Honda 5d2005 5dHonda Rubicon 2008 Service manual
Honda 5d2005 5dHonda Rubicon · 2008 · service manual · 540 pages
Technical data
Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.
Tightening torque
Values extracted from the document text. Check against the original before service work.
| Item | Value | Also | PDF page |
|---|---|---|---|
| Spark plug | 22 N·m | 2.2 kgf·m · 16 ft·lb | p. 19 |
| Valve adjusting screw lock nut | 17 N·m | 1.7 kgf·m · 13 ft·lb | p. 19 |
| Timing hole cap | 10 N·m | 1 kgf·m · 7 ft·lb | p. 19 |
| Engine oil drain bolt | 25 N·m | 2.5 kgf·m · 18 ft·lb | p. 19 |
| Engine oil filter center bolt | 18 N·m | 1.8 kgf·m · 13 ft·lb | p. 19 |
| Oil gallery sealing bolt | 34 N·m | 3.5 kgf·m · 25 ft·lb | p. 19 |
| Carburetor insulator band screw | 4 N·m | 0.4 kgf·m · 2.9 ft·lb | p. 19 |
| Cylinder head cover cap nut | 53 N·m | 5.4 kgf·m · 39 ft·lb | p. 19 |
| Centrifugal clutch lock nut | 118 N·m | 12 kgf·m · 87 ft·lb | p. 20 |
| Oil feed pipe setting cap | 18 N·m | 1.8 kgf·m · 13 ft·lb | p. 20 |
| Oil gallery sealing bolt | 10 N·m | 1 kgf·m · 7 ft·lb | p. 20 |
| Starter clutch outer bolt | 30 N·m | 3.1 kgf·m · 22 ft·lb | p. 20 |
| Recoil starter driven pulley bolt | 108 N·m | 11 kgf·m · 80 ft·lb | p. 20 |
| Alternator stator bolt | 10 N·m | 1 kgf·m · 7 ft·lb | p. 20 |
| Ignition pulse generator bolt | 6 N·m | 0.6 kgf·m · 4.3 ft·lb | p. 20 |
| Gearshift drum center bolt | 27 N·m | 2.8 kgf·m · 20 ft·lb | p. 20 |
| Gearshift drum stopper arm pivot bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 20 |
| Primary driven gear bolt | 17 N·m | 1.7 kgf·m · 12 ft·lb | p. 20 |
| Oil pump driven sprocket bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 20 |
| Angle sensor bolt | 6 N·m | 0.6 kgf·m · 4.3 ft·lb | p. 20 |
| Front carrier/carry pipe bolt | 37 N·m | 3.8 kgf·m · 27 ft·lb | p. 22 |
| Gearshift lever knob screw | 2 N·m | 0.2 kgf·m · 1.4 ft·lb | p. 22 |
| Rear carrier bolt | 37 N·m | 3.8 kgf·m · 27 ft·lb | p. 22 |
| Muffler band bolt | 23 N·m | 2.3 kgf·m · 17 ft·lb | p. 22 |
| Front exhaust pipe cover band screw | 3.2 N·m | 0.3 kgf·m · 2.4 ft·lb | p. 22 |
| Rear exhaust pipe cover end band screw | 5.4 N·m | 0.6 kgf·m · 4 ft·lb | p. 22 |
| Rear exhaust pipe cover center band screw | 5.4 N·m | 0.6 kgf·m · 4 ft·lb | p. 22 |
| Muffler cover screw | 3.2 N·m | 0.3 kgf·m · 2.4 ft·lb | p. 22 |
| Footpeg bracket nut | 32 N·m | 3.3 kgf·m · 24 ft·lb | p. 22 |
| Front differential oil filler cap | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 22 |
| Front differential oil drain bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 22 |
| Rear final gear case oil filler cap | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 22 |
| Rear final gear case oil check bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 22 |
