Throttle Housing Assembly - Honda TRX500FM Service Manual

FRONT WHEEUSUSPENSION/STEERING
16-12
Loosen the lock nut [1] and cable adjuster [2).
Bend down the lock washer tab and remove the
fallowing:
- pivot nut [3]
- lock washer [4]
- throttle lever [5] and plastic washer [6]
- return spring [7]
- throttle arm [8] (by disconnecting the cable [9])
- dust seal (from the housing)
ASSEMBLY
Coat the lips of a new dust seal [1] with grease and
install it into the housing until it is fully seated .
Apply grease to the throttle lever pivot in the housing
and to the throttle cable end.
Connect the cable (2) to the throttle arm (3] .
Insert the throttle lever [4] with the plastic washer (5)
into the housing.
Install the throttle arm with the spring (6) over the
throttle lever pivot by aligning the flat surfaces .
Install a new lock washer [7] and the nut [8]. and tighten
the it to the specified torque.
TORQUE : 7.0 N·m (0.7 kgf·m, 5.2 IbHt)
Bend up the lock washer tab against the nut.
Install the housing cover (1) with a new gasket [2] and
tighten the three screws (3) to the specified torque.
TORQUE : 1.5 N·m (0 .2 kgf·m, 1.1IbHt)
Adjust the throttle lever freeplay (page 3-4).