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