2005 honda trx500 tm fourtrax foreman service repair manual
- 1. 2 0 0 5 - 2 0 0 6 —- S E R V I C A N U A L .rr , X 5 0 0 F E / F FOURTRAX FOREMAN
- 2. HOW TOUSE THIS MANUAL CONTENTS This service manual describes the service procedures for the TRX500FE/FMA"M. Follow the Maintenance Schedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency (EPA) and California Air Resources Board (CARB). Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 4 apply to the whole vehicle. Section 3 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Sections 5 through 23 describe parts of the vehicle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. If you are not familiar with this vehicle, read Technical Features in Section 2. If you don't know the source of the trouble, go to section 25 Troubleshooting. Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: • Safety Labels - on the vehicle • Safety Messages - preceded by a safety alert symbol A and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.ADANGER A WARNING ACAUTION You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions. You CAN be HURT if you don't follow instructions. Instructions - how to service this vehicle correctly and safely. As you read this manual, you will find information that is preceded by a | NOTICE | symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI- GATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITH- OUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTE- NANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE LU Z u LU CO (0 (0 < u < u oc o UJ 111 GENERAL INFORMATION TECHNICAL FEATURES FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVE CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKCASE/TRANSMISSION/CRANKSHAFT/ BALANCER FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM (FM/FE models) REAR DRIVING MECHANISM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES ELECTRIC SHIFT PROGRAM (ESP: FE model) SELECTABLE 4WD SYSTEM (FM/FE models) WIRING DIAGRAMS TROUBLESHOOTING INDEX Date of Issue: November, 2004 ©Honda Motor Co., Ltd.
- 3. SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use the recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1) Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use fork or suspension fluid.
- 4. 1. GENERAL INFORMATION SERVICE RULES 1-2 MODEL IDENTIFICATION 1-2 GENERAL SPECIFICATIONS 1-5 LUBRICATION SYSTEM SPECIFICATIONS 1-8 FUEL SYSTEM SPECIFICATIONS 1-8 CYLINDER HEAD/VALVE SPECIFICATIONS 1-8 CYLINDER/PISTON SPECIFICATIONS 1-9 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS 1-9 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS 1-9 CRANKCASE/TRANSMISSION/CRANK- SHAFT/BALANCER SPECIFICATIONS 1-10 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS 1-10 REAR WHEEL/SUSPENSION SPECIFICATIONS 1-10 BRAKE SYSTEM SPECIFICATIONS 1-11 FRONT DRIVING MECHANISM SPECIFICATIONS (FM/FE models) 1-11 REAR DRIVING MECHANISM SPECIFICATIONS 1-11 BATTERY/CHARGING SYSTEM SPECIFICATIONS 1-11 IGNITION SYSTEM SPECIFICATIONS 1-12 ELECTRIC STARTER SPECIFICATIONS 1-12 LIGHTS/METERS/SWITCHES SPECIFICATIONS 1-12 STANDARD TORQUE VALUES 1-13 ENGINE & FRAME TORQUE VALUES 1-13 LUBRICATION & SEAL POINTS 1-18 CABLE & HARNESS ROUTING 1-22 EMISSION CONTROL SYSTEMS 1-38 1-1
