2007-2010 ; 2@ HONDA Cray a FourTrax Rancher®A Few Words About Safety Service Information “The service and repair information contained in this manual is intended for use by qualified, professional technicians, ‘Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also ‘damage the vehicle or create an unsate condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle It you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality For Your Customer's Safety AWARNING Proper service and maintenance are essential to the cusiomer’s safety and the reliability of the vehicle. Any ertor or oversight while servicing a vehicle Improper service or repairs can create an in fauity operation, damage tothe vehicle, or injury to others. Unsafe conattion that can cause your customer can result in faulty operation, damag . rey or others to be seriously hurt or killed. For Your Safety Follow the procedures and precautions in this Because this manual is intended for the professional service technician, we manual and other service materials caretuly do not provide warnings about many basic shop safety practices (e.g. Hot — parts-wear gaves). If you have nat received shop salaty training or do not feel confident about your knowledge of sale servicing practice, we CNN recommended that you de not attempt to perform the procedures described” Falure to properly tollow instrucions. and in this manual Precautions can cause you to be seriously hurt ‘Some of the most important general service safety precautions are given ora below. However, we cannot warn you of every conceivable hazard that can Follow the procedures and precautions inthis ‘arise in performing service and repair procedures. Only you can decide manual careful ‘whether or not you should perform a given task Important Safety Precautions ‘Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially caretul ofthe folowing: * Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. * Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, dil, orind, pry or work around pressurized air or liquids, and springs or other stored-eneray components. If there is any doubt, put on eye protection, * Use other protective wear when necessary, for example gloves or safely shoes. Handling hot or sharp parts can cause severe bburns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. * Protect yourself and cthers whenever you have the vehicle up in the air. Any time you it the vehicle, ether witha hoist or a jack, ‘make sure that itis always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise ‘This will help eliminate several potential hazards * Carbon monoxide poisoning from engine exhaust, Be sure there is adequate ventilation whenever you run the engine. * Burns from hot parts or coolant. Let th ngine and exhaust system cool before working in those areas. *Inlury from moving parts. Ifthe instruction tells you to run the engine, be sure your hands, fingers and cothng are out ofthe way Geascinevaors and ystogen gases tom bates ae explosive To redcn the a0 exlosive To reduce the psstlity of a fr o explosion, be att whon working around gasoline or batteries, ‘ ee ese * Use only a nonflammable solvent, not gasoline, to clean parts. ‘+ Never drain or store gasoline in an open container. * Keep all cigarettes, sparks and flames away from the battery and all fuel-elated parts,HOW TO USE THIS MANUAL CONTENTS TlSeauvbeaet her enter GENERAL INFORMATION pak Cperating condlion and ihe exssion TECHNICAL FEATURES Protection Agency (EA) Cavtomia Ae Resourene Bost Bruin gene (EM) FRAME/BODY PANELS/EXHAUST SYSTEM [IE CGumporeites oro Paal wear Wat ome Got, fe: bean MAINTENANCE EI Sector + ad 4 spi oth whole aie. Sesion 3 Nutimias LUBRICATION SYSTEM ps ane Soren ALeeiin GaN) ls ane - . COOLING SYSTEM Ha Eris arte wapope te weston en wn wa — See ee eee ENGINE RENOVALANGTALLATION [ e fae ve ciated posacaes me Te newenet CYLINDER HEADIVALVE CYLINDER/PISTON | 10 CLUTCH/GEARSHIFT LINKAGE El ALTERNATOR/STARTER CLUTCH EE Jeulmate armed scons aw have pond sey massages {ANKCASE/TRANSMISSION/CRANKSHAFT/ BPN paca portblewsnyosuonslvolaaiareded | (—-—SALANCER FRONT WHEEL/SUSPENSION/STEERING EZ ean we Errno St) sn myo em re ro REAR WHEEL/SUSPENSION Ea "Shed ince sonal words DANGER WAAING, 6 CAUTION. BRAKE SYSTEM Ea or “ou WILL be KILLED or SERIOUSLY FRONT DRIVING MECHANISM yeu teow boven FMF EJFPM/FPE models} BX iit eed tow tc REAR DRIVING MECHANISM ED wg. wom vros ant tow | | parTERVcHARGING svsTEM SRE len nail ia icy IGNITION SYSTEM ED (as oe te recone te meee ve tw ELECTRIC STARTER gt | LIGHTS/METERS/SWITCHES E / ELECTRIC SHIFT PROGRAM _(ESP: TE/FE/FPE models / ELECTRIC POWER STEERING —— _ (EPS: FPMIFPE models} EI WIRING DIAGRAMS El “Tnoustesioomne ENGINE Sion? WF you dont know the source of the trouble, go to seston 26 | Ifyou are not fariar wth this woh, rad Tectia! Features in | “Teubleshootng. | CHASSIS. ELECTRICALSYMBOLS “The symbols used throughout this manual show specific service procedures. if supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. 2 Foplace the part(s) with new one(s) before assembly. :) Use the recommended engine oil, unless otherwise specified. Use molybdenum oll solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). Use molybdenum disuifide grease (containing more than 3% molybdenum disuifide, NGI #2 or equivalent) Example: Molykote® BR-2 plus manulactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan a Use mult-purpose grease (lithium based mult-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning US.A. AEX Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, UK. ocol Paste manufactured by Sumico Lubricant, Japan Aa Use silicone grease. Apply a locking agent. Use a medium strength locking agent unless otherwise specified. om sem Apply sealant. A Use DOT 4 brake ui Use the recommended brake uid uness otherwise spected Use fork or suspension fluid1. GENERAL INFORMATION SERVICE RULES ~ MODEL IDENTIFICATION GENERAL SPECIFICATIONS. LUBRICATION SYSTEM SPECIFICATIONS: FUEL SYSTEM (PGM-FI SPECIFICATIONS COOLING SYSTEM SPECIFICATIONS --- 112 CYLINDER HEAD/VALVE SPECIFICATIONS CYLINDER/PISTON SPECIFICATIONS 113 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS --- ALTERNATOR/STARTER CLUTCH ‘SPECIFICATIONS -. CRANKCASE/TRANSMISSION/CRANK- ‘SHAFT/BALANCER SPECIFICATIONS ---- FRONT WHEEL/SUSPENSION/STEERING essen 115, SPECIFICATIONS. REAR WHEEL/SUSPENSION ‘SPECIFICATIONS BRAKE SYSTEM SPECIFICATIONS ----- 1-15 FRONT DRIVING MECHANISM SPECIFICA- TIONS (FM/FE/FPM/FPE models) ------~ 1-15 REAR DRIVING MECHANISM ‘SPECIFICATIONS - “1-16 BATTERY/CHARGING SYSTEM ‘SPECIFICATIONS - 1-16 IGNITION SYSTEM SPECIFICATIONS - 1-16 ELECTRIC STARTER SPECIFICATIONS ---- LIGHTS/METERS/SWITCHES SPECIFICATIONS STANDARD TORQUE VALUES. ENGINE & FRAME TORQUE VALUES-~ 1-18 LUBRICATION & SEAL POINTS -~ 1:24 CABLE & HARNESS ROUTING (‘07 - 08 model} 1-28 CABLE & HARNESS ROUTING (After ‘08 model) “1-87 EMISSION CONTROL SYSTEMS «==+--- 1-71GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the vehicle. