honda trx 500 parts
TRANSCRIPT
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PARTS CATALOG
TRX500FA’01•’02•’03•’04FOURTRAX RUBICON
TRX500FGA’04FOURTRAX RUBICON
JULY, 200
American Honda Motor Co., Inc. 14HN21E1M (Fiche Version
2003 American Honda Motor Co., Inc., 14HN21E1P (Paper Version(Order through Helm)
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TABLE OF CONTENTS
JULY, 2003 2003 American Honda Motor Co., Inc.
Introduction Grid / Page• HOW TO USE THIS CATALOG .................................... A2 4
• LOCATION OF SERIAL NUMBER ................................ A2 5
• SERIAL NUMBERS ...................................................... A3 7
• CONSTRUCTION OF VEHICLE IDENTIFICATIONNUMBER ................................................................ A4 8
• COLOR TABLE .............................................................. A4 9
• BULK HOSE PART NUMBER PATTERN...................... A7 14
• MASTER INDEX ............................................................ A8 16
Part Groups
• ENGINE SECTION ........................................................ 1-C1 1-1
• FRAME SECTION.......................................................... 1-E1 2-1
Index
• PART NUMBER INDEX ................................................ B1 3-1
• DESCRIPTION INDEX .................................................. 1-H1 4-1
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HOW TO USE THIS CATALOG
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LOCATION OF SERIAL NUMBER
JULY, 2003 2003 American Honda Motor Co., Inc. 5
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LOCATION OF SERIAL NUMBER
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SERIAL NUMBERS
JULY, 2003 2003 American Honda Motor Co., Inc. 7
Models and applicable serial numbers
Models and applicable serial numbers given in this parts catalog can be identified as follows.
TRX500FA DOES NOT HAVE GPS NAVIGATION.
TRX500FGA HAS GPS NAVIGATION.
Engine Frame Carburetor
Area Serial Serial Serial
Model Code No. No. No.
TRX500FA’01 A TE26E-8000001 TO
8099999
478TE260*14000001 TO
14099999
VE6AB A
TRX500FA’02 A TE26E-8000001 TO
8099999
478TE260*24100001 TO
24199999
VE6AB B
TRX500FA’03 A TE26E-8100001 TO
8199999
478TE260*34200001 TO
34299999
VE6AB B
TRX500FA’04 A TE26E-8200001~ 478TE260*44300001~ VE6AC A
TRX500FGA’04 A TE26E-8200001~ 478TE264*44300001~ VE6AC A
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CONSTRUCTION OF VEHICLE IDENTIFICATION NUMBER
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COLOR TABLE
JULY, 2003 2003 American Honda Motor Co., Inc. 9
When ordering a colored part:
1. Confirm the color code for the required part from the color table according to the part name and color type.
2. Select the corresponding part number from the appropriate PAGE/GRID.
3. Parts marked "X" are unused.
4. "*" = Basic Part Number, no extension (i.e. ZA, ZB).
TRX500FA’01 2001
No.
COLOR CODE
BASE COLOR
R232
Patriot red
R232
G152
Adventure
green
G152
A
RE
A
DESCRIPTION BASIC PART NO.