| Rear final gear case oil drain bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 22 |
| Left lower engine hanger bracket bolt | 32 N·m | 3.3 kgf·m · 24 ft·lb | p. 22 |
| Lower engine hanger nut | 54 N·m | 5.5 kgf·m · 40 ft·lb | p. 22 |
| Upper engine hanger bracket bolt | 54 N·m | 5.5 kgf·m · 40 ft·lb | p. 22 |
| Upper engine hanger bracket bolt | 32 N·m | 3.3 kgf·m · 24 ft·lb | p. 22 |
| Gearshift lever box cover bolt | 5 N·m | 0.5 kgf·m · 3.6 ft·lb | p. 22 |
| Gearshift lever linkage arm pivot bolt | 27 N·m | 2.8 kgf·m · 20 ft·lb | p. 22 |
| Gearshift lever linkage tie-rod lock bolt | 10 N·m | 1 kgf·m · 7 ft·lb | p. 22 |
| Handlebar lower holder nut | 39 N·m | 4 kgf·m · 29 ft·lb | p. 23 |
| Front wheel nut | 64 N·m | 6.5 kgf·m · 47 ft·lb | p. 23 |
| Front wheel hub nut | 78 N·m | 8 kgf·m · 58 ft·lb | p. 23 |
| Shock absorber mounting nut | 44 N·m | 4.5 kgf·m · 33 ft·lb | p. 23 |
| Upper arm pivot nut | 44 N·m | 4.5 kgf·m · 33 ft·lb | p. 23 |
| Lower arm pivot nut | 44 N·m | 4.5 kgf·m · 33 ft·lb | p. 23 |
| Brake hose clamp bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 23 |
| Tie-rod ball joint nut | 54 N·m | 5.5 kgf·m · 40 ft·lb | p. 23 |
| Assist headlight case mounting nut | 25 N·m | 2.6 kgf·m · 19 ft·lb | p. 23 |
| Steering shaft end nut | 108 N·m | 11 kgf·m · 80 ft·lb | p. 23 |
| Steering shaft holder bolt | 32 N·m | 3.3 kgf·m · 24 ft·lb | p. 23 |
| Rear wheel nut | 64 N·m | 6.5 kgf·m · 47 ft·lb | p. 23 |
| Shock absorber mounting flange nut (Upper) | 34 N·m | 3.5 kgf·m · 25 ft·lb | p. 23 |
| Shock absorber mounting flange bolt (Lower) | 44 N·m | 4.5 kgf·m · 33 ft·lb | p. 23 |
| Swingarm pivot bolt | 112 N·m | 11.4 kgf·m · 82 ft·lb | p. 23 |
| Swingarm right pivot lock nut | 112 N·m | 11.4 kgf·m · 82 ft·lb | p. 23 |
| Brake hose oil bolt | 34 N·m | 3.5 kgf·m · 25 ft·lb | p. 23 |
| Wheel cylinder bleed valve | 5.4 N·m | 0.6 kgf·m · 4 ft·lb | p. 23 |
| Front master cylinder reservoir cap screw | 2 N·m | 0.2 kgf·m · 1.4 ft·lb | p. 23 |
| Front brake lever pivot bolt | 1 N·m | 0.1 kgf·m · 0.7 ft·lb | p. 23 |
| Front brake lever pivot nut | 5.9 N·m | 0.6 kgf·m · 4.4 ft·lb | p. 23 |
| Front master cylinder holder bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 23 |
| Front brake caliper mounting bolt | 44 N·m | 4.5 kgf·m · 33 ft·lb | p. 23 |
| Front brake disc mounting bolt | 42 N·m | 4.3 kgf·m · 31 ft·lb | p. 23 |
| Front brake caliper slide pin bolt | 23 N·m | 2.3 kgf·m · 17 ft·lb | p. 23 |
| Splash guard | 11 N·m | 1.1 kgf·m · 8 ft·lb | p. 23 |
| Rear brake arm pinch bolt | 20 N·m | 2 kgf·m · 14 ft·lb | p. 23 |
| Rear wheel hub nut | 137 N·m | 14 kgf·m · 101 ft·lb | p. 23 |
| Rear brake panel drain bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 23 |
| Differential ring gear bolt | 49 N·m | 5 kgf·m · 36 ft·lb | p. 23 |
| Differential case cover bolt | 49 N·m | 5 kgf·m · 36 ft·lb | p. 23 |