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the vehicle, Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly, After reassembly, check all parts for proper installation and operation. Route all electrical wires as shown in the Cable & Harness routing (page 1-28). ABBREVIATION Throughout this manual, the following abbreviation are used to identify the respective parts or systems. ‘bbrev. term CKP sensor ‘crankshaft Posi ico Uiquid Crystal Dic Data Link Connector — ore Diagnostic Trouble Code 4 PCM (TE/FEIFPE models) | Powertrain Control Module ~ ECM (TWEMIFPM mo: Engine Control Module ECT sensor Engine Coolant Temperature sensor “EEPROM Electicaly Erasable Programmable Read Only Memory EPS Electric Power Steeri oo ESP Electric Shift Program 1 Fuel Pump “Honda Diagnostic System Idle Air Control Valve Intake Air Temperature senor Manifold Absolute Pressure sensor ~ Malfunction Indicator Lamp Programmed Fuel Injection Vehicle Speed sensor [4 Wheel DriveGENERAL INFORMATION MODEL IDENTIFICATION ‘This manual covers 4 types of TRX420 models: + TM - 2WDiLeft foot operated gearshift ‘TE ~ 2WDiElectric shift program (ESP) FM - 4WDiLeft foot operated gearshift + FE~ aWDiElectric shift program (ESP) + FPM - 4WDiLeft foot operated gearshiftElectric Power Steering (EPS) ‘+ FPE —4WDiElectric shift program (ESP)/Electric Power Steering (EPS) (Co Be sure to refer to the procedure that pertains to the appropriate version of the TAX420 ‘TRX420FE model shown: © SERIAL NUMBERS ‘The Vehicle Identification Number (VIN) is stamped on the front side of [— the frame through the front fender.GENERAL INFORMATION The engine serial number is stamped on the left side of the rear erankease. ENGINE SERIAL NUMBER ‘The throttle body identification number is stamped on the upper side of the throttle body, ‘THROTTLE BODY IDENTIFICATION NUMBER LABELS ‘07: The name plate (U.S.A. type) or safety certification label (Canada type) is attached on the left front frame down pipe. NAME PLATE (U.S.A) SAFETY CERTIFICATION LABEL (Cenada) After ‘07: The name plate (U.S.A. type) or safety certification label ~ (Canada type) is attached on the right front frame down pipe. NAME PLATE (U.S.A,) ‘SAFETY CERTIFICATION LABEL (Canada)GENERAL INFORMATION ‘The color label is attached on the left frame pipe under the seat. When ordering color-coded parts, always specify the designated color code. ‘07: The vehicle emission control information label is attached on the right front frame pipe. “08: The vehicle emission control information label is attached on the left front frame pipe. After ‘08: The vehicle emission control information label is attached on the left front frame pipe. MISSION CONTROL INFORMATI El (ON LABEL USA. only: - 7 { EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION LABEL (Canada type only} ~ EMISSION CONTROL INFORMATION LABEL (U.S.A. and Canada types) EMISSION CONTROL INFORMATION LABEL (Canada type only)GENERAL INFORMATION GENERAL SPECIFICATIONS TRX420TM/TE DIMENSIONS FRAME ENGINE ew Overall iength Overall with Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Curb weight Maximum weight capacity Frame type Front suspension Front whee! travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Roar rim size Front tire brand. Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity ‘o7: After ‘07: Fuel tank reserve capacity ‘07: After ‘07: Cylinder arrangement Bore and stroke Displacement Compression ratio ‘07-08: After ‘08 Valve train Intake valve opens ‘07 ~ 08: After ‘08: closes ‘07 ~“08: After ‘08: Exhaustvaive opens ‘07 - 08: After ‘08: closes ‘07 ~ 08: After ‘08: Lubrication system il pump type Cooling system Air filtration Engine dry weight T™: Te: SPECIFICATIONS 2,055 mim (80.9 in} 4,172 mm (46.1 in} 4,148 mm (482 in} 1,256 mm (49.4 in) 847 mm (33.3 in) 880 mm (84.8 in) 823 mm (32.4 in} TM: 246 mm (13.6 in} TE: $86 mm {13.2 in) 165 mm (6.5in) TM: 248 kg (547 tbs) TE: 249 kg (549 Ibs) 220 kg (485 tbs) Double cradie Double wishbone 4160 mm (6.3in) Double tube Swingarm (w 160 mm (6.3in) Double tube AT24 x 8412 ++ AT24 x 10-11 + 12x80 AT 1c 75 AT MS77 (Maxxis) M978 (Maxxis) Hydraulic dise brake Mechanical drum brake 638° 25.1 mm (0.88 in) 2 1327 liters (3.62 US gal, 3.01 Imp gal) 133 liters (3.51 US gal, 293 Imp gal) 28 liters (0.74 US gal, 0.82 Imp gal) 26 liters (0.69 US gal, 0.57 Imp gal) Single cylinder, longitudinally installed 86.5 x71.5 mm (3.41 x 281 in) 420 om? (25.6 cu-in) 98:1 a9: ‘OHV 6° BTDC (at 1 mm lt) 7 BTDC (at 1 mm lift) 45° ABDC (at 1 mm lif) 32° ABDC (at 1 mm lif) 45° BBDC (at 1 mm lift) 35° ABDC (at 1 mm lif} 2 ATDC (at 1 mm lif) 4 ATDC (at 1 mm lif) Forced pressure and wet sump Trochoid Liquid cooled Oiled double urethane foam ing type) “07 ~ ‘08: 48.6 kg (1071 tbs) ‘After ‘08: 48.5 kg (106.9 Ibs) “07 ~ "08: 49.6 kg (109.3 lbs) ‘After ‘08: 49.5 kg (109.1 Ibs)GENERAL INFORMATION Tem ‘SPECIFICATIONS FUEL DELIVERY | Type PGM-Fl (Programmed Fuel Injection) SYSTEM Throttle bore 34mm (1.3 in) DRIVE TRAIN Clutch system Centrifugal and multi-plate, wet Clutch operation system Automatic Transmission Constant mesh, §-speeds with reverse Primary reduction 2.103 (61/29) Secondary reduction 1.818 (40/22) Final reduction 3,183 (41/13) © Gear ati, 1 Sesy tana) 2nd 2.235 (38/17) 3rd 1.871 (33/21) ath 1.178 (33/28) sth 0.848 (28/33) Reverse 4,831 (46/14 x 25/17) © Gearshift pattern R-N-1-2-3-4-5 TM: Lett foot operated return system TE: Electric shift (left hand operated) return sys- tem ELECTRICAL Tanition system Full transistorized ignition Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase full wave rectif Lighting system BatteryGENERAL INFORMATION ‘TRX420FM/FE eM srciricarions 1@ DIMENSIONS | Overall length 055 mm (605 in} Overall width 1,172 mm (46.1 in) Overall height 41/148 mm (48.1 in) Wheelbase 1/249 mm (49.2 in} Front troad ‘840 mm (33.1 in} Rear tread £880 mm (34.6 in} Seat height 822 mm (32.4 in) Footpeg height FM: 345 mm (13.6 in) FE: 395 mm (13.2) Ground clearance 165 mm (65 in} Curb weight FM: ‘07-08 USA. and Canada: 266 kg (586 Ibs) Alter 08 U.S.A. 265 kg (584 Ibs) Fe: ‘07 ~ 08: 267 kg (589 Ibs) ‘After '08: 265 kg (586 Ibs) Maximum weight capacity 220 kg (485 ibs) FRAME rame Doubie cradle Front suspension Double wishbone Front wheel travel 160 mm (63 in) Front damper Double tube Rear suspension ‘Swingarm (trailing type) Rear wheel travel 160 mm (6.3 in) Rear demper Double tube | Front tte size AT24 x 8-12 #4 Rear tre size ‘AT24 x 10-11 3 Front rim size 12x80 AT Rear rim size 11x75 AT From tire brand (M377 (Maxxis) Rear tire brand M978 (Maxxis) Front brake Hydraulic dise brake Rear brake Mechanical drum brake Caster angle 2 Trail length ‘07-08 | 9.5mmi0.37 in) After‘08: | 9 mm (11/32 in) ‘camber angle o Fuel tank capacity ‘0 137 liters (3.62 US gal, 3.01 Imp gal) Afer‘o7: | 13.3 liters (3.51 US gal, 2.93 imp gal) Fuel tank reserve capacity 07 28 lters (0.74 US gal, 0.62 Imp gal) | © _After‘07: _ | 2.6 ters (0.69 US gal, 0.57 Imp gal) _ ENGINE T igie cylinder, longitudinally installed Bore and stroke 86.5 x 71.5 mm (3.41 x 2.81 in) Displacement 420 cm? (25.6 cu-in) Compression ratio ‘7-08 =| ga: Alier‘0& =| 9.921 Valve train onV Intake valve opens. ‘07 6° BTDC (at 1 mm lift) After ‘08 7° BTDC (at 1 mm lit) closes ‘07 '08: 45° ABDC (at 1 mm lift) After ‘08: 32° ABDC (at 1 mm lift) Exhaustvalve opens ‘07 ~'08: 45° BBDC (at 1 mm lift) After‘08: 35° BBDC (at 1 mm lift) closes 2° ATDC (at 1 mm lift) 4 ATDC (at 1 min lft) Lubrication system Forced pressure and wet sump. Oil pump type Trochoid Cooling system Liquid cooled Air filtration Oiled double urethane foam Engine dry weight FM: “07 ~ ‘0B: 49.0 kg {108.0 Ibs) After ‘08: 48.9 kg (1078 tbs) Fe (07 ~ ‘08: 49.9 kg (110.0 Ibs) After ‘08: 49.8 kg (109.8 Ibs)GENERAL INFORMATION - Trem - SPECIFICATIONS FUEL DELIVERY Type PGM-F (Programmed Fuel injection) SYSTEM Throttle bore 34 mmm (13 in) DRIVE TRAIN Clutch system Centrifugal and mulicpiate, wet Clutch operation system ‘Automatic Transmission Constant mesh, 5-speeds with reverse | Primary reduction 2.103 (61/29) | Secondary reduction 1.818 (40/22) Final reduction Front 3.230 (42/13) | Rear 3.153 (41/13) | Gear ratio 4st 3.857 (54/14) 2nd 2.235 (98/17) ard 1571 (33721) ath 1.178 (33/28) sth 0,848 (2833) Reverse | 4,831 (46/14 x 26/17) Gearshift pattern R-N-1-2-3-4-5 FM: Left foot operated return system FE: Electric shift (left hand operated) return sys~ _ tem) ELECTRICAL Ignition system Full transistorized ignition Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase full wave rectification Lighting system BatteryGENERAL INFORMATION ‘TRX420FPM/FPE — SPECIFICATIONS @ DIMENSIONS Overall length 2,085 mm (80.9in) 7 Overall width 41,172 mm (46.1 in) Overall height 11146 mn (46.1 in) Wheelbase 1,249 mm (48.2 in) Front tread £840 mm (83.1 in} Rear read £880 mm (34.6 in} Seat height 822 mm (32.4 in} e Footpeg height FPM: 345 mm (13.6 in) FPE: 335 mm (13.2 in) Ground clearance 165 mm (65 in) : | Curb weight FPM U.S.A: 274 kg (604 Ibs) FPE and FPM Canada: 275 kg (606 Ibs) Maximum weight capacity 220 kg (485 lbs) FRAME Frame type 7 Double cradle a Front suspension Double wishbone Front whee! tavel 160 mm (6.3 in) Front damper Double tube Rear suspension Swingarm {trailing type) Rear whoel travel 160 mm (6.3 in) Rear damper Double tube Front tire size AT24 x 8-12 + Rear tire size AT24 x 10-11 Front rim size 12x6.0AT Rear rim size 11x75 AT Front tre brand M877 (Maxxis) Rear tire brand M978 (Maxxis) Front brake Hydraulic dise brake Rear brake Mechanical drum brake e Caster angle ¥ Trail length 8mm (11182 in) Camber angle o Fuel tank capacity 13,3 liters (3.51 US gal, 2.83 Imp gal) Fuel tank reserve capacity 2.6 liters (0.69 US gal, 0.57 Imp gal) - ENGINE Cylinder arrangement Single cylinder, longitudinally installed Bore and stroke 86.5 x 71.5 mm (3.41 x 2.81 in) Displacement 420 cm? (25.6 cu-in) Compression ratio 99:1 Valve train OHV Intake valve opens | 7° BTDC (at 1 mm if) closes | 32° ABDC (at 1 mm if) Exhaust valve opens 35° BBDC (at 1 mm lift) closes 4° ATDC (at 1 mm lif) il pump type Trochoid Cooling system Liquid cooted Air filtration Giled doubie urethane foam Engine dry weight FPM: 48.9 kg (1078 Ibs) FPE: 49.8 kg (108.8 ibs) —_ FUELDELIVERY | Type PGM-FI (Programmed Fuel injection) e SYSTEM Throttle bore 34mm (1.3in) 1-10DRIVE TRAIN ELECTRICAL TEM Clute system Clutch operation system Transmission Primary reduction Secondary reduction Final reduction Gear ratio Gearshift pattern Ignition system Starting system Charging system Rogulatorirectifier Lighting system Front Rear st and 3rd 4th 5th Reverse GENERAL INFORMATION ‘SPECIFICATIONS Centrifugal and multi-plate, wet ‘Automatic Constant mesh, §-speeds with reverse 2.103 (61/29) 1818 (40/22) 3,230 (42/13) 3,153 (41/13) 3.857 (54/14) 2.235 (98/17) 1571 (33/21) 1.178 (33/28) 0.848 (28/33) 4.831 (46/14 x 25/17) R-N-1-2-3-4-5 FPM: Left foot operated return system FPE: Electric shift (left hand operated) return system Full transistorized ignition Electric starter motor Triple phase output alternator SCR shorted, triple phase full wave rectification Battery 1-11GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ‘STANDARD ‘SERVICE LIMIT Engine oil capacity 27 liters (29 US qt, 2.4 Imp gi) = 2.8 liters (3.0 US qt. 25 Imp qt | 2.7 imp qt = 1 Recommended engine of e iI (US.A. and Canada) or equivalent motor oil AP service classification: SG or higher - ‘JASO T 803 standard: MA ___|_ Viscosity: SAE 10W-30 Oil pump [Tip clearance 0.15 (0.008) [0:20 70,008) [Body clearance (0.15 ~0.21 (0:00 - 0.008) 0.25 (0.010), Side clearance 0.02 0.09 (0.001 ~ 0.004) [0.11 (0.004) FUEL SYSTEM (PGM-Fl) SPECIFICATIONS ren sr erircarionss | "throte Body iaentifeation A Cale sp “Throttle lever feepiay - ‘mm (18 - 13 ia) T sensor resistance ( 22-2710 ECT sensor resistance (20-Ci6a"F) 23-2649 | Fuel injector resistance (20°Ci68"F