1 CAP, HANDLE COVER 53206-HM8-000 ZA ZA
2 CASE, ASSIST HEADLIGHT
(LOWER)
61302-HN0-A00 ZA ZA
3 CASE, ASSIST HEADLIGHT
(UPPER)
61301-HN0-A00 ZC ZC
4 COVER ASSY., L. ENGINE SIDE 11325-HN2-000 ZA ZA
5 COVER ASSY., L. TANK SIDE
(WOL)
83650-HN2-000 ZA ZA
6 COVER ASSY., R. ENGINE SIDE 11315-HN2-000 ZA ZA
7 COVER ASSY., R. TANK SIDE
(WOL)
83550-HN2-000 ZA ZA
8 COVER, BATTERY BOX 80311-HN2-000 ZB ZA
9 COVER, FUEL TANK TOP 83700-HN2-000 ZA ZA
10 COVER, HANDLE 53205-HN2-000 ZA ZA
11 COVER, R. ENGINE SUB 80123-HN2-000 ZA ZA
12 COVER, R. SIDE 83800-HN2-000 ZC ZC
13 EMBLEM, L. FUEL TANK 87122-HN2-000 ZA ZB
14 EMBLEM, R. FUEL TANK 87121-HN2-000 ZA ZB
15 FENDER, FR. (WOL) 61100-HN2-000 ZB ZA16 FENDER, RR. (WOL) 80100-HN2-000 ZB ZA
17 GRILLE, FR. 66300-HN2-000 ZA ZA
18 GUARD, FR. PIPE 81170-HN2-000 ZA ZA
19 LABEL, COLOR 87565-HN2-000 ZA ZB
20 LEVER, PETCOCK 16963-HM8-000 ZA ZA
21 LID, RADIATOR CAP 61110-HN2-000 ZB ZA
22 LID, TOOL BOX 80211-HN2-000 ZB ZA
23 MARK, FR. FENDER 87124-HN2-000 ZA ZB
24 MARK, HONDAMATIC 87128-HN2-000 ZA ZB
25 MARK, RR. FENDER 87126-HN0-A60 ZE ZH
26 MUDGUARD, L. CENTER 80122-HN2-000 ZA ZA27 MUDGUARD, L. FR. (LOWER) 61867-HN2-000 ZA ZA
28 MUDGUARD, L. FR. SIDE 61866-HN2-000 ZA ZA
29 MUDGUARD, L. RR. SIDE 80221-HN2-000 ZA ZA
30 MUDGUARD, R. CENTER 80121-HN2-000 ZA ZA
31 MUDGUARD, R. FR. (LOWER) 61862-HN2-000 ZA ZA
32 MUDGUARD, R. FR. SIDE 61861-HN2-000 ZA ZA
33 MUDGUARD, R. RR. SIDE 80220-HN2-000 ZA ZA
34 SEAT 77100-HN2-000 ZA ZA
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COLOR TABLE
10 2003 American Honda Motor Co., Inc. JULY, 2003
When ordering a colored part:
1. Confirm the color code for the required part from the color table according to the part name and color type.
2. Select the corresponding part number from the appropriate PAGE/GRID.
3. Parts marked "X" are unused.
4. "*" = Basic Part Number, no extension (i.e. ZA, ZB).
TRX500FA’02 2002
No.
COLOR CODE
BASE COLOR
R232
Patriot red
R232
G152
Adventure
green
G152
Y151
Starburst
yellow
Y151R
A
RE
A
DESCRIPTION BASIC PART NO.
