Service Information - Honda 2005 FOURTRAX FOREMAN TRX500 TM Service Manual

FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION
GENERAL
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
• A jack or other support is required to support the vehicle.
• Adjust toe whenever the tie-rod, knuckle or steering shaft are replaced or removed (page 4-22).
• Do not twist or bend the brake hose and pipe when servicing.
• Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
• Refer to page 15-3 for brake system information.
• Refer to page 21-8 for handlebar switch inspection.
• Refer to page 21-9 for brake light switch inspection.
SPECIFICATIONS
Unit: mm (in)
ITEM
Minimum tire tread depth
Cold tire pressure
Tie-rod distance between the ball
joints
Toe
Standard
Minimum
Maximum
With cargo
TM
FM/FE
TM
FM/FE
STANDARD
-
25 kPa (0.25 kgf/cm
2
, 3.6 psi)
22 kPa (0.22 kgf/cm
2
, 3.2 psi)
28 kPa (0.28 kgf/cm
2
, 4.0 psi)
25 kPa (0.25 kgf/cm
2
, 3.6 psi)
382.5(15.06)
388.0(15.28)
Toe-out: 1 ± 15 (1/32 ± 19/32)
Toe-out: 30 ± 15 (1-3/16 + 19/32)
SERVICE LIMIT
4.0(0.16)
-
-
-
-
-
-
-
-
TORQUE VALUES
Handlebar lower holder nut
Front master cylinder holder bolt
Throttle housing cover screw
Throttle arm nut
2WD/4WD select switch screw (FM/
FE only)
Front wheel nut
Front wheel hub nut
Front brake disc bolt
Splash guard bolt
Shock absorber mounting nut
Upper arm pivot nut
Lower arm pivot nut
Upper and lower arm ball joint nut
Brake hose clamp bolt
Tie-rod stud joint nut
Tie-rod lock nut
Steering shaft end nut
Steering shaft holder bolt
39 N-m (4.0 kgf-m, 29 Ibf-ft)
12N-m(1.2kgf-m,9lbfft)
1.5 N-m (0.15 kgf-m, 1.1 Ibf-ft)
7.0 N-m (0.71 kgf-m, 5.2 Ibf-ft)
1.5 N-m (0.15 kgf-m, 1.1 Ibf-ft)
64 N-m (6.5 kgf-m, 47 Ibf-ft)
78 N-m (8.0 kgf-m, 58 Ibf-ft)
42 N-m (4.3 kgf-m, 31 Ibf-ft)
11 N-m (1.1 kgf-m, 8 Ibf-ft)
44 N-m (4.5 kgf-m, 32 Ibf-ft)
34 N-m (3.5 kgf-m, 25 Ibf-ft)
44 N-m (4.5 kgf-m, 32 Ibf-ft)
29 N-m (3.0 kgf-m, 21 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
54 N-m (5.5 kgf-m, 40 Ibf-ft)
54 N-m (5.5 kgf-m, 40 Ibf-ft)
108 N-m (11.0 kgf-m, 80 Ibf-ft)
32 N-m (3.3 kgf-m, 24 Ibf-ft)
Lock nut: replace with a new one.
Castle nut: tighten to the specified torque
and further tighten until its grooves aligns
with the cotter pin hole.
ALOC bolt: replace with a new one.
ALOC bolt: replace with a new one.
Lock nut: replace with a new one.
Lock nut: replace with a new one.
Lock nut: replace with a new one.
Castle nut: tighten to the specified torque
and further tighten until its grooves aligns
with the cotter pin hole.
Lock nut: replace with a new one.
Lock nut: replace with a new one.
13-3