Honda TRX500FA FourTrax Foreman 2001-2003 Service Manual

Honda TRX500FA FourTrax Foreman · 2001–2003 · service manual · 407 pages

Honda TRX500FA FourTrax Foreman
2001–2003
Service manual
407 pages
ATV

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	18 N·m	1.8 kgf·m · 13 ft·lb	p. 15
Valve adjusting lock nut	17 N·m	1.7 kgf·m · 12 ft·lb	p. 15
Timing hole cap	10 N·m	1 kgf·m · 7 ft·lb	p. 15
Engine oil drain bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 15
Engine oil filter center bolt	18 N·m	1.8 kgf·m · 13 ft·lb	p. 15
Oil gallery sealing bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 15
Carburetor insulator band screw	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 15
Cylinder head cover cap nut	53 N·m	5.4 kgf·m · 39 ft·lb	p. 15
Centrifugal clutch lock nut	118 N·m	12 kgf·m · 87 ft·lb	p. 15
Oil feed pipe setting cap	18 N·m	1.8 kgf·m · 13 ft·lb	p. 15
Starter clutch outer bolt	30 N·m	3.1 kgf·m · 22 ft·lb	p. 15
Recoil starter driven pulley bolt	108 N·m	11 kgf·m · 80 ft·lb	p. 15
Alternator stator bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 15
Ignition pulse generator bolt	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 15
Gearshift drum center bolt	26 N·m	2.7 kgf·m · 20 ft·lb	p. 15
Gearshift drum stopper arm pivot bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 15
Primary driven gear bolt	17 N·m	1.7 kgf·m · 12 ft·lb	p. 15
Oil pump driven sprocket bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 15
Angle sensor bolt	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 16
Throttle sensor torx screw	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 16
Front carrier/carry pipe bolt	37 N·m	3.8 kgf·m · 27 ft·lb	p. 16
Gearshift lever knob screw	2 N·m	0.2 kgf·m · 1.4 ft·lb	p. 16
Rear carrier bolt	37 N·m	3.8 kgf·m · 27 ft·lb	p. 16
Muffler band bolt	23 N·m	2.3 kgf·m · 17 ft·lb	p. 16
Front exhaust pipe cover band screw	3 N·m	0.3 kgf·m · 2.2 ft·lb	p. 16
Rear exhaust pipe cover end band screw	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 16
Center band screw	3 N·m	0.3 kgf·m · 2.2 ft·lb	p. 16
Muffler cover screw	3 N·m	0.3 kgf·m · 2.2 ft·lb	p. 16
Footpeg bracket nut	32 N·m	3.3 kgf·m · 24 ft·lb	p. 16
Front differential oil filler cap	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Rear final gear case oil check bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Tie-rod lock nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 16
Throttle drum cover screw	2 N·m	0.2 kgf·m · 1.4 ft·lb	p. 16
Left lower engine hanger bracket bolt	32 N·m	3.3 kgf·m · 24 ft·lb	p. 16
Lower engine hanger nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 16
Upper engine hanger bolt	54 N·m	5.5 kgf·m · 40 ft·lb	p. 16
Gearshift lever box cover bolt	5 N·m	0.5 kgf·m · 3.6 ft·lb	p. 16
Gearshift lever linkage arm pivot bolt	26 N·m	2.7 kgf·m · 20 ft·lb	p. 16
Gearshift lever linkage tie-rod lock nut	10 N·m	1 kgf·m · 7 ft·lb	p. 16
Handlebar lower holder nut	39 N·m	4 kgf·m · 29 ft·lb	p. 16
Front wheel nut	64 N·m	6.5 kgf·m · 47 ft·lb	p. 16
Front wheel hub nut	78 N·m	8 kgf·m · 58 ft·lb	p. 16
Shock absorber mounting nut	44 N·m	4.5 kgf·m · 33 ft·lb	p. 16
Upper arm pivot nut	34 N·m	3.5 kgf·m · 25 ft·lb	p. 16
Lower arm pivot nut	44 N·m	4.5 kgf·m · 33 ft·lb	p. 16
Brake hose clamp bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 16
Tie-rod ball joint nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 16
Steering shaft end nut	108 N·m	11 kgf·m · 80 ft·lb	p. 16
