2015 Honda Rubicon 500 DCT/IRS Torque Specs
-->General Maintenance | |||
---|---|---|---|
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Spark Plug | 1 | 14 | 16 |
Valve Adjusting Lock Nut | 2 | 6 | 13 |
Valve Adjusting Hole Cap | 2 | 36 | 9 |
Timing Hole Cap | 1 | 14 | 7 |
Engine Oil Drain Bolt | 1 | 12 | 18 |
Fuel and Lube System | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Throttle Body Insulator Band Screw | 2 | 5 | - |
Throttle Drum Cover Screw | 1 | 4 | 1.3 |
Fuel Feed Hose Clamp Stay Screw | 1 | 5 | 2.5 |
Wire Harness Clamp Stay Screw | 1 | 5 | 2.5 |
Fuel Injector Mounting Bolt | 2 | 5 | 3.8 |
IACV Torx Screw (T20) | 2 | 4 | 1.5 |
Cylinder Head / Cylinder / Piston | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Cylinder Head Nut | 4 | 10 | 35 |
Cam Chain Tensioner Pivot Bolt | 1 | 6 | 9 |
Cylinder Stud Bolt | 4 | 10 | 9 |
ECT Sensor | 1 | 10 | 9 |
Upper Engine Hanger Nut (Frame Side) | 1 | 10 | 46 |
Camshaft Bearing Setting Plate Bolt | 1 | 8 | 20 |
Upper Engine Hanger Bolt (Engine Side) | 2 | 8 | 24 |
Clutch / Gearcase Linkage | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Centrifugal Clutch Lock Nut | 1 | 20 | 87 |
Change Clutch Center Lock Nut | 1 | 18 | 80 |
Clutch Spring Bolt | 4 | 6 | 10 |
Shift Drum Stopper Arm Pivot Bolt | 1 | 6 | 9 |
Gearshift Cam Bolt | 1 | 6 | 12 |
Gearshift Spindle A Stopper Bolt (FM Models) | 1 | 8 | 20 |
Gearshift Spindle Return Spring Pin | 1 | 8 | 16 |
Alternator / Starter Clutch | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Starter Clutch Bolt (T40) | 6 | 8 | 27 |
Flywheel Bolt | 1 | 12 | 80 |
CKP Sensor Bolt | 2 | 5 | 4.4 |
Alternator Stator Bolt | 4 | 6 | 7 |
Crankshaft / Auto Transmission | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Shift Drum Bearing Setting Bolt | 2 | 6 | 9 |
Dual Clutch Transmission (FA Models) | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Centrifugal Clutch Lock Nut | 1 | 20 | 87 |
Oil Feed Pipe Setting Cap | 1 | 24 | 15 |
Orifice Relief Valve Socket Bolt | 1 | 10 | 25 |
Sealing Bolt | 1 | 8 | 12 |
Shift Clutch Lock Nut | 1 | 18 | 80 |
Shift Drum Stopper Arm Pivot Bolt | 1 | 6 | 9 |
Shift Drum Center Bolt | 1 | 8 | 17 |
Shift Drum Guide Plate Bolt | 2 | 6 | 9 |
Shift Spindle Angle Sensor Socket Bolt | 2 | 5 | 4.4 |
Shift Drum Position Switch Wire Bolt | 2 | 6 | 9 |
EOT Sensor | 1 | 10 | 13 |
Reverse Switch | 1 | 10 | 10 |
Rear VS Sensor Mounting Bolt | 1 | 6 | 7 |
Sub-Transmission (FA Models) | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Rear Sub-Frame Lower Mounting Nut | 2 | 12 | 96 |
Rear Sub-Frame Rear Mounting Nut | 1 | 12 | 96 |
Range Select Lever Pivot Nut | 1 | 8 | 15 |
Range Select Arm Socket Bolt | 1 | 6 | 9 |
