Service Information - Honda 2005 FOURTRAX FOREMAN TRX500 TM Service Manual

FRONT DRIVING MECHANISM (FM/FE models)
SERVICE INFORMATION
GENERAL
• Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The
extension lines from the gear engagement surfaces should intersect at one point.
• Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp it too tight as it could damage
the gear case.
• When using the lock nut wrench, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench
increases the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the
lock nut. The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench. Do
not overtighten the lock nut. The specification later in the text gives both actual and indicated.
• Replace the ring and pinion gears as a set.
• Replace the cam followers (12 pieces) as a set, and the cam followers, face cams and differential housing halves as an
assembly if the face cam or differential housing is faulty.
SPECIFICATIONS
Unit: mm (in)
ITEM
Front
differential
Oil capacity
After draining
After disassembly
Recommended oil
Gear backlash
Backlash difference
Slip torque
Face cam-to-housing distance
Differential ring gear depth
Cone spring free height
STANDARD
185 cm
3
(6.3 US oz, 6.5 Imp oz)
230 cm
3
(7.8 US oz, 8.1 Imp oz)
Hypoid gear oil SAE # 80
0.05-0.25(0.002-0.010)
-
1 4 - 17 N-m (1.45- 1.75 kgf-m,
10-13 Ibf-ft)
3.3-3.7(0.13-0.15)
6.55-6.65(0.258-0.262)
2.8(0.11)
SERVICE LIMIT
-
-
-
0.4 (0.02)
0.2(0.01)
12 N-m (1.2
kgf-m, 9 Ibf-ft)
3.3(0.13)
6.55 (0.258)
2.6(0.10)
TORQUE VALUES
Differential ring gear bolt
Front final gear case cover bolt (10 mm)
Front final gear case cover bolt (8 mm)
Front final clutch bolt
Front final gear mounting bolt (10 mm)
Front final gear mounting nut (10 mm)
Final gear mounting nut (8 mm)
Front vehicle speed sensor bolt
Rear vehicle speed sensor bolt
Clutch cover stay bolt
Front final clutch cover bolt
49 N-m (5.0 kgf-m, 36 Ibf-ft)
49 N-m (5.0 kgf-m, 36 Ibf-ft)
25 N-m (2.5 kgf-m, 18 Ibf-ft)
25 N-m (2.5 kgf-m, 18 Ibf-ft)
44 N-m (4.5 kgfm, 32 Ibf-ft)
44 N-m (4.5 kgf-m, 32 Ibf-ft)
22 N-m (2.2 kgf-m, 16 Ibf-ft)
10 N-m (1.0 kgfm, 7 Ibf-ft)
10 N-m (1.0 kgf-m, 7 Ibf-ft)
10 N-m (1.0 kgf-m, 7 Ibf-ft)
7 N-m (0.7 kgf-m, 5.2 Ibf-ft)
ALOC bolt: replace with a new one.
Apply locking agent to the threads.
ALOC bolt: replace with a new one.
Lock nut: replace with a new one.
16-3