Honda FourTrax Foreman Rubicon 2005 Service Manual page 600

INDEX
HONDA M ATIC
BEFORE STARTING TROUBLESHOOTING .......... 24-8
CIRCUIT DIAGRAM ................................................ 24-5
CONNECTOR LOCATION ... ..... ...................... ... ... ... 24-4
PROBLEM CODe INDEX .... ... .... ... .. .... .... .. .... .. ... ... 24- 11
TROUBLESHOOTING·· ··· ····· ····· ··· ··· ···· ··· ··· ···· ···· ···· 24-12
HORN \U type only) .... ..... .. .... ... ... ... ... ..... .. ... ............. 22-27
HORN SWITCH (U type only) .... ····· .. · ...... · .... · ...... · .... 22-27
IGNITION COil· ····· ················· ·· ···················· ··· ··· ······ ·· · 20-7
IGN ITION SW ITCH ......... ..... .. ..... ... ...... .. .... .. .......... .. ... . 22·9
IGNITION SYSTEM INSPECTION .. .... .. .... ...... .. ... ....... 20·5
IGNITION SYSTEM SPECiFiCATIONS ·············· ········· 1-13
IGNITION TIMING ......... .............................................. 20-8
INITIAL SETIING PROCEDURE .......... ............... ........ 24-6
INNER COVER ................................... ... ..... ..... ... ... ·· ···· ···2-7
INNER FENDER ..... ... ..... ..... .... ...... .. ... ... .... .. .... .. .... .... ... .. 2-9
LIGHTS/METERS/SWITCHES SPECiFiCATIONS·· ····· 1-14
LUBRICATION
&
SEAL POINTS· .. ··· ···· ··· ···················· 1-21
LUBRICATION SYSTEM DIAGRAM ········ ··············· .. ·· .. 4-2
LUBRICATION SYSTEM SPECiFiCATIONS ······ ···· ····· ·· 1-9
MAINTENANCE SCHEDULE ........ ..... ... ... .... ... ... .. ... .. .... 3-4
MODE SELECT SWITCH ................ .. .... .. ..... ... ... ... .. ... 24-39
MODEL IDENTIFICATION ······· ·· ··· ···· ······ ··· ··· ······ · ···· ·· ··· · 1-2
NUTS, BOLTS, FASTENERS ..... .. ..... ... .. .......... ..... ...... 3-25
OIL COOLER ... ... ...... .. ... .. ................................... ·········· ··4-7
OIL PRESSURE CHECK ···· ············································· 4-6
OIL PUMp ·························· ··································· ······ ·4· 12
OIL STRAINER ····· ···· ···· ········ ·········· ······· ·· ··· ··· ··· ··· ·· ··· ·· ··· · 4-8
OUTER FENDER ··· ·· ···· ···· ··· ···· ··· ·· ·· ····· ··· ··· ··· ··· ··· ··· ·· ··· ·· · 2· 13
PILOT SCREW ADJUSTMENT ..
·· ···· ·· ·· ····· ······ ············ 5·19
RADIATOR COOLANT ················································ 3·16
RADIATOR RESERVE TANK··· ·········· ·· ············ ····· ··· ··· ··· 6-7
RADIATOR/COOLING FAN ···· ·· ··· ·· ···· ··· ······· ······· ····· ·· ·· ·· 6-7
REAR AXLE INSTALLATION ··· ··· ··· ··· ····· ······ ······ ·· ··· ·· 18-23
REAR AXLE REMOVAL .. ····· ····· ·· ···· ··· ·· ···· ···· ···· ···· ······· · 18·7
REAR BRAKE ····························································· 16·19
REAR CARRIER .. ·············································· ... ......... 2-11
REAR CRANKCASE COVER .. ······· ······· ····· ··················· 12·6
REAR DRIVING MECHANISM SPECi FiCATiONS··· ··· 1-13
REAR FENDER ·· ····· ·· ···· ··· ···· ·· ···· ··· ··· ··· ······ ···· ··· ··· ·· ·· ···· ··2-12
REAR FINAL GEAR CASE OIL AND
DIFFERENTIAL OIL ···· ········································ ········ ·· 3-18
REAR SHOCK ABSORBER · .. ·· ··· ······ ·· ····· ············ ··· ······ 15·6
REAR VEHICLE SPEED SENSOR (VSS)· ···· ··· ·· ··· ··· ·· · 23-11