Range Select Gate Special Bolt | 2 | 6 | 9 |
Setting Cap | 1 | 18 | 13 |
Shift Arm Pinch Bolt | 1 | 6 | 12 |
PGM-FI System | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Sensor Unit Torx Screw (T25) | 3 | 5 | 2.5 |
ECT Sensor | 1 | 10 | 9 |
Bank Angle Sensor Mounting Bolt | 2 | 6 | 7 |
O2 Sensor | 1 | 12 | 18 |
Frame / Body Panels / Exhaust System | |||
---|---|---|---|
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Rear Carrier Bolt | 4 | 10 | 55 |
Step Bracket Nut | 8 | 8 | 24 |
Muffler Cover Bolt | 2 | 6 | 16 |
Muffler Cover Band Screw (Front Side) | 1 | - | 1.5 |
Muffler Cover Band Screw (Rear Side) | 1 | - | 2.4 |
Muffler Band Bolt | 2 | 8 | 17 |
Exhaust Pipe Cover Band Bolt | 2 | - | 1.5 |
Exhaust Pipe Stud Bolt | 2 | 8 | 4.4 |
Fuel and Cooling System | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Throttle Body Cover Bolt | 1 | 5 | 3.8 |
Cooling Fan Nut | 1 | 5 | 2.0 |
Fan Motor Bolt | 3 | 5 | 3.8 |
Fan Motor Stay Bolt | 3 | 6 | 6.2 |
Water Hose Band Screw | 8 | - | - |
Engine Removal / Installation | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Lower Engine Hanger Bolt/Nut (Left and Right) | 2 | 10 | 46 |
Upper Engine Hanger Nut (Frame Side) | 1 | 10 | 46 |
Upper Engine Hanger Bolt (Engine Side) | 2 | 8 | 24 |
Front Final Gear Case Mounting Nut | 2 | 10 | 32 |
Gearshift Pedal Pinch Bolt (FM Models) | 1 | 6 | 15 |
Shift Arm Pinch Bolt (FA Models) | 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 | 35 |
Final Gear Case Cover Bolt (cont) | 6 | 8 | 18 |
Rear Final Gear Case Mounting Bolt (FM/FE) | 8 | 10 | 55 |
Rear Final Gear Case Mounting Nut (FA's) | 2 | 10 | 32 |
Rear Brake Panel Stud Bolt (FM/FE) | 2 | 10 | - |
Rear Final Gear Pinion Joint Lock Nut (FA's) | 1 | 16 | 80 |
Rear Wheel Hub Nut (FM/FE Models) | 2 | 20 | 101 |
Rear Brake Panel Mounting Nut (FM/FE) | 4 | 10 | 34 |
Rear Brake Disc Bolt (FA's) | 5 | 6 | 15 |
Front Driving Mechanism | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Front Final Gear Pinion Bearing Lock Nut | 1 | 60 | 59 |
Differential Ring Gear Bolt | 11 | 8 | 36 |
Front Final Gear Case Cover Bolt | 10 | 8 | 19 |
Difflock Actuator Mounting Bolt | 3 | 6 | 9 |
Front Final Gear Case Mounting Nut | 2 | 10 | 32 |
Front Wheel / Suspension / Steering | |||
---|---|---|---|
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Front Master Cylinder Holder Bolt | 2 | 6 | 9 |
Throttle Housing Cover Screw | 3 | 4 | 1.1 |
Front Wheel Nut / Lugnut | 8 | 10 | 50 |
Front Wheel Hub Nut | 2 | 20 | 101 |
Outboard Guard Mounting Bolt | 4 | 6 | 8 |
Splash Guard Bolt | 6 | 6 | 8 |
Upper and Lower Arm Ball Joint Nut | 4 | 12 | 22 |
Tie-Rod Ball Joint Nut | 4 | 12 | 40 |
Front Brake Caliper Mounting Bolt | 4 | 8 | 22 |