1 CAP, HANDLE COVER 53206-HM8-000 ZA ZA ZA
2 CASE, ASSIST HEADLIGHT
(LOWER)
61302-HN0-A00 ZA ZA ZA
3 CASE, ASSIST HEADLIGHT
(UPPER)
61301-HN0-A00 ZC ZC ZC
4 COVER ASSY., L. ENGINE SIDE 11325-HN2-000 ZA ZA ZA
5 COVER ASSY., L. TANK SIDE
(WOL)
83650-HN2-000 ZA ZA ZA
6 COVER ASSY., R. ENGINE SIDE 11315-HN2-000 ZA ZA ZA
7 COVER ASSY., R. TANK SIDE
(WOL)
83550-HN2-000 ZA ZA ZA
8 COVER, BATTERY BOX 80311-HN2-000 ZB ZA ZC
9 COVER, FUEL TANK TOP 83700-HN2-000 ZA ZA ZA
10 COVER, HANDLE 53205-HN2-000 ZA ZA ZA
11 COVER, R. ENGINE SUB 80123-HN2-000 ZA ZA ZA
12 COVER, R. SIDE 83800-HN2-000 ZC ZC ZC
13 EMBLEM, L. FUEL TANK 87122-HN2-680 ZA ZB ZC
14 EMBLEM, R. FUEL TANK 87121-HN2-680 ZA ZB ZC
15 FENDER, FR. (WOL) 61100-HN2-000 ZB ZA ZC16 FENDER, RR. (WOL) 80100-HN2-000 ZB ZA ZC
17 GRILLE, FR. 66300-HN2-000 ZA ZA ZA
18 GUARD, FR. PIPE 81170-HN2-000 ZA ZA ZA
19 LABEL, COLOR 87565-HN2-680 ZA ZB ZC
20 LEVER, PETCOCK 16963-HM8-000 ZA ZA ZA
21 LID, RADIATOR CAP 61110-HN2-000 ZB ZA ZC
22 LID, TOOL BOX 80211-HN2-000 ZB ZA ZC
23 MARK, FR. FENDER 87124-HN2-680 ZA ZB ZC
24 MARK, HONDAMATIC 87128-HN2-680 ZA ZB ZC
25 MARK, RR. FENDER 87126-HN0-A60 ZE ZH ZF
26 MUDGUARD, L. CENTER 80122-HN2-000 ZA ZA ZA27 MUDGUARD, L. FR. (LOWER) 61867-HN2-000 ZA ZA ZA
28 MUDGUARD, L. FR. SIDE 61866-HN2-000 ZA ZA ZA
29 MUDGUARD, L. RR. SIDE 80221-HN2-000 ZA ZA ZA
30 MUDGUARD, R. CENTER 80121-HN2-000 ZA ZA ZA
31 MUDGUARD, R. FR. (LOWER) 61862-HN2-000 ZA ZA ZA
32 MUDGUARD, R. FR. SIDE 61861-HN2-000 ZA ZA ZA
33 MUDGUARD, R. RR. SIDE 80220-HN2-000 ZA ZA ZA
34 SEAT 77100-HN2-000 ZA ZA ZA
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COLOR TABLE
JULY, 2003 2003 American Honda Motor Co., Inc. 11
When ordering a colored part:
1. Confirm the color code for the required part from the color table according to the part name and color type.
2. Select the corresponding part number from the appropriate PAGE/GRID.
3. Parts marked "X" are unused.
4. "*" = Basic Part Number, no extension (i.e. ZA, ZB).
TRX500FA’03 2003
No.
COLOR CODE
BASE COLOR
R232
Patriot red
R232
G152
Adventure
green
G152
Y151
Starburst
yellow
Y151R
A
RE
A
DESCRIPTION BASIC PART NO.
1 CAP, HANDLE COVER 53206-HM8-000 ZA ZA ZA
2 CASE, ASSIST HEADLIGHT
(LOWER)
61302-HN0-A00 ZA ZA ZA
3 CASE, ASSIST HEADLIGHT
(UPPER)
61301-HN0-A00 ZC ZC ZC
4 COVER ASSY., L. ENGINE SIDE 11325-HN2-000 ZA ZA ZA
5 COVER ASSY., L. TANK SIDE
(WOL)
83650-HN2-000 ZA ZA ZA
6 COVER ASSY., R. ENGINE SIDE 11315-HN2-000 ZA ZA ZA
7 COVER ASSY., R. TANK SIDE
(WOL)
83550-HN2-000 ZA ZA ZA
8 COVER, BATTERY BOX 80311-HN2-000 ZB ZA ZC
9 COVER, FUEL TANK TOP 83700-HN2-000 ZA ZA ZA
10 COVER, HANDLE 53205-HN2-000 ZA ZA ZA
11 COVER, R. ENGINE SUB 80123-HN2-000 ZA ZA ZA
12 COVER, R. SIDE 83800-HN2-000 ZC ZC ZC
13 EMBLEM, L. FUEL TANK 87122-HN2-680 ZA ZB ZC
14 EMBLEM, R. FUEL TANK 87121-HN2-680 ZA ZB ZC
15 FENDER, FR. (WOL) 61100-HN2-000 ZB ZA ZC16 FENDER, RR. (WOL) 80100-HN2-000 ZB ZA ZC
17 GRILLE, FR. 66300-HN2-000 ZA ZA ZA
18 GUARD, FR. PIPE 81170-HN2-000 ZA ZA ZA
19 LABEL, COLOR 87565-HN2-830 ZA ZB ZC
20 LEVER, PETCOCK 16963-HM8-000 ZA ZA ZA
21 LID, RADIATOR CAP 61110-HN2-000 ZB ZA ZC