REAR WHEEL ·· ····· ··· ··· ······ ····· ···· ····· ··· ·· ··· ···· ···· .. .. ... .. ... . 15-6
REAR WHEEUSUSPENSION SPECIFICATIONS ····· ·· 1-12
RECOIL STARTER ········ ·· ····· ····· ···· ·········· ······· ········· .... · 1' ·5
RECOIL STARTER COVER ......... ................................... 2·4
REGULATOR/RECTIFIER .. ··································· ····· ··· 19·8
RE VERSE SWITCH .......... ..... ....................... ... .. ... .... .. 22-22
SEAT ... .. ...... ... ... .. ...... ... ... .. .... .... ... ... ..... .. ·· ··· ·· ··· ··· ··· ··· ··· ·· 2·4
SELECTABLE 4WO SYSTEM
BEFORE STARTING TROUBLESHOOTING .......... 23·4
PROBLEM CODE INDEX ....... ........................ ......... 23·4
TROUBLESHOOTING ···· ····· ·· ···· ···· ·· ·· ··· · 23·5
SERVICE INFORMATION
ALTERNATOR/STARTER CLUTCH ················ ·· ······ 11 ·3
BATIEAY/CHARG ING SYSTEM ·· ········ ····· ·· ·· ··· ·· ··· · 19-3
BRAKE SySTEM ·· ······· ····· ·· ···· ····· ····· ·············· ·· ······· 16·3
CENTRIFUGAL ClUTCH ........................................ 10·3
COOLING SYSTEM .. ..... .. .... .. .... ... ... .. ... ... .... .. ... .. ... .. . 6·3
CRANKSHAFT/AUTOMATIC
TRANSMISSION .... 13·3
CYLINDER HEADN ALVEICAMSHAFT .................... 8·3
CyLINDER/PiSTON ··· ··· ··· ··· ················ ··· ···· ···· ···· ····· ·· ·9·3
ELECTRIC POWER STEERING (EPS)· ·· · .. ·· ···· ·· ·· ····· 25·7
ELECTRIC STARTER ··········································· ·· ·· 21 -3
ENGINE REMOVAUINSTALLATION ... ... ...... ... .. ... ... 7·3
FRAME/BODY PANELS/EXHAUST SySTEM ·········· 2·2
FRONT DRIVING MECHANISM ····· ·· ···· ·· ·········· ·· ··· · 17·3
28-2
FRONT WHEEUSUSPENSION/STEERING ······ ····· · 14·4
FUEL SYSTEM ... .. ... ..... ... .. .. .... .... .. ... ........ .. .. .. .. .. ... ·· ·· 5-3
HONDAMATIC .. ... .. ... .. .. ... ... .. .... .. ... ....................... ·· 24-3
IGNITION SYSTEM ·················· ······ ······ ·· ················· 20-3
LIGHTS/METERS/SWITCHES ........... ........ ......... ... .. 22·3
LUBRICATION SYSTEM ····· ···· ··· ········· ·· ··· ···· ··· ·· ··· ··· ·· 4-3
MAINTENANCE ......... .. .... .. ... ........ .. .. ... .... .. .. .... .... ... ·· 3-2
REAR DAIVING MECHANISM ·· ·· ··· ·· ·· ··· ·· ·· ·· ·· ·· ········ 18-3
REAR WHEEUSUSPENSION ·· ··· ·········· ·················· 15-3
SELECTABLE 4WD SySTEM ·································· 23·3
SUB· TRANSMISSION/GEARSHIFT LINKAGE ··· ··· · 12·3
SERVICE RULES ..... ... .... .. .... .. ...... ....... .. ... .. .. .... .. .. .. .. . ·· ···1·2
SIDE COVER ··· ····· ·· ··· ······· ·· ··· ·· ··· ··· ··· ···· ·· ·· ··· ·· ·· ·· ··· ··· ··· ·· ···2-5
SKID PLATE, ENGINE GUARD ····· ·· ·· ··· ·· ··· ··· ··· ·· ··· ···· ·· ·3-23
SPARK ARRESTER .... ... ... .... ....... ..... ...... ...................... 3-24
SPARK PLUG ...... ... ........... .................................. ··········· 3·9
STANDARD TORQUE VALUES ····· ····· ·· ·· ··· ··· ·· ··· ····· ····1 -15
STARTER MOTOR ··· ······ ·· ··· ··· ·· ···· ·· ·· ··· ·· ·· ··· ·· ·· ·· ··· ·· ·· ···· · 21 -6
STARTER RELAY SWITCH ·· ··· ·· ··· ··· ··· ···· ·· ··· ·· ··· ···· ·· ··· · 21 -12
STEERING SHAFT .... .... .. ... .. .... .. ... .. ... .. .. .. ... .. ... .... .. .. .. ,4-28
STEERING SHAFT HOLDER BEARING ·· ······ ··· ······ ····· 3-26