- 5. GENERAL INFORMATION SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA'S design specifications may cause damage to the vehicle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown in the Cable & Harness routing (page 1-22). MODEL IDENTIFICATION This manual covers 3 types of TRX500 models: • TM - 2WD/Left foot operated gearshift • FM - 4WD/Left foot operated gearshift • FE - 4WD/Electric shift program (ESP) Be sure to refer to the procedure that pertains to the appropriate version of the TRX500. TRX500 FE model shown: DESTINATION CODES Throughout this manual, the following codes are used to identify individual types for each region. DESTINATION CODE A CM U REGION U.S.A. Canada Australia (New Zealand) 1-2
- 6. GENERAL INFORMATION The Vehicle Identification Number (VIN) is stamped on the front side of the frame. The engine serial number is stamped on the left side of the rear crankcase. The name plate (U.S.A. and U type) or safety certification label (Can- ada type) is attached on the right front frame pipe. VIN ENGINE SERIAL NUMBER U.S.A. and U type: NAME PLATE Canada type: SAFETY CERTIFICATION LABEL 1-3
- 7. GENERAL INFORMATION The carburetor identification number is stamped on the left side of the carburetor body. CARBURETOR IDENTIFICATION NUMBER The vehicle emission information label is attached on the rear fender behind the seat (U.S.A. only). The color label is attached on the front side of the right front frame pipe. When ordering color-coded parts, always specify the designated color code. EMISSION CONTROL INFORMATION LABEL COLOR LABEL 1-4
- 8. GENERAL INFORMATION GENERAL SPECIFICATIONS TRX500TM ITEM DIMENSIONS FRAME ENGINE CARBURETOR Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight Curb weight Maximum weight capacity Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes Lubrication system Oil pump type Cooling system Air filtration Engine dry weight Carburetor type Throttle bore SPECIFICATIONS 2,109 mm (83.0 in) 1,188 mm (46.8 in) 1,169 mm (46.0 in) 1,292 mm (50.9 in) 922 mm (36.3 in) 925 mm (36.4 in) 860 mm (33.9 in) 349 mm (13.7 in) 190 mm (7.5 in) 253 kg (558 lbs) 265 kg (584 lbs) 220 kg (485 lbs) Double cradle Double wishbone 170 mm (6.7 in) Double tube Swingarm 170 mm (6.7 in) Double tube AT25x8-12 • • AT25x 10-12 • • 12x6.0 AT 12x7.5 AT KT181 (Dunlop) KT185 (Dunlop) Hydraulic disc brake Mechanical drum brake 5° 17 mm (11/16 in) 0° 15.8 liters (4.17 US gal, 3.48 Imp gal) 3.3 liters (0.87 US gal, 0.73 Imp gal) Single cylinder, longitudinally installed 92.0x71.5 mm (3.62x2.81 in) 475.3 cm3 (28.99 cu-in) 8.3: 1 OHV 6° BTDC (at 1 mm lift) 44° ABDC (at 1 mm lift) 42° BBDC (at 1 mm lift) 4° ATDC (at 1 mm lift) Forced pressure and wet sump Trochoid Air cooled (with cooling fan and oil cooler) Oiled double urethane foam 55.2 kg (121.7 lbs) Constant Vacuum (VE type) 36 mm (1.42 in) 1-5