22 LID, TOOL BOX 80211-HN2-000 ZB ZA ZC
23 MARK, FR. FENDER 87124-HN2-680 ZA ZB ZC
24 MARK, HONDAMATIC 87128-HN2-680 ZA ZB ZC
25 MARK, RR. FENDER 87126-HN0-A60 ZE ZH ZF
26 MUDGUARD, L. CENTER 80122-HN2-000 ZA ZA ZA27 MUDGUARD, L. FR. (LOWER) 61867-HN2-000 ZA ZA ZA
28 MUDGUARD, L. FR. SIDE 61866-HN2-000 ZA ZA ZA
29 MUDGUARD, L. RR. SIDE 80221-HN2-000 ZA ZA ZA
30 MUDGUARD, R. CENTER 80121-HN2-000 ZA ZA ZA
31 MUDGUARD, R. FR. (LOWER) 61862-HN2-000 ZA ZA ZA
32 MUDGUARD, R. FR. SIDE 61861-HN2-000 ZA ZA ZA
33 MUDGUARD, R. RR. SIDE 80220-HN2-000 ZA ZA ZA
34 SEAT 77100-HN2-000 ZA ZA ZA
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COLOR TABLE
12 2003 American Honda Motor Co., Inc. JULY, 2003
When ordering a colored part:
1. Confirm the color code for the required part from the color table according to the part name and color type.
2. Select the corresponding part number from the appropriate PAGE/GRID.
3. Parts marked "X" are unused.
4. "*" = Basic Part Number, no extension (i.e. ZA, ZB).
TRX500FA’04 2004
No.
COLOR CODE
BASE COLOR
R232
Patriot red
R232
G152
Adventure
green
G152
Y151
Starburst
yellow
Y151R
A
RE
A
DESCRIPTION BASIC PART NO.
1 CAP, HANDLE COVER 53206-HM8-000 ZA ZA ZA
2 CASE, ASSIST HEADLIGHT
(LOWER)
61302-HN0-A00 ZA ZA ZA
3 CASE, ASSIST HEADLIGHT
(UPPER)
61301-HN0-A00 ZC ZC ZC
4 COVER ASSY., L. ENGINE SIDE 11325-HN2-000 ZA ZA ZA
5 COVER ASSY., L. TANK SIDE
(WOL)
83650-HN2-A00 ZA ZA ZA
6 COVER ASSY., R. ENGINE SIDE 11315-HN2-A00 ZA ZA ZA
7 COVER ASSY., R. TANK SIDE
(WOL)
83550-HN2-A00 ZA ZA ZA
8 COVER, BATTERY BOX 80311-HN2-000 ZB ZA ZC
9 COVER, FUEL TANK TOP 83700-HN2-000 ZA ZA ZA
10 COVER, HANDLE 53205-HN2-000 ZA ZA ZA
11 COVER, R. ENGINE SUB 80123-HN2-000 ZA ZA ZA
12 COVER, R. SIDE 83800-HN2-000 ZC ZC ZC
13 EMBLEM, L. FUEL TANK 87122-HN2-680 ZA ZB ZC
14 EMBLEM, R. FUEL TANK 87121-HN2-680 ZA ZB ZC
15 FENDER, FR. (WOL) 61100-HN2-000 ZB ZA ZC16 FENDER, RR. (WOL) 80100-HN2-A00 ZB ZA ZC
17 GRILLE, FR. 66300-HN2-000 ZA ZA ZA
18 GUARD, FR. PIPE 81170-HN2-000 ZA ZA ZA
19 LABEL, COLOR 87565-HN2-A00 ZA ZB ZC
20 LEVER, PETCOCK 16963-HM8-000 ZA ZA ZA
21 LID, RADIATOR CAP 61110-HN2-000 ZB ZA ZC
22 LID, TOOL BOX 80211-HN2-000 ZB ZA ZC
23 MARK, FR. FENDER 87124-HN2-680 ZA ZB ZC
24 MARK, HONDAMATIC 87128-HN2-680 ZA ZB ZC
25 MARK, RR. FENDER 87126-HN0-A60 ZE ZH ZF
26 MUDGUARD, L. CENTER 80122-HN2-000 ZA ZA ZA27 MUDGUARD, L. FR. (LOWER) 61867-HN2-000 ZA ZA ZA
28 MUDGUARD, L. FR. SIDE 61866-HN2-000 ZA ZA ZA
29 MUDGUARD, L. RR. SIDE 80221-HN2-000 ZA ZA ZA
30 MUDGUARD, R. CENTER 80121-HN2-000 ZA ZA ZA
31 MUDGUARD, R. FR. (LOWER) 61862-HN2-000 ZA ZA ZA
32 MUDGUARD, R. FR. SIDE 61861-HN2-000 ZA ZA ZA
33 MUDGUARD, R. RR. SIDE 80220-HN2-000 ZA ZA ZA
34 SEAT 77100-HN2-000 ZA ZA ZA
35 WHEEL SUB-ASSY., FR. 44650-HN8-000 ZA ZA ZA
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COLOR TABLE
JULY, 2003 2003 American Honda Motor Co., Inc. 13
When ordering a colored part:
1. Confirm the color code for the required part from the color table according to the part name and color type.
2. Select the corresponding part number from the appropriate PAGE/GRID.
3. Parts marked "X" are unused.