ns- 1240 | Fuel pressure at ide | RS 387 ee BT pa | Fuel pump flow (at 12V)_ ~80.em*(L7 US oz, 18 Imp o2) minimurn/i0 seconds COOLING SYSTEM SPECIFICATIONS eM SPECIFICATIONS Ri 1B liters (1.6 US gt, 13 Imp qt) for a Reserve tank 0.3 liter (0.3 US qt, 0.3 Imp qt) Coolant cap: Radiator cap - C 408 = 137 kPa [1.1 - 14 kaffem?, 16 ~ 20 pai) Thermostat Beginto open 80 84°C (176-1 Fully open ___96°C (203°F) — Valve [ Bm (0.3 in) minimum at 95°C [20] Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ‘ethylene glycol antifreeze containing silicate-free |_corrosion inhibitors - TA mixture with distilled water lant concenivation — 1-12GENERAL INFORMATION CYLINDER HEAD/VALVE SPECIFICATIONS Unit: mm (in) O@- Tem ‘STANDARD SERVICE Limit ‘cylindar compression at 400 rpm 36.1 kgtiem’, 73 pail = Valve clearance iN eX "Valve, valve) Valve stem | “07-708 IN SAS (02151 guide oD. models EX 5.43 (0.214) ) Ater08 IN) 8975-59901 0 5.95 (0.234) models EX 5955 - 5 970(0.2344 - 0.2350) 5.93 (0.233) Valve "07 - 08 IN/EX 5.500 - 5.512 (0.2165 - 0.2170) 5.53 (0.218) guide LD. _models iNEX > 6000-6012 10.2362 0.2366) 60210.237) models Stem-to-guide clearance [IN 0.070-0.037 (0.0004 - 0.0015) 0:12 (0.008) © [EX 0.030- 0057 0.0012 = 0.0022) | 0.440.008) Valve guide projection IN/EX 15.0 - 15.2 (0.59 - 0.60) a = above cylinder nead Vaive seat width INEX 4.2 (0.05) 1510.06) Valve spring | Free length ’07 ~ '08 Inner 378 (1.49) 32.0 (1.46) | models | Outer 42.7 (1.68) 47.8 (165) ‘for ‘08 [Inner 42.98 (1.694) 42,08 11.657) models | “Outer 3.631.718) 42.76 (1.683) Recker arm Armi.D INEX | 12.000- 12.078 (04724-04731) 12.05 (0.474) Shat 0.0 INEX | 11.964 11.984 (0.4710 - 0.4718) 11.92 (0.489), “Arm-to-shaft clearance: INEX | 0.016 — 0.054 [0.0006 - 0.0021) 0.08 (0.003) Camshaft Cam lobe “07-08 IN 35.9400 ~ 36.1800 (1.41496 ~ 1.42441) 38.74 (1.407) and cam height models | EX | 356811 - 36.9211 (1.40476 141421) | 3548 (1.397) follower ‘After 08 IN 35.4723 ~ 36.7123 (139654 - 140599) | 35.27 (1.388) Ge | _____ models. EX_| 95.9009 ~ 36.5409 (1.38980 - 1.39925) | 36.10 (1.382) Cam follower 0.0. INEX | 22.467 - 22.482 (0.8845 - 0.8851) 22.46 (0.884) | Follower bore LD. INEX | 22.510 - 22.526 (0.8862 - 0.8868) 22.54 (0.887) Followerto-bore clearance | IN/EX 0,028 ~ 0,059 (0.0011 - 0.0023) 0.07 (0.003) cylinder head warpage = 0.100.008) CYLINDER/PISTON SPECIFICATIONS Unit: mm {in} —— STANDARD SERVICE LIMIT {36.500 = 86510 (3.4055 ~ 3.4059) 186.60 (3.409) - 0.10 (0.008) ~ - 0.10 (0.008) — 0.10 ( 186,470 — 86.490 (3.4043 - 3.4067) & Piston ©. at 16 (6) from bottom 86.42 (3.402) Piston pin hole 1D. 49.002 - 18.008 (0.7481 0.7483) 13.08 (0.750) piston ing Piston pin OD 48.984 = 18,000 (0.7478 0.7480) | 1898 (0.748) | Piston-to-piston pin clearance 0,002 - 0.014 (0.0001 - 0.0006) 0.08 (0.003) Piston tng end Geb |Top 0.15 0,90 (0006 - 0.012) 0350.02) Second 0:30=0.45 (0.0t2= 0018) 0610.02) Oil ei rai | 020 0.7010.008= 0.028) 8.910.08) @ oa vee te Se Groove carance’ | Second 9.030 =0.080 (0.0012 = 0.0074) 8.08 (0.004) | Cylinder-to-piston clearance 0.010 - 0.040 (0.0004 - 0.0016) 0.10 (0.004) Connecting rod small end LD. 19.020 - 19.041 (0.7488 - 0.7496) 79.07 (0.751) Connecting rod-to-piston pin clearance 0.020 - 0.047 (0.0008 - 0.0019) 0.10 (0.004) 1-13GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS Unit: mm (in) Fe STANDARD seavice um Contrfagal | ~Dram 0. TW0.0= 1402 (5.512 - 5.520] 140.4653) clutch Wieight ining thickness 2.00.08) - (0:08) Clutch spring height 3.8 (0.18) 368 (0.148) Clutch welght spring fee tength 24.65 (0970) 35.6 (1011 ‘Change cuieh Spring free length | TMIEMIFPM | 473 (1.88) 45.5 (1.60) TEREIFPE | 48.7 (1.52) 472 (1.86) e Die thiekness 262 = 2.76 (0.10=0.10N) 233 (0.09) Plate warpage - 0:20 0.008) Outer D, 78.000 29.009 (1.1417 = 1.1496) 29.05 (1144) | Outer guide 1: 72.000 = 2.021 (0.8661 - 0.8670) 22.05 (0,868) | OD. ‘28.959 — 28.980 (1.1401 - 1.1409) 28.93 (1.139) ] Mainshaft 0D. at clutch outer guide | 21967-71980 (0.9648 0.654) [7193 0.863) primary ae ee He ee iat— @ gear Crankshaft O.D. at drive gear ‘28.959 - 28.980 (1.1401 - 1.1409) 28.93 (1.139) ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unit: min) TEM STANDARD SERVICE LIMIT |" Starter driven gear boss OD 51706 =51718 (2.0366 - 2.0361) 51.69 (2.026) 1. 31946 = 31,962 (1.2677 - 1.2563) 3190 (1.266) Crankshaft OD. at starter driven gear 31.884 = 31,900 (1.7553 1.2559) 31.85 (1254) CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER SPECIFICATIONS oe a __unit: mm tin) TEM STANDARD SERVICE LIMIT SSE TorK 1D TS000=¥E.021 (05118 - 05128) 14040513). Claw thickness 4.93 - 5.00 (0.194 - 0.197) 45 (0.18) Shaft 0.0. 12.966 - 12.984 (0.5105 - 0.5112) 12.96 (0.510) Transmission Gear 1D. [ms 25.000 - 25.021 (0.9843 - 0.9851) 25.05 (0.986) Ms 20.000 - 20.021 (0.7874 - 0.7882) 20.06 (0.789), [ct c2, ca, CR 28.020 28.044 (1.1031 =1.1040) 78.07 (1.105) Reverse idle 13000-12021 (05118-05126) | 13.04 (0513) Gear busking Me 24.959 - 24,980 (0.9826 -0.9895) 24.93 (0.981) 00. Ms 19.966 - 19.984 (0.7861 - 0.7868) 9.940.785) a 77984 ~ 28,006 (1.1017 = 1.1026) 2798 (1.100) Ci, C4, CR 27975 28,000 (7.1015 - 1.1024) 27.93 (1.100) Gearto-bushing [M3 04020 = 0.062 (0.0008 - 0.0024) oxo(oooa | clearance Me 0.016 =0.056 (0.0006 = 0.0022) 0:10(0.004), @ 0,015 = 0.057 (0.0008 = 0.0022) 0,08 (0.008) C1, C4, CR | 6,020 0.062 (0.0008 - 0.0024) ——~|~0.10 10.004) Gear bushing LD. M3 72.000 22.001 (08661 - 0.8670) 22.04 (0.868) MB 17016 17034 (0.6609 - 0.6706) 1706 (0.672) | ca 25,000 ~ 25.021 (0.9843 - 0.9851) 25.08 (0.986) eG wamsnar oD. at 3 21.959 = 21980 (0.8645 - 0.8654) 2193 (0.869) at MS 16.876 - 16.987 (0.6683 - 0.6688) 16.98 (0.667) | Countershaft 0.0. at ca 24.959 — 24 980 (0.9826 - 0.9835) (24.93 (0.981) Reverse ide shaft O.. 2866 = 12.984 (0.5105= 0.5112) 12.9410.500) Bushing-to-shatt | NS 0,020 ~ 0.062 (0.0008 -0.0024) 0.100.004), clearance Ms 0,029 = 0.058 (0.0071 0.0028) 0:10 (0.008) ca or0(000) Reverse idle gear-to-shaft clearance 0.016 - 0.055 (0.0006 0.10 (0.004) Crankahaft | Runout a SA (0:15 (0.006) Big end side clearance 005-166 10002-0026) 08 (0.03) Big end radial clearance 0.006 - 0.018 (0.0002 - 0.0007) 0.05 (6.002) 1-14© c © GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ITEM Minimum tire tread depth Cold tire TMITEFMIFE | Standard I pressure [With cargo FPMIFPE Standard With cargo TMITE /FPMIFPE /Tie-rod distance between the ball joints Toe FMIFE/FPMIFPE | Toevin: 10 1510408) [“oe-out: 9+ 15 (0.40.8) Unit: mm (in) SERVICE LIMIT 4.0 (0.16) ‘STANDARD 25 KPa (0.25 kgiiem? 