![2002 Honda Foreman Rubicon 500 4x4 Automatic](https://honda-overhaul.com/images/honda_TRX500-01.jpg)
2002 Honda Rubicon AT 500 4X4 Torque Specs
-->General Maintenance | |||
---|---|---|---|
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Spark Plug | 1 | 12 | 13 |
Valve Adjuster Lock Nut | 4 | 6 | 12 |
Timing Hole Cap | 1 | 14 | 7 |
Engine Oil Drain Bolt (Crankcase and Oil Tank) | 2 | 12 | 18 |
Engine Oil Filter Center Bolt | 1 | 20 | 13 |
Fuel and Lube System | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Oil Gallery Sealing Bolt (Front Crankcase Cover) | 2 | 10 | 25 |
Carburetor Insulator Band Screw | 2 | 5 | 2.9 |
Cylinder Head / Cylinder / Piston | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Cylinder Head Cover Cap Nut | 4 | 10 | 39 |
Clutch / Gearcase Linkage | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Centrifugal Clutch Lock Nut | 1 | 20 | 87 |
Oil Feed Pipe Setting Cap | 1 | 20 | 13 |
Oil Gallery Sealing Bolt (Inside Front Crankcase Cover) | 1 | 10 | 7 |
Alternator / Starter Clutch | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Starter Clutch Outer Bolt | 6 | 6 | 22 |
Recoil Starter Driven Pulley Bolt | 1 | 12 | 80 |
Ignition Pulse Generator Bolt | 2 | 5 | 4.3 |
Alternator Stator Bolt | 3 | 6 | 7 |
Sub-Transmission | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Gearshift Drum Center Bolt | 1 | 8 | 20 |
Gearshift Drum Stopper Arm Pivot Bolt | 1 | 6 | 9 |
Crankshaft / Automatic Transmission | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Primary Driven Gear Bolt | 4 | 6 | 12 |
Oil Pump Driven Sprocket Bolt | 1 | 6 | 9 |
Hondamatic | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Angle Sensor Bolt | 2 | 5 | 4.3 |
Throttle Sensor Torx Screw | 2 | 5 | 2.9 |
Frame / Body Panels / Exhaust System | |||
---|---|---|---|
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Front Carrier Pipe Bolt | 8 | 8 | 27 |
Gearshift Lever Knob Screw | 2 | 5 | 1.4 |
Rear Carrier Bolt | 6 | 8 | 27 |
Muffler Band Bolt | 2 | 8 | 17 |
Front Exhaust Pipe Cover Band Screw | 2 | 5 | 2.2 |
Rear Exhaust Pipe Cover End Band Screw | 2 | 5 | 4.3 |
Rear Exhaust Pipe Cover Center Band Screw | 1 | 5 | 2.2 |
Muffler Cover Screw | 2 | 5 | 2.2 |
Footpeg Bracket Nut | 4 | 8 | 24 |
Maintenance | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Front Differential Oil Filler Cap | 1 | 30 | 9 |
Front Differential Oil Drain Bolt | 1 | 8 | 9 |
Rear Final Gear Case Oil Check Bolt | 1 | 8 | 9 |
Rear Final Gear Case Oil Filler Cap | 1 | 30 | 9 |
Rear Final Gear Case Oil Drain Bolt | 1 | 8 | 9 |
Tie-Rod Lock Nut | 4 | 12 | 40 |
Fuel System | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Starting Enrichment Valve Nut | 1 | 14 | 1.4 |
Throttle Drum Cover Screw | 1 | 4 | 1.4 |
Engine Removal / Installation | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Left Lower Engine Hanger Bracket Bolt | 2 | 8 | 24 |