4. "*" = Basic Part Number, no extension (i.e. ZA, ZB).
TRX500FGA’04 2004
No.
COLOR CODE
BASE COLOR
R232
Patriot red
R232
G152
Adventure
green
G152
Y151
Starburst
yellow
Y151R
A
RE
A
DESCRIPTION BASIC PART NO.
1 CAP, HANDLE COVER 53206-HM8-000 ZA ZA ZA
2 CASE, ASSIST HEADLIGHT
(LOWER)
61302-HN0-A00 ZA ZA ZA
3 CASE, ASSIST HEADLIGHT
(UPPER)
61301-HN2-A10 ZA ZA ZA
4 COVER ASSY., L. ENGINE SIDE 11325-HN2-000 ZA ZA ZA
5 COVER ASSY., L. TANK SIDE
(WOL)
83650-HN2-A00 ZA ZA ZA
6 COVER ASSY., R. ENGINE SIDE 11315-HN2-A00 ZA ZA ZA
7 COVER ASSY., R. TANK SIDE
(WOL)
83550-HN2-A00 ZA ZA ZA
8 COVER, BATTERY BOX 80311-HN2-000 ZA ZB ZC
9 COVER, FUEL TANK TOP 83700-HN2-000 ZA ZA ZA
10 COVER, HANDLE 53205-HN2-000 ZA ZA ZA
11 COVER, R. ENGINE SUB 80123-HN2-000 ZA ZA ZA
12 COVER, R. SIDE 83800-HN2-000 ZC ZC ZC
13 EMBLEM, L. FUEL TANK 87122-HN2-680 ZB ZA ZC
14 EMBLEM, R. FUEL TANK 87121-HN2-680 ZB ZA ZC
15 FENDER, FR. (WOL) 61100-HN2-000 ZA ZB ZC16 FENDER, RR. (WOL) 80100-HN2-A00 ZA ZB ZC
17 GRILLE, FR. 66300-HN2-000 ZA ZA ZA
18 GUARD, FR. PIPE 81170-HN2-000 ZA ZA ZA
19 LABEL, COLOR 87565-HN2-A10 ZB ZA ZC
20 LEVER, PETCOCK 16963-HM8-000 ZA ZA ZA
21 LID, RADIATOR CAP 61110-HN2-000 ZA ZB ZC
22 LID, TOOL BOX 80211-HN2-000 ZA ZB ZC
23 MARK, FR. FENDER 87124-HN2-680 ZB ZA ZC
24 MARK, HONDAMATIC 87128-HN2-680 ZB ZA ZC
25 MARK, RR. FENDER 87126-HN0-A60 ZH ZE ZF
26 MUDGUARD, L. CENTER 80122-HN2-000 ZA ZA ZA27 MUDGUARD, L. FR. (LOWER) 61867-HN2-000 ZA ZA ZA
28 MUDGUARD, L. FR. SIDE 61866-HN2-000 ZA ZA ZA
29 MUDGUARD, L. RR. SIDE 80221-HN2-000 ZA ZA ZA
30 MUDGUARD, R. CENTER 80121-HN2-000 ZA ZA ZA
31 MUDGUARD, R. FR. (LOWER) 61862-HN2-000 ZA ZA ZA
32 MUDGUARD, R. FR. SIDE 61861-HN2-000 ZA ZA ZA
33 MUDGUARD, R. RR. SIDE 80220-HN2-000 ZA ZA ZA
34 SEAT 77100-HN2-000 ZA ZA ZA
35 WHEEL SUB-ASSY., FR. 44650-HN8-000 ZA ZA ZA
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BULK HOSE PART NUMBER PATTERN
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MASTER INDEXTitle Grid Page Title Grid Page
JULY, 200316 2003 American Honda Motor Co., Inc.
ENGINE SECTION
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C1 1-2
CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C2 1-4
CAM CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C3 1-6
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C3 1-7
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C4 1-8
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C4 1-9
FRONT CRANKCASE COVER. . . . . . . . . . . . . . . . . . . 1-C5 1-11
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C6 1-13
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C7 1-14
REAR CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . 1-C7 1-15
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C8 1-17
STARTER GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C9 1-18
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C9 1-19
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C10 1-20
CRANKSHAFT • PISTON . . . . . . . . . . . . . . . . . . . . . . . 1-C11 1-22HONDAMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C11 1-23
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C12 1-24