25 kPa (0.25 kafiem, 3.6 p 30 kPa (0.30 kaficm?, 4.4 psi) 30 kPa (0.30 kaficm’, 4.4 psi) 358.5 (14.1) 13.50) REAR WHEEL/SUSPENSION SPECIFICATIONS -_ ITEM (Minimum tire ivead depth Cold tire pressure ‘Standard With cargo BRAKE SYSTEM SPECIFICATIONS [ Tem Front brake Unit: mm (in) STANDARD ‘SERVICE LIMIT = 4.0 (0.16) 25 KPa (0.25 kgffom’, 3.6 psil - 25 kPa (0.25 kgffom', 3.6 psi) Unit: mm (in) ‘STANDARD SERVICE LIMIT Recommended brake fluid Honda DOT 4 brake fluid = Diso thicknoss 38-4.2(0.15-0.17) 3.0 (0.12), Dise runout = 0.30 (0.012) Master cylinder LD. 4.000 14.043 (0.5512 - 0.5525) 714.055 (0.5533) Master piston 0.0. 18.957 ~ 13.984 (0.5496 - 0.5508) 73.945 (0.5490) Caliper cylinder 1D, "32.030 ~ 32,080 (1.2610 - 1.2630) 32.090 (1.2634) Caliper piston 0.0. ‘31.984 — 31.998 (1.2578 — 1.2598) 31.94 (1.257) Drum LD. 160.0 - 160.2 (6.30 - 6.31) [161.0 (6.34) | Rear brake Shoe lining thickness 53 (021) ‘To index mark FRONT DRIVING MECHANISM SPECIFICATIONS (FM/FE/FPM/FPE models) Unit: mm fin} Cc —a— re STANDARD [SERVICE LIMIT Front final ‘capacity ‘After draining 230 cm® (78 US oz, 8.1 Imp oz) = drive ‘After disassembly 310 em? (10.5 US oz, 10.9 imp oz) = Recommended oi Hypoid gear oi, SAE #80 = Gear backlash 0,05 = 0.26 0.002 = 0.010) 0.4 (002) Backlash difference - 02 (001) Slip torque a= 17 Nem 148 = 178 Kah, 12Nm (12 10-13 thy kgm, § lot Face cam-to-housing distance 33-37 (013-018) 33013) Difereial rng geer depth 6.55 - 6.65 (0.258 - 0.262) 6.55 (0258) Cone spring free height 2800.1) 2.6 (0.10 1-15GENERAL INFORMATION REAR DRIVING MECHANISM SPECIFICATIONS ewe ‘Axle runout Rear final Oil capacity drive BATTERY/CHARGING SYSTEM SPECIFICATIONS Tem Capacity Current leakage — Voltage (2o'crearF) | Charging |_ current | Capacity Battery ‘Alternator [CARter disassembly _| Unit: mm (in) ‘STANDARD ‘After draining waa —| 0.2 (0.01) | ‘SPECIFICATIONS 12-12 Ah 0.01 mA max. Fully charged 130-132 Needs charging _ Below 12.3, ("Normal 14Ax5-10h ‘Quick 60Ax 10h “W343 WWE, 000 rom 359 KWES,000 rpm jer ‘08 models IGNITION SYSTEM SPECIFICATIONS Trem | Spark plug ‘Spark plug gap Ignition coil primary peak voltage Ignition pulse gener ignition timing (*F* mark) (20:Ci68°F) 01-100 ‘SPECIFICATION BKRSE-T1 (NGK), —| 1.01.1. mm 100 V minimum 0.7 V minimum 10° BTDC at idle ELECTRIC STARTER SPECIFICATIONS Unit: mm (in) em ‘STANDARD [SERVICE LiMiT ‘Starter motor brash lenath 72.0047) 65 (028) LIGHTS/METERS/SWITCHES SPECIFICATIONS ‘07 TM/FM and After ‘07 U.S.A. TM/FM models ITEM ‘SPECIFICATIONS Bulbs ~ Headlight (high/low beam) 12V- 3030 Wx 2 Braketailight LED Neutral indicator TaV.7W Reverse indicator Wav. W — Coolant temperature indicator 2 VA.7 W Mi 12Va.7 W @WD indicator (FM only) TaVATW Fuse Main fuse 320A ‘Sub-fuse —— WA TOAKS 1-16GENERAL INFORMATION TE/FE and After ‘07 Canada FM/FE models © eM SPECIFICATIONS ~ Bulbs ~ Headlight (high/fow bear) 12V- 30/30 Wx2 Brakertaillight Leo ‘Neutral indicator Leo LED indicator ted ted © ‘AWD indicator (FEIFM only) LED Meter tight —— Led Fuse Main fuse BOAx2 308 L Sub-fuse 15A,10Ax3 : FPM/FPE models © Tem SPECIFICATIONS Bulbs Headlight (hi 42V-30:30Wx2 Braketailight LED | Neutral Leo Reverse indicator LED — Coolant temperature indicator Leo ML Leo WD indicator LeD Meter light — : EPS indicator Fuse ‘Main fuse FPE PM. | Sub-fuse 15 A, 10AXx3 @! EPS fuse 40. 1-17GENERAL INFORMATION STANDARD TORQUE VALUES TORQUE FASTENER TYPE Nem (kgf-m, lb-ft) 5mm bolt and nut 5(0.5, 37) 6mm bolt and nut 10110, 7) 8mm bolt and nut 22 (2.2, 16) 10 mm bolt and nut 34 (35, 25) 12mm bolt and nut 545.5, 40) FASTENER TYPE 5mm screw & mm screw 6 mm flange bolt (8 mm head, small flange) 6 mm flange bolt (8 mm head, large flange) 6mm flange bolt (10 mm head) and nut 8 mm flange bolt and nut 10. mm flange bolt and nut ENGINE & FRAME TORQUE VALUES ‘© Torque specifications listed below are for important fasteners. + Others should be tightened to standard torque values listed above, ENGINE MAINTENANCE trem ‘Spark plug Valve adjusting lock nut Valve adjusting hole cap Timing hole cap Engine oll drain bolt FUEL SYSTEM Tem [Throttle body insulator band screw Throttle drum cover screw TP sensor/MAP sensor torx screw (T25) Wire harness clamp stay screw Fue! injector mounting bolt IACV torx screw (T20) ECT sensor Bank angle sensor mounting bolt CYLINDER HEAD/VALVE irem Cylinder Read aut Cam chain tensioner pivot bolt Exhaust pipe stud bolt 23+0.5mm (0.91 £0.02 in) CYLINDER/PISTON | imem | crankease stud bolt 1-18 THREAD DIA. (mm) 14 8 36 4 2 THREAD DIA. (mm) THREAD DIA. (mm) 10 6 8 THREAD DIA. (mm) 10 TORQUE Nem (kgf-m, Ibfft) 22 (22, 16) 1717.13) 1211.2, 9) 10 (10,7) 25 (25,18) TORQUE Nem (kaf-m, Ibftt) 18(0.18, 13) 3.4 (0.35, 2.5) 3.4 (0.35, 2.5) 5.1 (0.53, 38) 2.4 (0.21, 1.5) 12(1.2, 9) 15 (0.15, 1.41) TORQUE Nem (kgm, bt) 39 (4.0, 29) 12(12, 9) 6 (0.6, 44) ‘TORQUE Nem (kfm, Ibf-ft) 42(1.2, 9) TORQUE Nm (kgf, Ibtft) 410.4, 3.0) 910.9, 6.6) 10 (1.0, 7) 12(1.2,9) 12(1.2, 9) 27 (2.8, 20) 39 (4.0, 23) REMARKS REMARKS page 6-47 REMARKS ‘Apply engine oil Apply locking agent. REMARKS age 10-7CLUTCH/GEARSHIFT LINKAGE ( rem ‘Clutch spring bolt Centrifugal clutch lock nut Change clutch lock nut Shift drum stopper arm pivot bolt Gearshift cam bolt Gearshift spindle return spring pin Gearshift spindle A stopper bolt (TM/EMIFPM model only) ALTERNATOR/STARTER CLUTCH ITEM Starter cluteh Bort Flywheel bolt CKP sensor bott CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER, ITEM Mainshaft bearing setting bolt LIGHTS/METERS/SWITCHES © te Gear position sy ich wire clamp bolt arty a 1 arty 6 1 2 arty 2 aty 2 ELECTRIC SHIFT PROGRAM (ESP: TE/FE/FPE models) rem Shift angle sonsor bolt ony 2 GENERAL INFORMATION THREAD TORQUE DIA. (mm) _|_ Nim (kgm, Io) REMARKS 6 12112, 3} 20 118(720,87) Lock nut: replace with a new one. Apply engine oil Stake. 8 108 (110,80) | Lockrnut: replace with a new one Apply engine oil Stake 6 12(12,9) Apply locking agent 6 16(16, 12) | Apply locking agent. 8 22 (22,16) | Apply locking agent. 