2001-2003 Honda Rubicon 500 / TRX500FA Service Manual

2001–2003 Honda Rubicon 500 and TRX500FA Technical Reference

• Covers 2001–2003 Honda Rubicon 500 and TRX500FA all-terrain vehicles including the Hondamatic automatic transmission system
• Original OEM publication, May 2000 edition
• Contains 408 pages of technical specifications, maintenance schedules, and system illustrations
• Stored against your account so you can retrieve it after a hard-drive loss
• Full-text search finds any part number in seconds
• Suitable for printing individual sections for shop-floor use
• This official document serves as the primary factory reference for the 2001–2003 Honda Rubicon 500 series launch build, providing precise calibration data for the unique longitudinal engine architecture.

What the Manual Documents:

This 408-page official service publication provides comprehensive documentation for the Honda Rubicon 500 and TRX500FA. The content spans complete system-level diagnostics and maintenance, starting with detailed general information, identification, and safety precautions. Key chapters document the frame and body panels, lubrication systems, fuel delivery components, and liquid-cooled engine internals. The manual includes dedicated sections for the proprietary Hondamatic automatic transmission, including centrifugal clutch, starter clutch, and sub-transmission mechanisms. Chassis coverage details the front and rear suspension, steering geometry, and braking systems. The electrical section covers charging system outputs, ignition timing, and full wiring schematics.

Specification Highlights:

The document includes extensive specification tables, tolerance charts, and fluid capacity references for the Honda Rubicon 500. Cylinder compression is documented at 608–902 kPa at 450 rpm. The cooling system capacity is 1.7 liters for the radiator and engine, with a thermostat valve lift of 8 mm minimum. Torque values are cataloged for major fasteners, such as the cylinder head cover cap nut at 53 Nm and the front wheel hub nut at 78 Nm. Sensor reference values and wiring diagrams assist with electrical diagnosis. Maintenance schedules specify service intervals for fluid changes and wear-part inspections. This is an official 408-page Honda OEM workshop manual covering the 2001–2003 Honda Rubicon 500 and TRX500FA, documenting engine, chassis, electrical, and transmission specifications for the primary 500-series build.