Service Information - Honda 2005 FOURTRAX FOREMAN TRX500 TM Service Manual

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
SERVICE INFORMATION
GENERAL
• The crankcase halves must be separated to service the transmission and crankshaft. To service these parts, the engine
must be removed from the frame (page 7-2).
• Be careful not to damage the crankcase mating surfaces when servicing.
• Transmission lubricating oil is fed through the oil passages in the crankcase and crankcase cover. Clean the oil pas-
sages before assembling the crankcase halves.
SPECIFICATIONS
Unit: mm (in)
ITEM
Shift fork
Transmission
Crankshaft
I.D.
Front, center
Rear
Claw thickness
Shaft O.D.
Gear I.D.
Gear bushing
O.D.
Gear-to-bushing
clearance
Gear bushing I.D.
Mainshaft O.D.
M4
M5
C1,C2,C3,CR
Reverse idle
M4
M5
C1
C2, CR
C3
M4
M5
C1
C2, CR
C3
M4
M5
atM4
atM5
Reverse idle shaft O.D.
Bushing-to-shaft
clearance
M4
M5
Reverse idle gear-to-shaft clearance
Runout
Big end side clearance
Big end radial clearance
STANDARD
13.000-13.021 (0.5118-0.5126)
13.000 - 13.018 (0.5118 - 0.5125)
4.93-5.00(0.194-0.197)
12.966 - 12.984 (0.5105 - 0.5112)
25.000 - 25.021 (0.9843 - 0.9851)
20.000-20.021 (0.7874-0.7882)
28.020-28.041 (1.1031 -1.1040)
13.000-13.021 (0.5118-0.5126)
24.959 - 24.980 (0.9826 - 0.9835)
19.966 - 19.984 (0.7861 - 0.7868)
27.986 - 28.005 (1.1018 - 1.1026)
27.979 - 28.000 (1.1015 - 1.1024)
27.959 - 27.980 (1.1007 - 1.1016)
0.020 - 0.062 (0.0008 - 0.0024)
0.016 - 0.055 (0.0006 - 0.0022)
0.015 - 0.055 (0.0006 - 0.0022)
0.020 - 0.062 (0.0008 - 0.0024)
0.040 - 0.082 (0.0016 - 0.0032)
22.000-22.021 (0.8661 -0.8670)
17.016 - 17.034 (0.6699 - 0.6706)
21.959 - 21.980 (0.8645 - 0.8654)
16.976 - 16.987 (0.6683 - 0.6688)
12.966 - 12.984 (0.5105 - 0.5112)
0.020 - 0.062 (0.0008 - 0.0024)
0.029 - 0.058 (0.0011 - 0.0023)
0.016-0.055(0.0006-0.0022)
-
0.05-0.65(0.002-0.026)
0.006 - 0.018 (0.0002 - 0.0007)
SERVICE LIMIT
13.04(0.513)
13.04(0.513)
4.5(0.18)
12.96(0.510)
25.05 (0.986)
20.05 (0.789)
28.07 (1.105)
13.04(0.513)
24.93(0.981)
19.94 (0.785)
27.94(1.100)
27.93 (1.100)
27.91 (1.099)
0.10(0.004)
0.10 (0.004)
0.08 (0.003)
0.10 (0.004)
0.15(0.006)
22.04 (0.868)
17.06 (0.672)
21.93 (0.863)
16.93 (0.667)
12.94(0.509)
0.10(0.004)
0.10(0.004)
0.10 (0.004)
0.15(0.006)
0.8 (0.03)
0.05 (0.002)
TORQUE VALUE
Secondary gearshift spindle stopper bolt 12 N-m (1.2 kgf-m, 9 Ibf-ft) Apply locking agent to the threads.
12-4