8 27 (28,20) Apply locking agent. THREAD TORQUE DIA, (mm) Nim (kfm, Ib) REMARKS 8 37(38,27) Apply locking 8 2 108 710,80) Apply engine ol 5 8108.44) Apply locking agont THREAD TORGUE DIA. (mm) __ Nim (kgm, It) REMARKS 5 12112,9) Apply locking agent THREAD TORQUE ] DIA. (mm) ___ Nim (kgm, Ibt A) REMARKS 6 1212, 9} Apply locking agent. | THREAD TORQUE DIA. (mm) | Nem (kgm, lb-ft) REMARKS 5 6106.44) Apply locking agant. 1-19GENERAL INFORMATION FRAME FRAME/BODY PANELS/EXHAUST SYSTEM ITEM ony REMARKS Rear carrier bolt 4] 54 (5.5, 40) dquo bracket nut 3 mia 20 Mur bane bot 2 Beam taster cover > Baa Zhou pipe ever band bot 3 202.15) Muller cover bend bet rom id) : : 2102.18) Muffler cover band bot ear sie) i Lab toss'2s | MAINTENANCE [ a eee THREAD” ‘TORQUE I eM QTY IA. (mm) (kgf.m, tbf-ft) ReManks | Fal goa ve a ar cap i 2 anes (FMUPERPINFPE on Fron nal gan ete rin bok 1 3 1212.9) (EMUrERPMFPE ony) Me Fad pour cues ak tt 1 8 22029) fan ben gear ease cr iercap 1 0 eae Rear final gear case oil drain bolt 1 8 12 (1.2, 9) Tie-rod lock nut (knuckle side} 2 12 54 (5.5, 40) Teed took tory read) 3 12 | Ealserao) | Lotmhand threads FueL syste rem or | ptORQUE | newanws [Throttle body cover bolt - i 5.2 (0.53, 38) - coun system Pp “THREAD TORQUE mem Oy | Statin) | Nemcgtn, or) | —_—_ REMARKS Cooling fan nut 1 5 2.7 (0.27, 2.0) Apply locking agent. Fanmatorbot 3 5 521083, 38) Fan motor stay bolt — 3 | 6 | 8aios6 62) ENGINE REMOVAL/INSTALLATION - — T _ TORQUE | : eM OY DIA. mm) | Nem (kgm, Ibe Keane Lower angina hangar mit To ard Hh z gates) Upper engine hanger nut (frame side) 1 10 =| 84(5.5, 40) Upper engine hanger bolt (engine side) 2 8 | 32 (3.3, 24) Genrehit pedal pinch bot i § 2018 (TM/FMIEPM only) 1-20© © FRONT WHEEL/SUSPENSION/STEERING ITEM [Throttle housing cover screw Front whee! nut Front whee! hub nut (TM/TE) Front wheel hub nut (FM/FE/FPM/FPE} Front brake dise bolt Splash guard bolt Shock absorber mounting nut | Upper and lower atm pivot nut Upper and lower arm ball joint nut Brake hose clamp bolt Tie-rod joint nut Steering shaft end nut Steering shaft holder bolt Steering shatt pinch bolt (FPM/FPE) EPS unit mounting nut (FPM/FPE) EPS motor mounting bolt (FPM/FPE) REAR WHEEL/SUSPENSION rem Rear wheat nut ‘Shock absorber upper mounting nut ‘Shock absorber lower mounting nut Universal joint guard bolt ‘Swingarm pivot nut oy 3 8 2 2 16 8 8 6 6 4 10 8 10 4 2 7 6 4 2 1 14 2 a 1 10 2 8 2 8 y THREAD QTY IA. (mm) 8 10 1 10 1 0 2 6 2 2 GENERAL INFORMATION “TORQUE ‘Nim (gt, IDF ft) SEMARNS 15(015,.) 6416.5, 47) 78 (8.0, 58) Castle nut: tighten to the specified torque and further tighten Until its grooves align with the cotter pin hole. 78 (8.0, 58) Castlo nut: tighten to the specified torque ‘and further tighten Until its grooves align with the cotter pin hole. 42 (43,31) ALOC bolt: replace with a new one. w1(14,8) ALOC bolt: raplace ‘with a new one. 30 (3.1, 22) Lock nut: replace with a new one 44 (48, 32) Lock nut: replace 29 (3.0, 21) Castle nut tightonto the specified torque land further tighten Until its grooves align with the cotter pin hole. 12(12,9) ALOC bolt: replace with a new one. 5455, 40) Lock aut: replace with a new one. 108(110,80) Lock nut replace with a new one. 32 (3.3, 24) 60 (6.1, 44), ‘ALOC bolt: replace ‘with a new one 22(2.2,18) 20120, 15) TORQUE Nim tkgfm,Ibf tt) REMARKS 4 (65, 47) 4a (45, 22) Lock nut: replace with a new one. 64 65, 47) Lock nut: replace with a new one. 10(10,7) ALOC bolt: replace ‘with a new one. 7918.1, 58) Lock nut: replace with a new one. 1-21GENERAL INFORMATION BRAKE SYSTEM 1 THREAD TORQUE rem QTY DIA. (mm)_|_ Nem (kgf, bf) REMARKS oe Brake hose oil bolt 3 jo} 34135, 25) Front brake caliper bleed valve 2 8 5.40.55, 40) Front master cylinder reservoir cap screw 2 4 210.2, 15) Ped pin 2 10 17112, 13) Pad pin plug 2 10 2.4 0.24, 18) Front brake lever pivot bolt 1 6 5.9 (0.60, 6.4) Front brake lever pivot nut 1 6 59 (0.60, 44} oe Front master cylinder holder bott 2 6 12(12,9) Front brake caliper mounting bolt 4 8 303.1, 22) ALOC bolt: replace with @ new one. Front brake caliper slide pin 2 8 22(2.2, 18) Apply locking agent. Front brake caliper bracket pin 2 8 17 (17,13) Rear brake arm pinch bolt 1 8 20(20,15) | @ Rear brake panel skid plate bolt 2 8 328.3, 24) ALOC bolt: replace with a new one. Rear wheel hub nut 2 20 187 (140,101) Castle nut:tightento the specified torque ‘and further tighten until its grooves align with the cotter pin hole, Rear brake panel drain bolt 1 8 12(1.2,9) Brake pipe joint bolt Ja 10 14(1.4,10) FRONT DRIVING MECHANISM (FM/FE/FPM/FPE models) . THREAD ‘TORQUE Gen CTY DIA. (mm) Nim (kgf, lott) REMARKS Front final gear pinion bearing lock nut 7 64 98(10.0,72) Lock nut replace with a new one @ Stake. Differential ring goar bolt 10 8 49 5.0, 36) ALOC bolt: replace with a new one. Front final gear caso cover bolt 2 10 47 (48, 35) Apply locking agent, 4 8 25 (25, 18) Front final clutch shit fork bolt 1 6 10 (10,7) ALOC bolt: replace with a new one Front final clutch housing bolt 3 8 25 (25, 18) Front final gear case mounting bolt 1 10 44 (45, 32) Front final gear case mounting nut 1 10 44/45, 32) Lock nut: replace with a new one. AWD select switch fa 10 12(12,9) Final clutch arm cover bolt | 3 6 10 (1.0, 7), REAR DRIVING MECHANISM THREAD TORQUE Ren OY DIA. (mm)_|_ Nim ikghm,IbFt) REMARES oar final goar pinion bearing lock rut 7 64 98 (10.0,72) Lock nut: replace with a new one. Stake. Rear final gear case cover bolt 2 10 47 (4.8, 35) Apply locking agent. 