- 9. GENERAL INFORMATION ITEM DRIVE TRAIN ELECTRICAL Clutch system Clutch operation system Transmission Primary reduction Secondary reduction Final reduction Gearratio 1st 2nd 3rd 4th 5th Reverse Gearshift pattern Ignition system Starting system Charging system Regulator/rectifier Lighting system SPECIFICATIONS Centrifugal and multi-plate, wet Automatic Constant mesh, 5-speeds with reverse 2.103 (61/29) 1.818 (40/22) 3.153(41/13) 4.231 (55/13) 2.389(43/18) 1.609 (37/23) 1.179(33/28) 0.848 (28/33) 5.600(28/15x39/13) R - N - 1 - 2 - 3 - 4 - 5 Left foot operated return system DC-CDI Electric starter motor and emergency recoil starter Triple phase output alternator FET shorted, triple phase full wave rectification Battery TRX500FM/FE ITEM DIMENSIONS Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight Curb weight Maximum weight capacity SPECIFICATIONS 2,109 mm (83.0 in) 1,188 mm (46.8 in) 1,181 mm (46.5 in) 1,287 mm (50.7 in) 913 mm (35.9 in) 925 mm (36.4 in) 860 mm (33.9 in) 349 mm (13.7 in) 190 mm (7.5 in) FM: 270 kg (595 lbs) FE: 271 kg (597 lbs) FM: 282 kg (622 lbs) FE: 284 kg (626 lbs) 220 kg (485 lbs) 1-6
- 10. GENERAL INFORMATION ITEM FRAME ENGINE CARBURETOR DRIVE TRAIN ELECTRICAL Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes Lubrication system Oil pump type Cooling system Air filtration Engine dry weight Carburetor type Throttle bore Clutch system Clutch operation system Transmission Primary reduction Secondary reduction Final reduction Front Rear Gearratio 1st 2nd 3rd 4th 5th Reverse Gearshift pattern Ignition system Starting system Charging system Regulator/rectifier Lighting system SPECIFICATIONS Double cradle Double wish-bone 170 mm (6.7 in) Double tube Swingarm 170 mm (6.7 in) Double tube AT25x8-12 • • AT25x 10-12 • • 12x6.0 AT 12x7.5 AT KT181 (Dunlop) KT185(Dunlop) Hydraulic disc brake Mechanical drum brake 2° 9 mm (11/32 in) 0° 15.8 liters (4.17 US gal, 3.48 Imp gal) 3.3 liters (0.87 US gal, 0.73 Imp gal) Single cylinder, longitudinally installed 92.0x71.5 mm (3.62x2.81 in) 475.3 cm3 (28.99 cu-in) 8.3: 1 OHV 6° BTDC (at 1 mm lift) 44°ABDC(at 1 mm lift) 42° BBDC (at 1 mm lift) 4° ATDC (at 1 mm lift) Forced pressure and wet sump Trochoid Air cooled (with cooling fan and oil cooler) Oiled double urethane foam FM: 55.5 kg (122.4 lbs) FE: 57.7 kg (127.2 lbs) Constant Vacuum (VE type) 36 mm (1.42 in) Centrifugal and multi-plate, wet Automatic Constant mesh, 5-speeds with reverse 2.103(61/29) 1.818(40/22) 3.230 (42/13) 3.153(41/13) 4.231 (55/13) 2.389 (43/18) 1.609 (37/23) 1.179(33/28) 0.848 (28/33) 5.600(28/15x39/13) R _ N _ 1_ 2 - 3 - 4 - 5 FM: Left foot operated return system FE: Electric shift (left hand operated) return system DC-CDI Electric starter motor and emergency recoil starter Triple phase output alternator FET shorted, triple phase full wave rectification Battery 1-7