| Differential case mounting bracket bolt | 22 N·m | 2.2 kgf·m · 16 ft·lb | p. 23 |
| Differential case mounting nut | 22 N·m | 2.2 kgf·m · 16 ft·lb | p. 23 |
| Final drive clutch assembly mounting bolt | 25 N·m | 2.6 kgf·m · 18 ft·lb | p. 23 |
| Front vehicle speed sensor cover bolt | 10 N·m | 1 kgf·m · 7 ft·lb | p. 23 |
| Clutch cover stay bolt | 10 N·m | 1 kgf·m · 7 ft·lb | p. 23 |
| Clutch cover bolt | 7 N·m | 0.7 kgf·m · 5.1 ft·lb | p. 23 |
| Final gear case pinion bearing lock nut | 98 N·m | 10 kgf·m · 72 ft·lb | p. 24 |
| Final gear case cover bolt | 49 N·m | 5 kgf·m · 36 ft·lb | p. 24 |
| Final gear case mounting nut | 54 N·m | 5.5 kgf·m · 40 ft·lb | p. 24 |
| Rear brake panel nut | 44 N·m | 4.5 kgf·m · 33 ft·lb | p. 24 |
| Rear exhaust pipe cover center band screw | 3.2 N·m | 0.3 kgf·m · 2.4 ft·lb | p. 52 |
| Valve adjusting screw lock-nut | 17 N·m | 1.7 kgf·m · 13 ft·lb | p. 71 |
| Tie-rod lock nut | 54 N·m | 5.5 kgf·m · 40 ft·lb | p. 71 |
| Spark arrester bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 71 |
| Cover by hand | 18 N·m | 1.8 kgf·m · 13 ft·lb | p. 83 |
| Cap screws | 2 N·m | 0.2 kgf·m · 1.5 ft·lb | p. 88 |
| Sealing washer | 34 N·m | 3.5 kgf·m · 25 ft·lb | p. 100 |
| Sealing washer | 18 N·m | 1.8 kgf·m · 13 ft·lb | p. 105 |
| Acket bolt | 54 N·m | 5.5 kgf·m · 40 ft·lb | p. 153 |
| Left lower hanger bracket bolts | 32 N·m | 3.3 kgf·m · 24 ft·lb | p. 159 |
| Engine side upper hanger bolts | 32 N·m | 3.3 kgf·m · 24 ft·lb | p. 159 |
| Frame side upper hanger bolt | 54 N·m | 5.5 kgf·m · 40 ft·lb | p. 159 |
| Upper engine hanger bolt/nut | 54 N·m | 5.5 kgf·m · 40 ft·lb | p. 165 |
| Sor head | 10 N·m | 1 kgf·m · 7 ft·lb | p. 183 |
| Washers and seven bolts | 53 N·m | 5.4 kgf·m · 39 ft·lb | p. 185 |
| Gearshift lever linkage tie-rod lock nut | 10 N·m | 1 kgf·m · 7 ft·lb | p. 233 |
| Shaft pivot | 5 N·m | 0.5 kgf·m · 3.6 ft·lb | p. 247 |
| Tie-rod lock nuts | 10 N·m | 1 kgf·m · 7 ft·lb | p. 249 |
| Oil pump driven gear bolt | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 253 |
| Hose clamp bolts | 12 N·m | 1.2 kgf·m · 9 ft·lb | p. 292 |
| Cotter pin holes | 54 N·m | 5.5 kgf·m · 40 ft·lb | p. 293 |
| Shock absorber upper mounting flange nut | 34 N·m | 3.5 kgf·m · 25 ft·lb | p. 307 |
| Shock absorber upper mounting flange bolt | 44 N·m | 4.5 kgf·m · 33 ft·lb | p. 307 |
| Left pivot bolt | 112 N·m | 11.4 kgf·m · 82 ft·lb | p. 316 |
| Right pivot bolt | 10 N·m | 1 kgf·m · 7 ft·lb | p. 316 |
| Sealing washers | 34 N·m | 3.5 kgf·m · 25 ft·lb | p. 331 |
| Bolt Differential case mounting nut | 44 N·m | 4.5 kgf·m · 33 ft·lb | p. 351 |
Spark plugs
Values extracted from the document text. Check against the original before service work.
| Item | Value | Also | PDF page |
|---|---|---|---|
| VX22BC | — | p. 17 |
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