6 8 25 (25, 18) Rear final gear case’brake panel mounting 2 10 44 145, 32) Lock nut: replace nut with a new one. Final gear case skid plate bolt 3 8 3218.3, 24) ALOC bolt: replace with a new one. ‘Axle nut (inner) 2 32 39 (4.0, 29) Apply locking agent. ‘Axle lock nut (outer) 2 32 127 (13.0, 94) 1-22GENERAL INFORMATION LIGHTS/METERS/SWITCHES . THREAD TORQUE @ irew QTY DIA. (mm) Nem (kgfm, Ibf ft) FEMAAKS Faar brake lever pivot bolt 7 6 70(10,0.7) Rear brake lever pivot nut 1 8 10(10,0.2) Porking brake lever pivot screw 1 4 6. (0.70, 0.5.1) Brake light switch screw (rear brake lever 1 4 412 (0.12, 0) bracket) Front brake lightinhibitor switch serew 1 4 12(0.12,09) | Apply locking agent. © 1-23GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE [ MATERIAL) LOCATION — _ REMARKS | Molybdenum oil solution Camshaft cam lobes (a mixture of 1/2 engine | Rocker arm shaft sliding surface Gil and 1/2 molybdenum | Valve stem (valve guide sliding surface) disulfide grease) Change clutch outer guide inner and outer surfaces Crankshaft starter driven gear sliding surfeces | Piston pin outer surface Starter reduction gear shaft whole surface Water pump shaft journal Mainshaft gear and bushing sliding surfaces Countershaft gear and bushing sliding surfaces ft end Engine ol cover Rocker arm followers and adjusting screw Cam chain whole surfaces Cam follower whole surfaces Cylinder head nut threads and seating surfaces Connecting rod small end inner surface Piston outer surface and piston pin hole Piston ring whole surfaces Cylinder bore Clutch adjusting plate boss outer surface Change clutch disc lining whole surfaces Change clutch lock nut threads and seating surface Centrifugal clutch drum sprag clutch contacting surface Centrifugal clutch drive plate sprag clutch contacting surface Centrifugal clutch lock nut threads and seating surfa Starter reduction gear teeth Reverse stopper shaft journal surface Flywheel bolt threads Starter sprag clutch whole surface Mainshaft and countershaft journal surfaces Shift fork shaft whole surface Shift drum grooves Collar and bushing journal surfaces Each bearing rotating area Each O-ring whole surface Each oil seal lip 1-24© © © | Cocking agent Liquid sealant — Templex N3 grease (ESSO) ‘Cam chain tensioner lifter boit threads ‘Cam chain tensioner pivot bolt threads ‘Camshaft bearing setting plate bolt thr ds Shift drum stopper arm pivot bolt threads Gearshift cam bolt threads Gearshift spindle return spring pin threads Gearshift spindle A stopper bolt threads Starter clutch bolt threads CKP sensor bolt threads Mainshaft bearing setting bolt threads Gear position switch retaining bolt threads Gear position switch wire clamp bolt threads Shift angle sensor bolt threads Front crankcase cover mating surface Alternator/CKP sensor wire grommet seating surface Gear position switch wire grommet seating surface Roar crankcase cover mating surface Crankease mating surface Reduction gear cover mating surface Electric shift reduction gear teeth and journals (front crankcase cover) GENERAL INFORMATION ___ REMARKS Coating width: 6.5 =T mm (0.26 + 0.04 in} Coating width: 6 +1 mm (0.26 + 0.04 in} Coating width: 5-8 mm (0.20 £0.31 in} Coating width: 65 2 2 mm (0.26 0.08 in} Coating width: 65 = 1 mm (0.26 + 0.04 in) Coating width: 6. (0.26 + 0.04 in) Coating width: 6.5 £1 mm (026+ 0.04in) Coating width: 6.5 £1 mm (0.26 £0.04 in) Coating wieth: 6: 1 mm (0.24 £0.04 in) Coating width: 65 «1 mm {0.26 £0.04 in} Coating width: 65 + 1 mm (0.26 £0.04 in} Coating width: 65 + 1 mm (0.26 + 0.04 in} TE/FE/FPE only Costing width 5 +1 mm (0.20 +0.04 in) page 11-23, page 12-6 page 22-15 page 127 page 1321 TEIFEIFPE only page 23:34 TE/FEIFPE only 2-49 page 23.33, 1mm 1-25GENERAL INFORMATION FRAME MATERIAL — Location Multi-purpose grease Throttle cable end (lever side) Throttle cable outer threads (each end) Throttle lover pivot and dust seal lip Rear (parking) brake lever pivot Parking arm pin Knuckle inner and outer dust seal ips FA/FE/FPMVFPE only 25-39 per each seal Front whee! hub inner and outer dust seal lips TMVTE only Steering shaft bushing sliding surface 2-39 Steering shaft dust seal lips Rear brake cam dust seal lips ear brake cam spindle 02-039 Rear brake cam shoe contacting surfaces 02-039 Rear brake panel anchor pin shoe contacting surfaces | 02-039 Rear brake drum cover dust seal ips 3-49 Fear brake drum seal ring Fear brake panel O-ring Fear brake panel dust seal lips Rear brake pedal pivot Rear brake pedal pivot dust seal lips Rear brake cable ends (lever and pedal side) Front final gear case oil seal lips (for drive shafts) FM/FE/FPMUFPE only Front final gear case cover O-ring FM/FE/FPMVFPE only Front final gear cil filler cap O-ring FM/FE/FPMVFPE only Front final clutch arm shaft oll se FM/FE/FPMVFPE only Front final clutch arm shaft O-ring FM/FE/FPMVFPE only Front final clutch arm shaft outer surface FM/FE/FPMVFPE only Front final clutch joint oll seal ips FM/FE/FPMIFPE only Front final clutch ease O-ring FMIFE/FPMUFPE only Fear final gear case oil sea lips (for propeller shatt) Fear final gear case oil sea lips (or ring gear| Loft side: 25-39 | Rear final gear case O-ring (axle housing side) Rear final gear ol filler cap O-ring Molybdenum disulfide Front drive shaft splines (wheel side) FW/FEIFPMIFPE only grease Front shock absorber lower pivot bushing and dust seal lips Steering shaft spline TMTE/FMIFE only EPS unit output shaft spline FPMIFPE only Rear shock absorber lowor pivot bushing and dust seal lips Swingarm pivot bearing Swingarm pivot dust seal lips Front propeller shaft boot lip FM/FE/FPMFPE only Front propeller shaft oint spines (both sides) EMIFE/FPM/FPE only Propellar shat side: 5-8 g Front fine! clutch pinion joint splines FMIFEIFPMIFPE only 5-89 Front propeller shaft end {final clutch joint contacting | FMIFE/FPM/FPE only area) Universal joint splines (both sides) eer propelier shaft splines (gear case side) Output shaft O-ring Rear propelier shaft O-ring Rear axle splines NKG708 [Kyodo Vushi) Front drive sha outboard joint inside FMIFEIRPMIFPE only 30-509 FIMIFE/FPM/FPE only 40-609 Front drive shaft inboard joint inside 1-26© © ‘Tiguid sealant MATERIAL Honda Bond A or Pro Honda Handarip Coment, (US.A. only} or equiva lent (Engine of Silicone grease DOT 4 brake fluid WR:S [Nippon Grease) Cable lubricant GENERAL INFORMATION LOCATION REMARKS __| Handlebar grip rubber inside Air cleaner housing-to-connecting tube mating area Air cleaner housing-to-duct tube mating area Air cleaner housing-to-IAT sensor grommet mating area Air cleaner housing breather hose joint grommet mat- 19 areas (inner and outer surfaces) Rear brake cam felt seal a EPS motor O-ring FPMIFPE only Front brake lever-to-master piston contacting area Front brake laver pivot Front brake caliper piston boot inside Front brake caliper slide pin groove Front brake caliper bracket pin boot inside Brake master cylinder piston and cups Brake caliper piston and piston seal EPS unit worm gear splines 05 FPMIFPE only Throttle inner cable Rear brake inner cables 2WD/AWD selector inner cable FMIFEIFPMIFPE only Rear final gear case cover mating surface