Lower Engine Hanger Nut (Left and Right) | 2 | 10 | 40 |
Upper Engine Hanger Bolt (Frame Side) | 1 | 10 | 40 |
Upper Engine Hanger Bolt (Engine Side) | 2 | 8 | 24 |
Sub-Transmission | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Gearshift Lever Box Cover Bolt | 2 | 6 | 3.6 |
Gearshift Lever Linkage Arm Pivot Bolt | 1 | 8 | 20 |
Gearshift Lever Linkage Tie-Rod Lock Nut | 4 | 6 | 7 |
Rear Driving Mechanism | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Final Gear Case Pinion Bearing Lock Nut | 1 | 64 | 72 |
Final Gear Case Cover Bolt | 2 | 10 | 36 |
Final Gear Case Cover Bolt (cont) | 6 | 8 | 19 |
Final Gear Case Mounting Nut | 4 | 10 | 40 |
Left and Right Axle Housing Bolt | 12 | 10 | 33 |
Skid Plate Bolt | 3 | 8 | 24 |
Rear Brake Panel Nut | 4 | 10 | 33 |
Front Driving Mechanism | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Differential Ring Gear Bolt | 6 | 8 | 36 |
Differential Pinion Bearing Lock Nut | 1 | 64 | 72 |
Differential Case Cover Bolt | 2 | 10 | 36 |
Differential Case Cover Bolt | 6 | 8 | 19 |
Differential Mounting Bolt | 1 | 10 | 33 |
Differential Mounting Bolt | 2 | 8 | 16 |
Differential Mounting Nut | 1 | 10 | 33 |
Differential Mounting Nut | 1 | 8 | 16 |
Front Wheel / Suspension / Steering | |||
---|---|---|---|
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Handlebar Lower Holder Nut | 2 | 10 | 29 |
Throttle Housing Cover Screw | 3 | 4 | 2.5 |
Front Wheel Nut / Lugnut | 8 | 10 | 47 |
Front Wheel Hub Nut | 2 | 16 | 58 |
Shock Absorber Upper and Lower Mounting Nut | 4 | 10 | 33 |
Upper Arm Pivot Nut | 2 | 10 | 25 |
Lower Arm Pivot Nut | 4 | 10 | 33 |
Upper and Lower Arm Ball Joint Nut | 4 | 12 | 22 |
Brake Hose Clamp Bolt | 4 | 6 | 9 |
Tie-Rod Ball Joint Nut | 4 | 12 | 40 |
Steering Shaft End Nut | 1 | 14 | 80 |
Steering Shaft Holder Bolt | 2 | 8 | 24 |
Rear Wheel / Suspension | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Rear Wheel Nut / Lugnut | 8 | 10 | 47 |
Shock Absorber Lower Mounting Bolt | 2 | 10 | 33 |
Swingarm Pivot Bolt (right) | 1 | 30 | 2.9 |
Swingarm Pivot Bolt (left) | 1 | 30 | 82 |
Swingarm Right Pivot Lock Nut | 1 | 30 | 82 |
Rear Wheel Hub Nut | 2 | 20 | 101 |
Brake System | |||
---|---|---|---|
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Brake Hose Oil Bolt | 3 | 10 | 25 |
Wheel Cylinder Bleed Valve | 2 | 8 | 4 |
Front Master Cylinder Reservoir Cap Screw | 2 | 4 | 1.4 |
Front Brake Lever Pivot Bolt | 1 | 6 | 0.7 |
Front Brake Lever Pivot Nut | 1 | 6 | 4.4 |
Front Master Cylinder Holder Bolt | 2 | 6 | 9 |
Front Brake Wheel Cylinder Bolt | 4 | 6 | 5.8 |
Wheel Cylinder Nut | 4 | 8 | 12 |
Front Brake Panel Bolt | 8 | 8 | 22 |
Rear Brake Arm Pinch Bolt | 1 | 8 | 14 |
Rear Brake Panel Drain Bolt | 1 | 8 | 9 |
Wheel Cylinder Oil Pipe | 4 | 10 | 12 |
Brake Hose 2-Way Joint | 2 | 8 | 11 |