2001 - 2004 Honda TRX500 Foreman Rubicon Repair, Service & Maintenance Manual by CLYMER
The following models are covered:
Clymer ATV repair manuals are considered
to be the only ATV repair manuals worth owning. They are used by some of the
most prestigious professionals to your average everyday ATV owner. Along with
superior design Clymer ATV repair manuals always provide the most up-to-date
information available for your ATV.
The manual gives you complete information
regarding maintenance, tune-up, repair and overhaul.
Like all Clymer ATV repair manuals, this book also contains:
Clymer manuals provide step-by-step procedures based on the complete disassembly of the machine. This hands-on experience combined with extensive research results in a manual that is both detailed and user friendly. Accurate, clear and concise text, combined with detailed illustrations and photography, make it possible for the novice ATV enthusiast to safely and enjoyably service their vehicle. At the same time, the in-depth coverage provides indispensable information for those tackling more complicated procedures.
Table of Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial
numbers / Fasteners / Shop supplies / Basic tools / Precision measuring
tools / Electrical system fundamentals / Basic service methods / Storage
/ Specifications
CHAPTER TWO / TROUBLESHOOTING
Engine operating requirements / Starting the engine / Starting
difficulty / Poor idle speed performance / Poor medium and high speed
performance / Electric starting system / Charging system / Ignition
system / Lighting system / Cooling system / Combination meter / Fuel
system / Engine overheating / Engine / Engine noises / Cylinder leakdown
test / Engine oil pressure test / Clutch / Sub-transmission / Main
(automatic) transmission / Global positioning system (GPS) / Drivetrain
troubleshooting / Handling / Frame noise / Brakes
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride check list / Maintenance schedule / Battery / Periodic
lubrication / Engine oil and filter change / Front and rear differential
gearcase oil change / Control cable lubrication / Periodic maintenance /
Air filter / Spark arrestor / Toe adjustment / Tune-up / Valve
clearance check adjustment / Cylinder compression check / Spark plug /
Specifications
CHAPTER FOUR / ENGINE TOP END
Cleanliness / Exhaust system / Cylinder head cover, rocker arms and
push rods / Cylinder head / Valves and valve components / Camshaft /
Camshaft chain tensioner / Cylinder / Piston and piston ring /
Specifications
CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine removal and installation / Recoil
starter / Driven pulley / Alternator cover / Starter reduction gears /
Rear crankcase cover / Flywheel and starter clutch / Crankcase and
crankshaft / Lubrication system / Oil strainer screens / Oil tank / Oil
pump / Engine break-in / Specifications
CHAPTER SIX / CLUTCH AND PRIMARY DRIVE GEAR
Clutch cover / Centrifugal clutch and primary drive gear / Specifications
CHAPTER SEVEN / TRANSMISSIONS AND SHIFT MECHANISM
Shift mechanism / Sub-transmission / Automatic transmission / Specifications
CHAPTER EIGHT / FUEL SYSTEM
Carburetor / Carburetor float level adjustment / Carburetor
adjustments / Carburetor heater / Throttle housing and cable / Fuel tank
/ Fuel valve / Air box / Air intake duct / Air intake guide plate /
Choke cable / Specifications
CHAPTER NINE / ELECTRICAL SYSTEM
Resistance and peak voltage testing / Charging system / Alternator /
Ignition system / Electric starting system / Starter relay switch /
Start circuit diode / Automatic transmission Hondamatic / Lighting
system / Combination meter / Switches / Throttle position sensor / Oil
thermosensor / Coolant thermosensor / Coolant fan motor / Speed sensor
unit / Fuses / GPS / Wiring diagrams / Specifications
CHAPTER TEN / COOLING SYSTEM
Coolant / Coolant reserve tank / Radiator / Cooling fan / Thermostat /
Water pump / Oil cooler / Thermosensors / Specifications
CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Wheel / Tires and wheels / Hub / Shock absorbers / Tie rods / Steering
knuckle / Control arms / Handlebar / Steering shaft / Specifications
CHAPTER TWELVE / FRONT DRIVE MECHANISM
Front drive axles / Driveshaft / Front differential
CHAPTER THIRTEEN / REAR AXLE, SUSPENSION AND FINAL DRIVE
Wheels / Shock absorbers / Rear axle / Final drive unit / Swing arm / Specifications
CHAPTER FOURTEEN / BRAKES
Front brake drum / Front brake shoe / Front brake panel / Wheel
cylinders / Front master cylinder / Brake fluid draining / Brake
bleeding / Rear drum brake / Rear brake shoe / Brake panel / Front brake
hose replacement / Rear brake pedal and cable / Rear brake lever
parking brake cable / Specifications
CHAPTER FIFTEEN / BODY
Seat / Recoil starter cover / Right side cover / Left side cover /
Fuel tank cover / Front carrier / Front bumper / Center mud guards /
Front mud guards / Inner front fender / Front fender / Headlight grill /
Rear carrier / Rear fender / Tool box / Handlebar cover /
Specifications
INDEX
COLOR WIRING DIAGRAMS
Specifications:
Publisher: Clymer Publishing
Paperback: 382 Pages
Dimensions: 7.0 x 10.1 x 0.5 inches