Meter Cover Stay Bolt | 2 | 8 | 24 |
Brake Hose Clamp Bolt | 7 | 6 | 9 |
Steering Shaft End Nut | 1 | 14 | 80 |
Steering Shaft Pinch Bolt (Certain FM/FE/FA's) | 1 | 10 | 44 |
Steering Shaft Holder Bolt | 2 | 8 | 24 |
EPS Unit Mounting Nut (Certain FM/FE/FA's) | 3 | 10 | 25 |
Handlebar Switch Housing Screw (FM Models) | 2 | 5 | 2.0 |
Handlebar Switch Housing Screw (FE/FA) | 3 | 5 | 2.0 |
Rear Brake Lever Bracket Holder Screw | 2 | 5 | 3.1 |
Front Master Cylinder Holder Bolt | 2 | 6 | 9 |
Front Brake Caliper Mounting Bolt | 4 | 8 | 22 |
Steering Bearing Holder Nut (Certain FM/FE/FA's) | 3 | 10 | 25 |
Rear Wheel / Suspension | |||
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Rear Wheel Nut / Lugnut | 8 | 10 | 50 |
Rear Wheel Hub Nut | 2 | 20 | 101 |
Trailer Hitch Mounting Nut | 2 | 10 | 25 |
Shock Absorber Upper Mounting Bolt (Dual Shock IRS Models) | 2 | 10 | 32 |
Shock Absorber Lower Mounting Bolt (Non IRS Models) | 1 | 12 | 83 |
Shock Absorber Lower Mounting Bolt (Dual Shock IRS Models) | 2 | 14 | 65 |
Universal Joint Guard Bolt (Non IRS Models) | 2 | 6 | 7 |
Swingarm Pivot Nut (Non IRS Models) | 2 | 12 | 96 |
Upper Arm Pivot Nut (Frame Side, IRS Models) | 2 | 10 | 32 |
Lower Arm Pivot Nut (Frame Side, IRS Models) | 4 | 10 | 25 |
Upper and Lower Arm Pivot Nut (Knuckle Side, IRS Models) | 4 | 10 | 32 |
Stabilizer Arm Holder Bolt (IRS Models) | 4 | 8 | 20 |
Stabilizer Link Nut (IRS Models) | 4 | 10 | 29 |
Brake System | |||
---|---|---|---|
Item | QTY | Thread Dia. (mm) | Torque (lb-ft) |
Front Brake Caliper Bleed Valve | 2 | 8 | 4.0 |
Front Brake Caliper Mounting Bolt | 4 | 8 | 22 |
Front Master Cylinder Reservoir Cap Screw | 2 | 4 | 1.5 |
Pad Pin | 4 | 10 | 13 |
Pad Pin Plug | 4 | 10 | 1.8 |
Front Brake Lever Pivot Bolt | 1 | 6 | 4.3 |
Front Brake Lever Pivot Nut | 1 | 6 | 4.4 |
Front Brake Switch Screw | 1 | 4 | 0.9 |
Front Master Cylinder Holder Bolt | 2 | 6 | 9 |
Front Brake Caliper Slide Pin | 2 | 8 | 16 |
Brake Hose Oil Bolt | 3 | 10 | 25 |
Outboard Guard Mounting Bolt | 4 | 6 | 8 |
Rear Brake Arm Pinch Nut (Non IRS Models) | 1 | 8 | 15 |
Rear Brake Panel Drain Bolt (Non IRS Models) | 1 | 8 | 9 |
Front Brake Inhibitor Switch Screw | 1 | 4 | 0.9 |
Rear Brake Caliper Bleed Valve (IRS Models) | 1 | 8 | 4.0 |
Rear Brake Hose Oil Bolt (IRS Models) | 2 | 10 | 25 |
Rear Brake Caliper Mounting Bolt (IRS Models) | 2 | 8 | 22 |
Rear Brake Caliper Bracket Pin Bolt (IRS Models) | 1 | 8 | 24 |
Rear Brake Caliper Slide Pin Bolt (IRS Models) | 1 | 8 | 16 |
Rear Brake Caliper Parking Brake Arm Nut (IRS Models) | 1 | 10 | 20 |
Rear Brake Master Cylinder Reservoir (IRS Models) | 1 | 4 | 1.1 |
Rear Brake Lever Pivot Bolt | 1 | 6 | 7.2 |
Rear Brake Lever Pivot Nut | 1 | 6 | 7.2 |