2009 Honda Foreman 500 ES/4X4 Torque Specs

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General Maintenance
Item QTY Thread Dia. (mm) Torque (lb-ft)
Spark Plug 1 14 16
Valve Adjusting Lock Nut 2 6 13
Timing Hole Cap 1 14 7
Engine Oil Drain Bolt 1 12 18
Engine Oil Filter Cover Bolt 3 6 7
Clutch Adjusting Screw Lock Nut 1 8 16
Valve Adjusting Hole Cap 2 34 9
Fuel and Lube System
Item QTY Thread Dia. (mm) Torque (lb-ft)
Relief Valve Cap 1 14 14
Carburetor Insulator Band Screw 1 5 2.9
Throttle Position Sensor Space Screw 2 5 2.5
Cylinder Head / Cylinder / Piston
Item QTY Thread Dia. (mm) Torque (lb-ft)
Cylinder Head Cap Nut 6 10 29
Cam Sprocket Bolt 2 7 15
Cam Chain Tensioner Pivot Bolt 1 6 9
Exhaust Pipe Stud Bolt 2 8 4.4
Cylinder Stud Bolt 2 10 9
Cylinder Stud Bolt 4 10 9
Clutch / Gearcase Linkage
Item QTY Thread Dia. (mm) Torque (lb-ft)
Centrifugal Clutch Lock Nut 1 20 87
Clutch Spring Bolt 4 6 9
Change Clutch Lock Nut 1 18 80
Shift Drum Stopper Arm Pivot Bolt 1 6 9
Gearshift Cam Bolt 1 6 12
Gearshift Spindle Return Spring Pin 1 8 16
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
CKP Sensor Bolt 2 5 4.4
Alternator Stator Bolt 4 6 7
Crankshaft / Automatic Transmission
Item QTY Thread Dia. (mm) Torque (lb-ft)
Secondary Gearshift Spindle Stopper Bolt 1 6 9
Electric Shift (ESP; FE/FPE models)
Item QTY Thread Dia. (mm) Torque (lb-ft)
Angle Sensor Bolt 2 5 4.4
Reverse Shift Switch 1 10 10
Frame / Body Panels / Exhaust System
Item QTY Thread Dia. (mm) Torque (lb-ft)
Front Carrier Pipe Bolt 8 8 27
Rear Carrier Bolt 8 8 27
Muffler Band Bolt 2 8 17
Front Exhaust Pipe Cover Band Screw 2 5 2.4
Heat Protector Band Bolt 3 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 (Except TM) 1 30 9
Front Differential Oil Drain Bolt (Except TM) 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 and Lube System
Item QTY Thread Dia. (mm) Torque (lb-ft)
Starting Enrichment Valve Nut 1 14 1.7
Cooling Fan Motor Screw 3 5 1.1
Cooling Fan Nut 1 5 2.0
Cooling Fan Shroud Tapping Screw 3 4 0.6
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
Gearshift Pedal Pinch Bolt (Not ESP Model) 1 6 12
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 (Except TM Model)
Item QTY Thread Dia. (mm) Torque (lb-ft)
Differential Ring Gear Bolt 10 8 36
Final Drive Clutch Assembly MOunting Bolt 3 8 18
Differential Case Cover Bolt 2 10 36
Differential Case Cover Bolt 4 8 19
Differential Mounting Bolt 1 10 33
Differential Mounting Bolt 1 8 16
Differential Mounting Nut 1 10 33
Differential Mounting Nut 1 8 16
Front Vehicle Speed Sensor Cover Bolt 2 6 7
Rear VS Sensor 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 4 10 25
Lower Arm Pivot Nut 8 10 33
Upper and Lower Arm Ball Joint Nut 4 12 21
Brake Hose Clamp Bolt 6 6 9
Tie-Rod Ball Stud 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
Throttle Arm Nut 1 6 5.2
2WD/4WD Select Switch Screw 2 4 1.1
EPS Unit Output Shaft Nut (EPS model) 1 14 80
EPS Unit Mounting Bolt (EPS model) 2 8 16
EPS Unit Mounting Nut (EPS model) 2 8 16
EPS Unit Steering Shaft Flange Bolt (EPS model) 1 10 44
EPS Motor Flange Bolt (EPS model) 2 8 15
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
Front Brake Caliper Bleed Valve 2 8 4
Front Master Cylinder Reservoir Cap Screw 2 4 1.5
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
Brake Pipe Joint (Green Surface) 2 10 13
Brake Pipe Joint (Black Surface) 2 10 10
Rear Brake Arm Pinch Bolt 1 8 15
Rear Brake Panel Drain Bolt 1 8 9