- 11. GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ITEM Engine oil capacity After draining After draining/filter change After disassembly Recommended engine oil Oil pump Tip clearance Body clearance Side clearance STANDARD 2.4 liters (2.5 US qt, 2.1 Imp qt) 2.5 liters (2.6 US qt, 2.2 Imp qt) 3.0 liters (3.2 US qt, 2.6 Imp qt) Pro Honda GN4 or HP4 (without molyb- denum additives) 4-stroke oil or equiv- alent motor oil API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-40 0.15(0.006) 0.15-0.21 (0.00-0.008) 0.02-0.09(0.001 -0.004) SERVICE LIMIT - - - - 0.20 (0.008) 0.25 (0.010) 0.11 (0.004) FUEL SYSTEM SPECIFICATIONS ITEM Carburetor identification number Main jet Slow jet Pilot screw opening Float level Idle speed Throttle lever free play SPECIFICATIONS VE6DA #162 #45 See page 6-19 15.9 mm (0.63 in) 1,400 ± 100 rpm (min"1 ) 3 - 8 mm (1/8-5/16 in) CYLINDER HEAD/VALVE SPECIFICATIONS Unit: mm (in) ITEM Cylinder compression at 380 rpm (min"1 ) Valve clearance Valve, valve guide Valve spring Rocker arm Camshaft and cam follower Valve stem O.D. Valve guide I.D. Stem-to-guide clearance Valve seat width Free length Arm I.D. Shaft O.D. Arm-to-shaft clearance Cam lobe height Cam follower O.D. Follower bore I.D. Follower-to-bore clearance IN/EX IN EX IN/EX IN EX IN/EX Inner Outer IN/EX IN/EX IN/EX IN EX IN/EX IN/EX IN/EX Cylinder head warpage STANDARD 440 kPa (4.5 kgf/cm3 , 64 psi) 0.15 + 0.02(0.006 + 0.001) 5.975 - 5.990 (0.2352 - 0.2358) 5.955 - 5.970 (0.2344 - 0.2350) 6.000 - 6.012 (0.2362 - 0.2366) 0.010 - 0.037 (0.0004 - 0.0015) 0.030 - 0.057 (0.0012 - 0.0022) 1.2 (0.05) 42.94(1.691) 43.63(1.718) 12.000 - 12.018 (0.4724 - 0.4731) 11.964 - 11.984 (0.4710 - 0.4718) 0.016 - 0.054 (0.0006 - 0.0021) 35.8315 - 35.9915 (1.41069 - 1.41699) 35.5512 - 35.7112 (1.39965 - 1.40595) 22.467 - 22.482 (0.8845 - 0.8851) 22.510 - 22.526 (0.8862 - 0.8868) 0.028 - 0.059 (0.0011 - 0.0023) - SERVICE LIMIT - - 5.95 (0.234) 5.93 (0.233) 6.02 (0.237) 0.12(0.005) 0.14 (0.006) 1.5(0.06) 42.08(1.657) 42.76 (1.683) 12.05 (0.474) 11.92 (0.469) 0.08 (0.003) 35.60(1.402) 35.38 (1.393) 22.46 (0.884) 22.54 (0.887) 0.07 (0.003) 0.10 (0.004) 1-8
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- 13. GENERAL INFORMATION CYLINDER/PISTON SPECIFICATIONS Unit: mm (in) ITEM Cylinder Piston, piston pin, piston ring I.D. Out-of-round Taper Warpage Piston O.D. at 15 (0.6) from bottom Piston pin hole I.D. Piston pin O.D. Piston-to-piston pin clearance Piston ring end gap Piston ring-to-ring groove clearance Top Second Oil (side rail) Top Second Cylinder-to-piston clearance Connecting rod small end I.D. Connecting rod-to-piston pin clearance STANDARD 92.000 - 92.010 (3.6220 - 3.3.6224) - - - 91.965 - 91.985 (3.6207 - 3.6214) 20.002 - 20.008 (0.7875 - 0.7877) 19.994 - 20.000 (0.7872 - 0.7874) 0.002 - 0.014 (0.0001 - 0.0006) 0.15-0.30(0.006-0.012) 0.30-0.45(0.012-0.018) 0.20-0.70(0.008-0.028) 0.030 - 0.060 (0.0012 - 0.0024) 0.030 - 0.060 (0.0012 - 0.0024) 0.015 - 0.045 (0.0006 - 0.0018) 20.020 - 20.041 (0.7882 - 0.7890) 0.020 - 0.047 (0.0008 - 0.0019) SERVICE LIMIT 92.10 (3.626) 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) 91.93 (3.619) 20.04 (0.789) 19.96 (0.786) 0.08 (0.003) 0.5 (0.02) 0.6(0.02) 0.9 (0.04) 0.09 (0.004) 0.09 (0.004) 0.10 (0.004) 20.07 (0.790) 0.10 (0.004) CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) ITEM Change clutch Centrifugal clutch Primary drive gear Spring free length