Clymer Honda TRX500FA TRX500FGA Rubicon 2001 2004 Service Repair Manual M210

Save money on repair and maintenance jobs. This manual covers Honda Rubicon TRX500 [TRX500FA (2001-2004) and TRX500FGA (2004)]models made between 2001 and 2004.It has chapters on troubleshooting , fuel system overhaul and adjustment , plus brakes and every other system onboard. As with all Clymer publications this manual has step by step instructions for each repair procedure , complete with multiple illustrations. There are wiring diagrams and specification charts , plus many great tips on types of tools , fasteners , and specialty chemicals used in motorcycle maintenance. Not only save money on repairs , but know that it was done correctly.

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
210210b210p