2001–2003 Honda Rubicon 500 / TRX500FA ATV Service Manual

This Honda factory service manual covers the 2001–2003 Rubicon 500 (TRX500FA), with a May 2000 issue date. It addresses scheduled maintenance, mechanical repair and Hondamatic fault diagnosis.

• Engine and valvetrain: Engine removal, crankcase separation, camshaft and crankshaft service, cylinder inspection, valve clearance adjustment, and cylinder head repair.
• Hondamatic diagnosis: Fault-code retrieval, sensor and control-motor tests, initial-setting procedures, and transmission-unit replacement, supported by circuit drawings and diagnostic flowcharts.
• Clutches and drivetrain: Centrifugal clutch, starter clutch and recoil starter service, plus sub-transmission inspection, front differential overhaul and rear final drive repair.
• Fuel and lubrication: Carburetor disassembly, float and pilot-screw checks, high-altitude adjustment, oil-pressure testing, and oil-pump inspection and service.
• Cooling system: Radiator pressure testing, thermostat inspection, coolant replacement, water-pump service, and troubleshooting for overheating and coolant leakage.
• Chassis and brakes: Steering, suspension and wheel-bearing service, hydraulic front drum brake bleeding and cylinder repair, and mechanical rear drum brake maintenance.
• Electrical troubleshooting: Charging, ignition and electric-starting diagnosis, with wiring diagrams, connector references, cable/harness routing views and component-specific inspection procedures.

Written for qualified professional technicians familiar with Honda ATV maintenance, workshop tools and the precautions required for engine, drivetrain and brake work.

Engine Service and Assembly Checks

Maintenance schedules sit alongside valve-clearance checks, cylinder and piston inspection, valve-guide and seat work, and crankshaft/balancer service. Exploded assembly views support disassembly and reassembly of the longitudinal engine, while the service sections distinguish work possible in the frame from procedures requiring engine removal.

Incorrect rocker-arm-to-pushrod alignment during cylinder head cover installation can cause severe engine damage. The manual identifies this assembly risk alongside the relevant installation instructions.

Hondamatic Troubleshooting and Service Limits

Diagnosis connects fault codes with the ECM, angle sensor, throttle sensor, shift switches and control motor. The motor-lock flowchart separates motor or wiring faults from mechanical locking, helping technicians narrow the cause of a drive complaint before selecting a repair. Circuit drawings and hydraulic operating diagrams explain transmission operation in D1/D2 automatic modes and ESP mode.

Initial-setting procedures cover specified component replacements and throttle-cable work. Incorrect initialization has its own diagnostic indication. The Hondamatic transmission unit is replaced as an assembly; the manual prohibits internal disassembly of that unit.

Drivetrain, Brake and Cooling Repairs

Front differential and rear final drive procedures include backlash checks, shim selection and gear-tooth contact patterns. Steering and suspension chapters address tie rods, ball joints, wheel bearings, shocks and swingarm bearings. Brake coverage distinguishes hydraulic front drum bleeding and cylinder repair from the mechanical rear drum assembly, with precautions for brake-fluid handling and service work.

Cooling procedures include radiator pressure testing, thermostat inspection and water-pump service. Centrifugal clutch instructions warn that molybdenum-disulfide oil additives reduce friction and can interfere with proper engagement.

Electrical Circuits and Component Tests

Charging, ignition and starting chapters cover alternator and regulator/rectifier tests, ignition peak-voltage measurements, starter-motor inspection and relay checks. Cable/harness routing views, connector references and the full wiring schematic help trace circuits; separate procedures cover the cooling fan, thermosensor and speedometer.

Examples of Compression, Cooling and Fastener Specifications

Cylinder compression is specified at 608–902 kPa at 450 rpm with the engine warmed and throttle fully open.

Cooling data list 1.7 liters for the radiator and engine, excluding the reserve tank. Thermostat inspection specifies a minimum valve lift of 8 mm at 95°C (203°F).

Fastener data specify 53 N·m for cylinder head cover cap nuts with oiled threads and seating faces, using staged crisscross tightening. The front wheel hub nut specification is 78 N·m, followed by further tightening for cotter-pin alignment.

PDF Search, Navigation and Page Count

Text search, bookmarks and wiring detail: Embedded OCR supports searches through much of the manual, but some pages and diagram labels are not searchable. Bookmarks link to the contents, service chapters and index; additional legacy file links may not function. Small wiring labels require zooming, and some switch-contact lines in the full wiring diagram remain faint.

Supplied as one printable English-language PDF with 408 pages in total, including one introductory page, the manual cover and eight memo pages.