Cooling fan nut threads Front brake caliper slide pin Front final gear case cover 10 mm bolt Rear final gear case cover 10 mm bolt Rear axle nut Rear axle lock nut Front brake lightiinhibitor switch screw 1-27GENERAL INFORMATION CABLE & HARNESS ROUTING (‘07 - ‘08 model) All models: THROTTLE REAR (PARKING) CABLE BRAKE CABLE FRONT BRAKE HOSE wires. a HANDLEBAR ‘SWITCH WIRE BAND (Secure at blue tape position) \ 07 TMIFM and ‘08 U.S.A. TM/FM: INDICATOR WIRE ‘TE/FE and ‘08 Canada TM/FM: METER WIRE WIRE GUIDE IGNITION HANDLEBAR SWITCH WIRE SWITCH WIRE 1-28GENERAL INFORMATION ‘TE/FE and ‘08 Canada TM/FM: REAR BRAKE LIGHT SWITCH (Lever Side} FRONT BRAKE SWITCH for starting inhibitor) GRAY TAPE FUEL TANK BREATHER HOSE FRONT BRAKE UGHT SWITCH COMBINATION METER IGNITION SWITCH BREATHER HOSE HOLDER (Equipped with meter) HANDLEBAR SWITCH WIRE METER WIRE 1-29GENERAL INFORMATION "07 TM/FM and ‘08 U.S.A. TM/FM: REAR BRAKE LIGHT ‘SWITCH (Lever Side) FRONT BRAKE SWITCH (for starting inhibitor) FUEL TANK BREATHER HOSE FRONT BRAKE NEUTRAL LIGHT SWITCH INDICATOR, REVERSE ENGINE COOLANT INDICATOR, ‘TEMPERATURE INDICATOR ieienon swaren IG ) A Co) exp mpycaTon front BREATHER HOSE HOLDER (Equipped with cover) HANDLEBAR SWITCH WIRE INDICATOR WIRE 1-30GENERAL INFORMATION All model REVERSE OPTIONAL 2° CONNECTOR © Werner Sout SELECTOR caste REAR (PARKING) BRAKE CABLE HANDLEBAR ‘SWITCH WIRE IGNITION ‘THROTTLE CABLE SWITCH WIRE ‘07 TMFM and ‘08 US.A. ‘TMVEM: INDICATOR WIRE TE/FE and ‘08 Canada TM/ (e: FM: METER WIRE HEADLIGHT WIRE COOLANT HOSE RADIATOR SIPHON HOSE +07 TW/FM and ‘08 U.S.A. IGNITION SWITCH WIRE ‘TMM: INDICATOR WIRE ‘TEIFE ‘08 Canada TWVFM: METER WIRE HANDLEBAR SWITCH WIRE 07 TW/FM and ‘08 U.S.A.TM/FM: INDICATOR 10P GRAY CONNECTOR ‘TE/FE ‘08 Canada TM/FM: METER 8? GRAY CONNECTOR FAN MOTOR 2P CONNECTOR > S— AWD SELECT SWITCH ot WIRE (FMIFE only) « TMIFM: HANDLEBAR SWITCH 10P GREEN CONNECTOR IGNITION SWITCH TEIFE: HANOLEBAR SwiTcH 4? WHITE CONNECTOR 14P GREEN CONNECTOR 1-31GENERAL INFORMATION ‘All models: © COOLANT HOSE HEADLIGHT 3P BLACK CONNECTOR: Reverse side of radiator: Y\ [T PAINT MARK \we 4WD SELECT SWITCH FAN MOTOR WIRE (FM/FE only) BREATHER HOSE COOLANT HOSE 1-32GENERAL INFORMATION All models: BRAKE PIPE BRAKE HOSE 2s sevect swmen WIRE (FM/FE only) FRONT FINAL GEAR CASE BREATHER HOSE (FM/FE only) BREATHER HOSE (FM/FE only) 7+ FRONT FINAL GEAR CASE WD SELECT SWITCH ———"~ (FMIFE only) i 1-33GENERAL INFORMATION ‘All models: Inside of front fender: GROOVE HEADLIGHT WIRE GROOVE | FRONT BRAKE HOSE RUBBER MOUNT 1-34GENERAL INFORMATION elie © monet Hose coousnr Hose —* © FRONT BRAKE HOSE | PAINT MARK ) STOPPER RIGHT FRONT BRAKE CALIPER FRONT BRAKE HOSE STOPPER LEFT FRONT BRAKE CALIPER 1-35GENERAL INFORMATION All models: FUEL TANK VAPOR HOSE (From fuel tank) FUEL TANK VAPOR HOSE nt sic FuetFeeDHose \ eyes pump wiRE Front side FUEL HOSE FUEL HOSE (From fuel tank) ECT SENSOR WIRE THROTTLE CABLE = REVERSE SELECTOR CABLE REAR (PARKING) \ BRAKE CABLE FRONT FINAL GEAR CASE BREATHER HOSE (FMIFE only) FAN MOTOR BREATHER, HOSE (Pink) FRONT FINAL GEAR CASE BREATHER HOSE (FIFE only) FAN MOTOR S BREATHER HOSE (Pink) THROTTLE CABLE REAR FINAL GEAR CASE BREATHER HOSE HEAT GUARD PLATE REVERSE SELECTOR \ CABLE T J \ REAR (PARKING) \ BRAKE CABLE REAR BRAKE PANEL BREATHER HOSE SIPHON HOSE MAIN WIRE HARNESS 1-36 o e o e o eoGENERAL INFORMATION ‘SHIFT CONTROL MOTOR WIRE (TE/FE only) oO WATER PUMP BREATHER HOSE FRONT FINAL GEAR CASE BREATHER HOSE (FMIFE only) MAIN WIRE HARNESS FUEL TANK VAPOR HOSE SHIFTCONTROL MOTOR WIRE (TEIFE only) FUEL PUMP WIRE FUELHOSE = FUEL FEED HOSE FRONT FINAL GEAR CASE FAN MOTOR BREATHER BREATHER HOSE (FM/FE only] HOSE (Pink) 1-37GENERAL INFORMATION “08: Be Clamp tab position PAINT MARK 0-3mm {0-0.12in) ™~ey If // FUEL TANK PAINT MARK 0-3mm Clamp tab position (0~0.12 in) FUEL VALVE FUEL VALVE 0-5mm FuELHose = fom FUELTANK VAPOR HOSE 0-10mm (0 -0.39 in) 1-38GENERAL INFORMATION All models: FUEL FEED HOSE © EE + tesensow | 8 MAPSENSOR 7 | sankanclesenson _THRoTTLe BaDy Segre CONNECTOR aN MorOR INTAKE AIR DUCT REAR FINAL GEAR BRUATHER HOSE Pin Case entaiea Hose \ \ \ e ) i Greenvyellow © THROTTLE CABLE © 1-39GENERAL INFORMATION ‘eodets Up SPARK PLUG WIRE ) INSULATOR CONNECTING BANDS, TUBE BANDS ‘THROTTLE BODY BANK ANGLE SENSOR 1-40GENERAL INFORMATION ‘All models: ‘TE/FE: SHIFT ANGLE SENSORWVS SENSOR 6? CONNECTOR GEAR POSITION SWITCH "08 Canada TM/FM: VS SENSOR 6P CONNECTOR © 8P GRAY CONNECTOR GROUND POINT REAR (PARKING) BRAKE CABLE © FRAME BATTERY +I CABLE ALTERNATOR SPCONNECTOR — REVERSE SELECTOR STARTER MOTOR CABLE CABLE REAR FINAL GEAR CASE REAR BRAKE PANEL © STARTER MOTOR CABLE BREATHER HOSE BREATHER HOSE REAR BRAKE LIGHT SWITCH BATTERY [-) CABLE 2P BLACK CONNECTOR, REAR FINAL GEAR CASE BREATHER HOSE SIPHON HOSE REVERSE SELECTOR CABLE REAR BRAKE PANEL BREATHER HOSE BATTERY (-) CABLE STARTER MOTOR CABLE \ov REVERSE SELECTOR sranrér SO ever MOTOR STARTER MOTOR CABLE CO rere: suier ance GROUND CABLE engin to-ame) ‘SENSOR/VS SENSOR WIRE BATTERY (-) CABLE “08 Canada TM/FM: GEAR POSITION SWITCH WIRE VS SENSOR WIRE ALTERNATOR WIRE 1-41GENERAL INFORMATION ‘Al models TE/FE: SHIFT ANGLE SENSORVVS SENSOR WIRE Teaaer nse SeERRae ie e STARTER MOTOR CABLE GROUND CABLE fenginetosrame) GEAR POSITION SWITCH Wine BATTERY -) CABLE ‘ eo \\ Z> Vs SENSOR ALTERNATOR WIRE (TE/FE and ‘08 Canada TWFM) (CABLE GEAR POSITION - SWITCH WIRE cy oe CLAMP (TEIFE and ‘SHIFT ANGLE SENSOR "08 Canada TW/FM) (TE/FE only) 08 Canada TMM: —) | [Mad AVE | WE st iL VS SENSOR (TE/FE only) 1-42GENERAL INFORMATION PEDAL RETURN SPRING BRAKE LIGHT SWITCH SPRING REAR BRAKE LIGHT SWITCH Spring installation direction © BRAKE PEDAL,MAIN WIRE MAINWIRE SUB WIRE HARNESS SUB-WIRE HARNESS HARNESS HARNESS ‘STARTER MOTOR CABLE REAR FENDER SUB.WIRE HARNESS \ \2\\ ‘14P GRAY CONNECTOR a \ BATTERY (-) CABLE BATTERY RADIATOR RESERVE TANK BREATHER HOSE ( (dF [AL T NESS Owen a od mus lr NS REGULATOR/RECTIFIER,GENERAL INFORMATION MAIN FUSE 2P CONNECTOR TAILLIGHT 3 CONNECTOR STARTER RELAY SWITCH 2P GREEN CONNECTOR REAR FENDER ‘SUB-WIRE HARNESS DATA LINK CONNECTOR (DLC); 4P (Red) MAINWIRE STARTER MOTOR CABLE HARNESS TEIFE: PCM. PCMECM 33 BLACK CONNECTOR TMIEMEECM PCMECM 33P PCMECM 5P BLACK GRAY CONNECTOR CONNECTOR ‘STARTER RELAY SWITCH RELAY MODULE &P CONNECTOR 1-45