Steering shaft holder bolt	32 N·m	3.3 kgf·m · 24 ft·lb	p. 16
Rear wheel nut	64 N·m	6.5 kgf·m · 47 ft·lb	p. 16
Swingarm right pivot lock nut	112 N·m	11.4 kgf·m · 82 ft·lb	p. 16
Brake hose oil bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 17
Wheel cylinder bleed valve	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 17
Front master cylinder reservoir cap screw	2 N·m	0.2 kgf·m · 1.4 ft·lb	p. 17
Front brake lever pivot bolt	1 N·m	0.1 kgf·m · 0.7 ft·lb	p. 17
Front brake switch screw	1 N·m	0.1 kgf·m · 0.7 ft·lb	p. 17
Front master cylinder holder bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 17
Wheel cylinder bolt	8 N·m	0.8 kgf·m · 5.8 ft·lb	p. 17
Wheel cylinder oil pipe joint nut	16 N·m	1.6 kgf·m · 12 ft·lb	p. 17
Front brake panel bolt	29 N·m	3 kgf·m · 22 ft·lb	p. 17
Rear brake arm pinch bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 17
Rear wheel hub nut	137 N·m	14 kgf·m · 101 ft·lb	p. 17
Rear brake panel drain bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 17
Differential ring gear bolt	49 N·m	5 kgf·m · 36 ft·lb	p. 17
Differential pinion bearing lock nut	98 N·m	10 kgf·m · 72 ft·lb	p. 17
Differential case cover bolt	49 N·m	5 kgf·m · 36 ft·lb	p. 17
Differential mounting bolt	44 N·m	4.5 kgf·m · 33 ft·lb	p. 17
Final gear case pinion bearing lock nut	98 N·m	10 kgf·m · 72 ft·lb	p. 17
Final gear case cover bolt	49 N·m	5 kgf·m · 36 ft·lb	p. 17
Final gear case mounting nut	54 N·m	5.5 kgf·m · 40 ft·lb	p. 17
Left and right axle housing nut	44 N·m	4.5 kgf·m · 33 ft·lb	p. 17
Skid plate bolt	32 N·m	3.3 kgf·m · 24 ft·lb	p. 17
Rear brake panel nut	44 N·m	4.5 kgf·m · 33 ft·lb	p. 17
Rear carrier bolt 37 N-m	36.6 N·m	27 ft·lb	p. 39
Front differential oil drain bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 52
Rear final gear case oil filler cap	12 N·m	1.2 kgf·m · 9 ft·lb	p. 52
Rear final gear case oil drain bolt	12 N·m	1.2 kgf·m · 9 ft·lb	p. 52
Front master cylinder reservoir cap screw	1.9 N·m	1.4 ft·lb	p. 52
Cap groove	12 N·m	1.2 kgf·m · 9 ft·lb	p. 64
Cap screws	2 N·m	0.2 kgf·m · 1.4 ft·lb	p. 66
Tie-rod lock nuts	54 N·m	5.5 kgf·m · 40 ft·lb	p. 71
Sealing washer	34 N·m	3.5 kgf·m · 25 ft·lb	p. 75
Carburetor insulator band screw 4 .N-m	3.9 N·m	2.9 ft·lb	p. 87
SE valve nut	2 N·m	0.2 kgf·m · 1.4 ft·lb	p. 100
Sensor head	10 N·m	1 kgf·m · 7 ft·lb	p. 147
Engine side hanger bolts	32 N·m	3.3 kgf·m · 24 ft·lb	p. 147
Engine hanger nuts	54 N·m	5.5 kgf·m · 40 ft·lb	p. 147
Washers and seven bolts	53 N·m	5.4 kgf·m · 39 ft·lb	p. 149
Gear shift drum center bolt	26 N·m	2.7 kgf·m · 20 ft·lb	p. 183
Tie-rod lock nuts	10 N·m	1 kgf·m · 7 ft·lb	p. 197
Cotter pin holes	29 N·m	3 kgf·m · 22 ft·lb	p. 228
Brake panel bolts	29 N·m	3 kgf·m · 22 ft·lb	p. 229
Shock absorber lower mounting bolt	44 N·m	4.5 kgf·m · 33 ft·lb	p. 243
Bearing remover weight	112 N·m	11.4 kgf·m · 82 ft·lb	p. 243
Bearing remover weight	10 N·m	1 kgf·m · 7 ft·lb	p. 243
Left pivot bolt	112 N·m	11.4 kgf·m · 82 ft·lb	p. 250
Right pivot bolt	10 N·m	1 kgf·m · 7 ft·lb	p. 250
Special bolt	137 N·m	14 kgf·m · 101 ft·lb	p. 254
WASHER i	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 258
Nuts and bolts	8 N·m	0.8 kgf·m · 5.8 ft·lb	p. 265
Nuts and bolts	17 N·m	1.7 kgf·m · 12 ft·lb	p. 265
Cotter pin hole	137 N·m	14 kgf·m · 101 ft·lb	p. 271

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	PDF page
VX22BC	0.8–0.9 mm	p. 13
AT25	—	p. 52
VX22BC	—	p. 57
ND1	—	p. 363

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