GEARSHIFT FORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C13 1-26
FINAL SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C13 1-27
RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C14 1-28
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C15 1-30
GASKET KIT A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C16 1-33
GASKET KIT B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-D1 1-34
FRAME SECTION
HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E1 2-2METER (TRX500FA). . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E2 2-4
METER (TRX500FGA) . . . . . . . . . . . . . . . . . . . . . . . . . 1-E2 2-5
HANDLE LEVERS • SWITCHES • CABLES. . . . . . . . . 1-E3 2-6
FR. BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . 1-E4 2-8
HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E5 2-11
STEERING SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E6 2-13
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E7 2-15
FRONT FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E8 2-16
SELECT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E9 2-18
FRONT SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . 1-E10 2-20
FRONT ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E10 2-21
KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E11 2-22
FRONT FINAL GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E12 2-24FRONT BRAKE PANEL . . . . . . . . . . . . . . . . . . . . . . . . 1-E14 2-29
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E16 2-32
REAR WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F1 2-34
REAR BRAKE PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . 1-F1 2-35
FINAL DRIVEN GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . 1-F2 2-37
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F4 2-40
BODY COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F5 2-42
SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F6 2-44
AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F6 2-45
SNORKEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F8 2-48
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F8 2-49
STEP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F9 2-51
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F10 2-52
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . 1-F11 2-54
REAR FENDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F11 2-55
TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F13 2-58
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F13 2-59
WIRE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F14 2-60
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F15 2-62
OIL COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F16 2-64
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F16 2-65
CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-G1 2-67
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-G2 2-68
LABELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-G2 2-69
MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-G3 2-71
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JULY, 2003 1-2003 American Honda Motor Co., Inc.
