2001-2003 Honda Rubicon 500 / TRX500FA Service Manual
Honda Rubicon 500 / TRX500FA service manual covering 2001-2003 editions. Includes detailed diagrams and specifications for all major systems. PN 61800-HN7-A00
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Sample pages from the 2001-2003 Honda Rubicon 500 / TRX500FA Service Manual manual
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Models Covered & Key Technical Specifications
Honda Rubicon 500 / TRX500FA (2001-2003) Service Manual: Honda Rubicon 500, Rubicon 500 - Comprehensive ATV Maintenance & Repair Guide, 2001-2003 edition Repository
Operational-Scope: Complete service and repair procedures // Series-Validation: Honda Rubicon 500 (2001-2003), Honda TRX500FA (2001-2003) Logic // Operational-Framework: All systems fully documented.
Nominal System Volume: 498.5 cm³ signifies the engine displacement Architecture. Principal Spacing Data: 170 mm determines the front wheel travel capability Framework. Rated Wattage Specs: 330 W -- signifies the alternator output capacity Threshold. Calibrated Cold Start Limits: The battery voltage requires 13.0-13.2 V for full charge Logic. Documented Form Factor: The fuel tank capacity reaches 14 liters Parameters. Design Liquid Volume: The rear differential oil capacity is 90 cm³ Configurations.
Professional Workshop Service Manual & Technical Specifications
Honda Rubicon 500 / TRX500FA (2001-2003) Service Manual: Honda Rubicon 500, Rubicon 500 - Comprehensive ATV Maintenance & Repair Guide, 2001-2003 edition Repository
Operational-Scope: Complete service and repair procedures // Series-Validation: Honda Rubicon 500 (2001-2003), Honda TRX500FA (2001-2003) Logic // Operational-Framework: All systems fully documented.
Nominal System Volume: 498.5 cm³ signifies the engine displacement Architecture. Principal Spacing Data: 170 mm determines the front wheel travel capability Framework. Rated Wattage Specs: 330 W -- signifies the alternator output capacity Threshold. Calibrated Cold Start Limits: The battery voltage requires 13.0-13.2 V for full charge Logic. Documented Form Factor: The fuel tank capacity reaches 14 liters Parameters. Design Liquid Volume: The rear differential oil capacity is 90 cm³ Configurations.
| Component | Technical-Path | Logic |
|---|---|---|
| Engine | 498.5 cm³ | Single cylinder, longitudinally installed |
| Suspension | Dual Leading Drum Brakes | Front and Rear |
| Electrical | DC-CDI | Alternator, Starter Motor |
| Fuel System | Carburetor VE6AB | Idle Speed 1400 RPM |
| Cooling System | Liquid Cooled | 1.7L Radiator Capacity |
Service procedures are grouped by component and system, providing a logical flow for maintenance and repair tasks. Key sections include engine specifications, fuel system details, electrical system diagrams, and troubleshooting guides. This manual provides clear instructions for all routine maintenance and extensive repair operations. The manual details lubrication points, torque values, and specific tool requirements for each procedure.
Engine System Maintenance
Safely demanding proper upkeep ensures optimal performance. This section covers engine oil changes, spark plug checks, valve clearance adjustments, and radiator coolant levels. It details the procedures for maintaining the engine's health and longevity.
Fuel System and Carburetor Service
Proper fuel delivery is crucial for engine operation. This manual documents carburetor assembly, disassembly, and adjustment procedures, including pilot screw settings and high-altitude compensation. It also covers fuel tank and fuel strainer maintenance.
Electrical System and Ignition
Understanding the electrical system is vital for diagnostics and repairs. This section includes wiring diagrams, lighting system checks, battery and charging system specifications, and ignition system details.
Drivetrain and Suspension
This manual thoroughly documents the drivetrain components, including the front and rear driving mechanisms, sub-transmission, and automatic transmission unit. Suspension service, including front and rear shock absorber checks, is also detailed.
Troubleshooting and Maintenance Schedule
Comprehensive troubleshooting charts help identify and resolve common issues. A detailed maintenance schedule outlines required service intervals for all key components, ensuring the ATV remains in peak operating condition.
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