STEERING SYSTEM .. ............... .. ...... ........ ...... ......... .... 3-26
STEERINGSHAFTIEPS UNIT (EPS model) ··············· 14-34
SUB-TRANSMISSION ·············· ························· ···· ·· ·· 12-12
SUB-TRANSMISSION/
GEARSHIFT LINKAGE SPECIFICATIONS .. ··· ·· ··· ·· ··· ····1 - 11
SUSPENSION ... ... .... .. .... .... .. ... .. ... .. ... .. ... .. ... .. ... .. .. ·· ··· ·· ·3-23
SUSPENSION ARM ·· ··· ·· ···· ····· ····· ···· ··· ······· ········ ···· ·· ·· 14-20
SWINGARM ............ ................. .. ... .................... ······ ···· ·15·9
SYMPTOM TROUBLESHOOTING
EPS ··· ·· ··· ·· ···· ·· ·· ·· ··· ·· ··· ····· ·· ··· ·· ··· ····· ·· ··· ·· ··· ·· ·· ····· ·· ··· · 25-34
SYMPTOM TROUBLESHOOTING INDEX
EPS··· ·· ··· ·· ··· ·· ··· ·· ··· ·· ··· ·· ··· ····· ····· ·· ·· ··· ··· ···· ··· ·· ·· ······ ··· 25-17
SYSTEM COMPONENTS
ALTERNATORISTARTER CLUTCH · .. ······················ 11·2
CRANKSHAFT/AUTOMATIC TRANSMISSION ··· ··13·2
CYLINDER HEADN ALVE/CAMSHAFT ··· ·· ··· ·· ··· ····· ·· ·8-2
CYLINDER/PISTON ··· ······· ··· ··· ······· ·· ·· ··· ··· ·· ············ ···· 9·2
ENGINE REMOVAUIN STALLATION .......... .. .. ... .... ... 7.2
FRONT DRIVING MECHANISM ···· ··· ·········· ·· ····· .... · 17·2
FRONT WHEEUSUSPENSION/STEERING ············ 14-2
FUEL SYSTEM .. .. .................. .. ... ... ...... ...... ... .. ... .... ···· 5-2
REAR DRIVIN G MECHANISM ······ ··· ···· ·· ··· ·· ··· ·· ·· ·· ···18·2
REAR WHEEUSUSPENSION ···· ·· ·· ·· ··· ··· ·· ···· ·· ··· ·· ··· · 15·2
SUB-TRANSMISSION/GEARSH IFT lINKAGE· ·· ··· · 12-2
SYSTEM DIAGRAM
BATIERY/CHARGING SYSTEM ···· ········· ··········· .... · 19·2
ELECTRIC POWER STEERING (EPS) ····· ················ 25-3
ELECTRIC STARTER ·· ·· ·· ···· ··· ·· ···· ······ ···· ··· ·· ·· · .... ·· ··· · 21 ·2
IGNITION SYSTEM ... ... .......... ... .... ... .... .. ... .. .. ..... .. ... 20·2
SELECTABLE 4WD SYSTEM· ··· ···· ··· ···· ·· ····· ·· ·· ····· ···23-2
TAIUBRAKE LIGHT IAf05, Af06) ······· ···· ····· ··· ··········· ·· · 22-6
TAIUBRAKE LIGHT IAfter Af06) .. ............................... 22-7
TEMPERATURE INDICATOR ······· ·········· ····· ····· ······· ·· 22-17
THERMOSTAT ········· ·········· ··········· ·· ··· ···· ······ ····· ··········· 6-10
THROTILE HOUSING ···· ··········································· 14-13
THROTILE OPERATION ·· ······· ···· ·· ······· ·· ····· ······ ·· ·· ········ 3-5
THROTILE POSITION ITP) SENSOR ··· ·· ··· ····· ··· ··· ··· ·24-40
TIE-ROD·········· .. ......... ..... .. ........ ... ..... ........... ..... ... .... ... 14-42
TIE ·ROD AND JOINT BOOTS (After '07 ) ············ ······· 3·25
TIRES··· ·· ···· ······ ··· ·· ··· ·· ··· ·· ········ ····· ···· ··· ··· ····· ···· ·· ··· ···· ·· ·14· 15
TOOL BOX ....... .. .. ...... ... ... .. ..... .. .... .. .. ... .. ..... .... ·· ·· ···· ·· ·· · 2· 13
TRIM CLIP ...................................................... ··········· ····· 2-4
TROUBLESHOOTING
AL TEANATORISTARTER CLUTCH · .. ······ ····· ··· ···· ··· · 11-4
BATIERY/CHARGING SYSTEM ········ ·· ··· ················ 19·5
BRAKE SYSTEM ·· ··· ·· ··· ·· ·· ·· ··· ·· ··· ·· ··· ·· ··· ·· ··· ·· ··· ···· ·· ·· · 16-5
CENTRIFUGAL CLUTCH ··············· ·························· 10-4
COOLING SYSTEM ... .. .... .. .... ... ..... ......... ...... ..... ........ 6-3