2016 Honda Rubicon 500 EPS 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 |
| 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 |