FM/FE models)
THREAD OIA. (mm)
TORQUE N m (kgf m, Ibf R)
REMARKS
ITEM
Centrifugal clutCh lock nut 1 20 118 (t2.0, 87) Lock nut replace with a new one. Apply engine oil to the threads and seating surface. Slake.
Change clutch lock nut 18 108 ï 0. 80) Lock nut replace with a new one Apply engine oil to lhe threads and seating surface Stake.
Clutch spring ball 4 6 13 ( 1.3, 10 )
Gearshift spindie return spring pin 1 22 (2.2. 16) Apply locking agent io the threads Coating width 6.5 I 1.0 mm (0.26 0.04 in) except
3.0 4.0 m 10.12 - 0 16 in) from tip
Gearshift cam bolt
6

16 (1.6, 12)
Apply locking agent to the (hr6ads
Coating width! 6 S z \ .0 mm (0.26 z 0 04 in)
except 3.0 J.0 mm t0.12 0 16 in)
Shift drum stoppen arm ptvol holt
1
6
12 1. 2, 9)
Apply locking agent to the threads Coating width
8.0 1 .0 mm (0.31 4 0.04 in) except 2.0 I 1.0 mm
(0.08 1 0.04 in) from tip Apply locking agent to
the threads. Coating width 6.5 z 1.0 mm (0.26 z
0.04 in) axcspt 6.0 8.0 mm 0.24 0.31
in) from tip
'
I
8
27 ï2.8, 20)
DUAL CLUTCH TRANSMISSION (FA models)
TOROUE N m (kgf-m, lbf ft) 118 i ï2 0. 87)
ITEM
REMARKS
Centrifugal slutch lock nut
1
20
Lock nui repface with a new one. Apply engine
oit to the threads. Slake.
Oil feed pipe S0tting cap Orifce elief valve
sockefibolt Sealing bott Gear shift spindie
retumsprtng pin
l Z4 1 t 1Ö 1 8 1 8"
21 (2 L 15) 34 (3.5. 25) 16 (1.6. 12) 22"f2.2, 16)

' Do not remove unless necessary.
i
Do not rem-o-ve u-nless necessary AppTy locking
agent to the threads Coating width 6.5 1.0
mm U.26 t 0.04 in except 3.0 4.0 mm (0.12
0.16 in) from tip Lock nut replaca with a new
one. Apply engine wil to the threads and seating
surface Stake App y tooking agent to the threacts
Coatin9 width 8.0 1 1.0 mm (0.31 1 0.04 in)
excapt 2.0 z 1.0 rum 0.08 a 0.04 in) from
tip Apply boeking agent to the threads Coating
wid(h 6.5 1 1.0 mm (0.6 z 0.04 in except 3.0
4.0 mm 0.12 0.16 in) from tip Apply lockng
agent to the threads. Coating widlh! 6.5 a \ 0
mm (0.26 t 0 04 in) except 3 0 4 0 mm \0.12
0. t6 in) from tip Apply iocking ageni to tFe
threads Coating width 5.0 t 1.0 mm
!" 108 (11.0, 8Ö)
Shift clutch Ïock nut
1 !
18
Shift drum stoppen arm pivut boll
1
6
12 ( 1.2 è)
SÊiAdÜm canter ball
1
B
23(2 3, 17)
Shift drum guide plate bolt
6 0 6, 4 4)
(0.2 z 0.04 in) except 1.0 2.0 mm (O.04 -
0.08 in) from lip
1-16
22
GENERAL INFORMATION
HRÊAD
TORQUE N-m (kgfm, Ibf ft) 12 (t.2, 9)
REMA
ITEM
Q'TY
DIA, mm) 6

A locki î!! hethfeads.
Shift drüm position switch y/ira clamp bolt
Coadriq wldth 6.5 1.0 mm
(D.26 z 0.04 in) except 3.04.0 mm (0.12 0.t6
In).from tip
Shift drum position switch retairjing bolt
1
6
12 (1.2, 9)
App locking agent to the threads.
Coating width 6.5 z 1.0 mm (0,26 10.04 in)
except 1.0 2.0mm
(0.04 - 0.08 In) from tip
EOT sensôr
1 1 10 1 18 (1.8, 13) I
Rue swch
Rear VS sensor mounting bolt
(1.3?10 ) (1.0. 7)

SUB-TRANSMtS6ION (FA models).
THREAD I DIA. (mm) 12
TORDUE Nrn (kgfwi, Ibfft) 120 (133,96)
ITEM
REMARKS Lock nut replaœ with a new one.

Rear sub-èmelower rnounting 2 nut
130 (13.3., 98) Lock nut replace with a paw
one. 21 (2.1, 15) I
Raar sub-frame rear mountlng nut 1 12
Ränge select lever plvot nut 1 8
Rangeselect arm sooket bolt Rase lectgatespecial
bolt
1 2
6 6
12(1.2, s) I
12 T1.2,.9) I 13)
Settingcap 1 18 18 (1.8.
.Shîftàrmpinchbo/t ALTGRNATOR/STARTER CL?TCH 1 6 " 16 (1.6,
1.2) I TOROUE
ITEM )'Starter IutcÎi bôÏÏ (T4Ö)
N'm (kgf-m, REMARKC
DIA.
lbfR
6 8 37 (3.8, 27) Apply locking agent to the
threads.
Coàting wldth 6.5 z 1.0 mm (0.26 0.04 in)
except 3.Ô 40 mm (ü.12 .0.16 in) from t1p
Flywheel bnlt (U.S.A. type)
1
108 (11.0 80)
Applyengine oil to the threads and
saating surface.
Él heeHdrlveñ pulley bolt (Canada. type) CKP
serisor.bolt
12
108 (11.0, 80)
Apply egirie oil to tha threads and
seating surface,
2
5
6. (0.6, 4.4)
Apply locking agent to the threads. .Coating
width 6.0 z 1.0 mm (0.24 4 0.04 in) excapT 14
3.Q mm (0.04 0.12 in)
from tip
9tator mounting boit (FM/FE 4
12 (1.2, 9)
iriodeIg)
Gtator mocînting bolt (FA models) 1 4 1 6
1ô (1.07)

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER THREAD
TORQUE Ibf R
REMARîS
DIA. (mm) .6

Apply locking agenl tö th'ë thrsadsÏ
ShÏft drum bearlng set plate (FA mode!s)
2
12 (1.2, 9)
Coating width 5.0 z 1.0 mm
(0.210.04 In) except 1.03.0 mm (0.04 0.12 In)
from tip
23
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com