2006 Honda Rubicon AT 500 4X4 Torque Specs
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| General Maintenance | |||
|---|---|---|---|
| Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
| Spark Plug | 1 | 12 | 16 |
| Valve Adjusting Screw Lock Nut | 4 | 6 | 13 |
| 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 | 8 | 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 | 8 | 8 | 27 |
| Muffler Band Bolt | 2 | 8 | 17 |
| Front Exhaust Pipe Cover Band Screw | 2 | 5 | 2.4 |
| Rear Exhaust Pipe Cover End Band Screw | 2 | 5 | 4.0 |
| Rear Exhaust Pipe Cover Center Band Screw | 1 | 5 | 4.0 |
| Muffler Cover Screw | 2 | 5 | 2.4 |
| 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 |
| Spark Arrestor | 3 | 6 | 9 |
| Fuel System | |||
| Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
| Starting Enrichment Valve Nut | 1 | 14 | 1.7 |
| Throttle Drum Cover Screw | 1 | 4 | 1.1 |
| 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 |
| Final Drive Clutch Assembly MOunting Bolt | 3 | 8 | 18 |
| 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 Vehicle Speed Sensor Cover Bolt | 2 | 6 | 7 |
| Clutch Cover Stay Bolt | 3 | 6 | 7 |
| Clutch Cover Bolt | 2 | 6 | 5.1 |
| 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 | 33 |
| Lower Arm Pivot Nut | 4 | 10 | 33 |
| Upper and Lower Arm Ball Joint Nut | 4 | 12 | 40 |
| 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 |
| Assist Headlight Case Mounting Nut | 2 | 8 | 19 |
| 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 |
| Shock Absorber Upper Mounting Bolt | 2 | 10 | 25 |
| Swingarm Pivot Bolt (right) | 1 | 30 | 7 |
| 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 Caliper Mounting Bolt | 4 | 10 | 33 |
| Front Brake Disc Mounting Bolt | 8 | 8 | 31 |
| Front Brake Caliper Slide Pin Bolt | 4 | 8 | 17 |
| Splash Guard | 4 | 6 | 8 |
| Rear Brake Panel Drain Bolt | 1 | 8 | 9 |
| Rear Brake Arm Pinch Bolt | 1 | 8 | 14 |
| Brake Hose 2-Way Joint | 2 | 8 | 11 |