TM/FM FE Disc thickness Plate warpage Outer I.D. Outer guide I.D. O.D. Mainshaft O.D. at clutch outer guide Drum I.D. Weight lining thickness Clutch spring height Clutch weight spring free length Gear I.D. Crankshaft O.D. at drive gear STANDARD 43.8(1.72) 42.5 (1.67) 2.62-2.78(0.103-0.109) - 29.000-29.021 (1.1417-1.1426) 22.000-22.021 (0.8661 -0.8670) 28.959 - 28.980 (1.1401 - 1.1409) 21.967 - 21.980 (0.8648 - 0.8654) 150.0-150.2(5.906-5.913) 2.0 (0.08) 3.72(0.146) 23.17(0.912) 29.000-29.021 (1.1417-1.1426) 28.959 - 28.980 (1.1401 - 1.1409) SERVICE LIMIT 42.49(1.673) 41.23 (1.623) 2.3 (0.09) 0.20 (0.008) 29.05(1.144) 22.05 (0.868) 28.93(1.139) 21.93 (0.863) 150.4(5.92) 1.3 (0.05) 3.6(0.14) 24.10 (0.949) 29.05 (1.144) 28.93(1.139) Unit: mm (in) ITEM Starter driven gear boss O.D. STANDARD 51.705 - 51.718 (2.0356 - 2.0361) SERVICE LIMIT 51.69 (2.035) 1-9
- 14. GENERAL INFORMATION CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER SPECIFICATIONS Unit: mm (in) ITEM Shift fork Transmission Crankshaft I.D. Front, center Rear Claw thickness Shaft O.D. Gear I.D. Gear bushing O.D. Gear-to-bushing clearance Gear bushing I.D. Mainshaft O.D. M4 M5 C1,C2, C3,CR Reverse idle M4 M5 C1 C2, CR C3 M4 M5 C1 C2, CR C3 M4 M5 atM4 atM5 Reverse idle shaft O.D. Bushing-to-shaft clearance M4 M5 Reverse idle gear-to-shaft clearance Runout Big end side clearance Big end radial clearance STANDARD 13.000-13.021 (0.5118-0.5126) 13.000 - 13.018 (0.5118 - 0.5125) 4.93-5.00(0.194-0.197) 12.966 - 12.984 (0.5105 - 0.5112) 25.000-25.021 (0.9843-0.9851) 20.000-20.021 (0.7874-0.7882) 28.020-28.041 (1.1031 -1.1040) 13.000-13.021 (0.5118-0.5126) 24.959 - 24.980 (0.9826 - 0.9835) 19.966 - 19.984 (0.7861 - 0.7868) 27.986 - 28.005 (1.1018 - 1.1026) 27.979 - 28.000 (1.1015 - 1.1024) 27.959 - 27.980 (1.1007 - 1.1016) 0.020 - 0.062 (0.0008 - 0.0024) 0.016 - 0.055 (0.0006 - 0.0022) 0.015 - 0.055 (0.0006 - 0.0022) 0.020 - 0.062 (0.0008 - 0.0024) 0.040 - 0.082 (0.0016 - 0.0032) 22.000-22.021 (0.8661-0.8670) 17.016 - 17.034 (0.6699 - 0.6706) 21.959 - 21.980 (0.8645 - 0.8654) 16.976 - 16.987 (0.6683 - 0.6688) 12.966 - 12.984 (0.5105 - 0.5112) 0.020 - 0.062 (0.0008 - 0.0024) 0.029 - 0.058 (0.0011 - 0.0023) 0.016 - 0.055 (0.0006 - 0.0022) - 0.05-0.65(0.002-0.026) 0.006 - 0.018 (0.0002 - 0.0007) SERVICE LIMIT 13.04(0.513) 13.04(0.513) 4.5(0.18) 12.96(0.510) 25.05 (0.986) 20.05 (0.789) 28.07 (1.105) 13.04(0.513) 24.93(0.981) 19.94 (0.785) 27.94(1.100) 27.93 (1.100) 27.91 (1.099) 0.10(0.004) 0.10 (0.004) 0.08 (0.003) 0.10 (0.004) 0.15(0.006) 22.04 (0.868) 17.06 (0.672) 21.93 (0.863) 16.93 (0.667) 12.94(0.509) 0.10 (0.004) 0.10 (0.004) 0.10(0.004) 0.15(0.006) 0.8 (0.03) 0.05 (0.002) FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) ITEM Minimum tire tread depth Cold tire pressure Tie-rod distance between the ball joints Toe Standard Minimum Maximum With cargo TM FM/FE TM FM/FE STANDARD - 25 kPa (0.25 kgf/cm2 , 3.6 psi) 22 kPa (0.22 kgf/cm2 , 3.2 psi) 28 kPa (0.28 kgf/cm2 , 4.0 psi) 25 kPa (0.25 kgf/cm2 , 3.6 psi) 382.5(15.06) 388.0(15.28) Toe-out: 1 ± 15 (1/32 ± 19/32) Toe-out: 30 ± 15 (1-3/16 ± 19/32) SERVICE LIMIT 4.0(0.16) - - - - - - - - REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM Minimum tire tread depth Cold tire pressure Standard Minimum Maximum With cargo STANDARD - 25 kPa (0.25 kgf/cm2 , 3.6 psi) 22 kPa (0.22 kgf/cm2 , 3.2 psi) 28 kPa (0.28 kgf/cm2 , 4.0 psi) 25 kPa (0.25 kgf/cm2 , 3.6 psi) SERVICE LIMIT 4.0(0.16) - - - - 1-10
