Service Information - Honda 2005 FOURTRAX FOREMAN TRX500 TM Service Manual

CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION
GENERAL
• This section covers service of the clutch (centrifugal clutch and change clutch) and gearshift linkage. To service the
reverse stopper shaft and gearshift spindles, the engine must be removed from the frame.
• The crankcase must be separated when the sub-gearshift spindle, transmission, shift drum and shift forks require ser-
vice (page 12-2).
• Engine oil viscosity and level and the use of oil additives have an effect on clutch operation. Oil additives of any kind are
specifically not recommended. When the clutch does not disengage or the vehicle creeps, inspect the engine oil and oil
level before servicing the clutch system.
• Engine lubricating oil is fed through the oil passages in the front crankcase cover. Clean the oil passages before install-
ing the crankcase cover.
• The FE model is equipped with the electric shift program (ESP), see page 22-19 for this service.
SPECIFICATIONS
Unit: mm (in)
ITEM
Change
clutch
Centrifugal
clutch
Primary drive
gear
Spring free length TM/FM
FE
Disc thickness
Plate warpage
Outer l.D.
Outer guide l.D.
O.D.
Mainshaft O.D. at clutch outer guide
Drum l.D.
Weight lining thickness
Clutch spring height
Clutch weight spring free length
Gear l.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)
TORQUE VALUES
Clutch spring bolt
Centrifugal clutch lock nut
Change clutch lock nut
Shift drum stopper arm pivot bolt
Gearshift cam bolt
Gearshift spindle return spring pin
12N-m(1.2kgf-m, 9lbfft)
118 N m (12.0 kgf-m, 87 Ibf-ft)
108 N-m (11.0 kgf-m, 80 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
16 N-m (1.6 kgf-m, 12 Ibf-ft)
Apply engine oil to the threads and seating sur-
face. Stake.
Apply engine oil to the threads and seating sur-
face. Stake.
Apply locking agent to the threads.
Apply locking agent to the threads.
22 N-m (2.2 kgf-m, 16 Ibf-ft) Apply locking agent to the threads.
10-3