- 15. GENERAL INFORMATION BRAKE SYSTEM SPECIFICATIONS Unit: mm (in) ITEM Front brake Rear brake Recommended brake fluid Disc thickness Disc runout Master cylinder I.D. Caliper cylinder I.D. Drum I.D. Shoe lining thickness STANDARD Honda DOT 4 brake fluid 3.8-4.2(0.15-0.17) - 14.0 (0.55) 33.96 (1.3379 180.0 (7.09) 5.3(0.21) SERVICE LIMIT - 3.0(0.12) 0.30 (0.012) - - 181 (7.1) To index mark FRONT DRIVING MECHANISM SPECIFICATIONS (FM/FE models) REAR DRIVING MECHANISM SPECIFICATIONS BATTERY/CHARGING SYSTEM SPECIFICATIONS Unit: mm (in) ITEM Front differential Oil capacity After draining After disassembly Recommended oil Gear backlash Backlash difference Slip torque Face cam-to-housing distance Differential ring gear depth Cone spring free height STANDARD 185 cm3 (6.3 US oz, 6.5 Imp oz) 230 cm3 (7.8 US oz, 8.1 Imp oz) Hypoid gear oil SAE # 80 0.05-0.25(0.002-0.010) - 14-17N-m(1.45-1.75kgfm, 10- 13 Ibf-ft) 3.3-3.7(0.13-0.15) 6.55-6.65(0.258-0.262) 2.8(0.11) SERVICE LIMIT - - - 0.4 (0.02) 0.2(0.01) 12N-m(1.2 kgfm, 9 Ibf-ft) 3.3(0.13) 6.55 (0.258) 2.6(0.10) Unit: mm (in) ITEM Axle runout Rear final drive Oil capacity After draining After disassembly Recommended oil Gear backlash Backlash difference Ring gear-to-stop pin clearance STANDARD - 75 cm3 (2.5 US oz, 2.6 Imp oz) 100 cm3 (3.4 US oz, 3.5 Imp oz) Hypoid gear oil SAE # 80 0.05-0.25(0.002-0.010) - 0.3-0.6(0.01-0.02) SERVICE LIMIT 3.0(0.12) - - - 0.4 (0.02) 0.2(0.01) - ITEM Battery Alternator Capacity Current leakage Voltage (20°C/68°F) Charging current Fully charged Needs charging Normal Quick Capacity Charging coil resistance (20°C/68°F) SPECIFICATIONS 12V-12Ah 1 mA max. 13.0-13.2 V Below 12.3V 1.4Ax5-10h 6.0 Ax 1.0 h 0.357 kW/5,000 rpm (min'1 ) 0.1 -1.0 Q 1-11
- 16. GENERAL INFORMATION IGNITION SYSTEM SPECIFICATIONS ITEM Spark plug Spark plug gap Ignition coil primary peak voltage Ignition pulse generator peak voltage Ignition timing ("F" mark) SPECIFICATIONS BKR5E-11 (NGK), K16PR-U11 (DENSO) 1.0-1.1 mm (0.039-0.043 in) 100 V minimum 0.7 V minimum 10° BTDC at idle ELECTRIC STARTER SPECIFICATIONS Unit: mm (in) ITEM Starter motor brush length STANDARD 12.5 (0.49) SERVICE LIMIT 9.0 (0.35) LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM Bulbs Fuse Headlight (high/low beam) Assist headlight Brake/taillight Neutral indicator Reverse indicator Oil temperature indicator 4WD indicator (FM/FE only) Meter light Main fuse TM/FM FE Sub-fuse SPECIFICATIONS 12V-30/30Wx2 12V-45W 12V-21/5Wx2 12 V-1.7 W (A/CM type TM model) LED (Except A/CM type TM model) 12 V-1.7 W (A/CM type TM model) LED (Except A/CM type TM model) 12 V-1.7 W (A/CM type TM model) LED (Except A/CM type TM model) LED LED x 10 (Except A/CM type TM model) 30 A 30 Ax 2 15Ax2,10Ax2 1-12