ENGINE SECTIONChapter Table of Contents
Page Title Grid Page
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C1 1-2
CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C2 1-4
CAM CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C3 1-6
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C3 1-7
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C4 1-8
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C4 1-9FRONT CRANKCASE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C5 1-11
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C6 1-13
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C7 1-14
REAR CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C7 1-15
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C8 1-17
STARTER GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C9 1-18
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C9 1-19
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C10 1-20
CRANKSHAFT • PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C11 1-22
HONDAMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C11 1-23
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C12 1-24
GEARSHIFT FORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C13 1-26
FINAL SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C13 1-27
RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C14 1-28
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C15 1-30
GASKET KIT A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C16 1-33
GASKET KIT B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-D1 1-34
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CYLINDER HEAD
1-2 2003 American Honda Motor Co., Inc. JULY, 2003 1-C1
HN24E0100A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-1
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 CYLINDER HEAD........................................ 1 2 3 4 4G -------- -------- 1 12200-HN2-000 6433676
2 GUIDE, VALVE (OS) .................................. 1 2 3 4 4G -------- -------- 4 12204-HN2-305 6433684
3 BOLT, SEALING (18MM) ............................ 1 2 3 4 4G -------- -------- 1 12206-371-300 1876283
BOLT, SEALING (18MM) ............................ 1 2 3 4 4G -------- -------- 1 12206-371-305 0422725
BOLT, SEALING (18MM) ............................ 1 2 3 4 4G -------- -------- 1 12206-611-300 0417451
4 GASKET, CYLINDER HEAD ...................... 1 2 3 4 4G -------- -------- 1 12251-HN2-003 6433700
GASKET, CYLINDER HEAD (OS) .............. 1 2 3 4 4G -------- -------- (1) 12252-HN2-305 6433718
5 COVER, CYLINDER HEAD ........................ 1 2 3 4 4G -------- -------- 1 12310-HN2-000 6433726
6 GASKET, HEAD COVER............................ 1 2 3 4 4G -------- -------- 1 12315-HN2-003 6433734
7 COVER, TAPPET ADJUSTING HOLE........ 1 2 3 4 4G -------- -------- 2 12351-HN2-000 64337428 INSULATOR, CARBURETOR .................... 1 2 3 4 4G -------- -------- 1 16211-HN2-000 6441711
9 BAND B, INSULATOR ................................ 1 2 3 4 4G -------- -------- 2 16218-MW4-000 4482014
10 NUT, SQUARE (5MM) ................................ 1 2 3 4 4G -------- -------- 2 16222-MV4-300 3694882
11 THERMOSTAT ASSY. ................................ 1 2 3 4 4G -------- -------- 1 19300-HN2-003 6434245
12 COVER, THERMOSTAT ............................ 1 2 3 4 4G -------- -------- 1 19321-HN2-000 6441802
13 THERMO UNIT............................................ 1 2 3 4 4G -------- -------- 1 37750-MAZ-003 6434617
14 NUT, FLANGE CAP (10MM) ...................... 1 2 3 4 4G -------- -------- 4 90201-HA0-000 2049757
NUT, FLANGE CAP (10MM) ...................... 1 2 3 4 4G -------- -------- 4 90202-HA0-000 2049765
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CYLINDER HEAD
JULY, 2003 2003 American Honda Motor Co., Inc. 1-3
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-1
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
15 WASHER, PLAIN (10MM) .......................... 1 2 3 4 4G -------- -------- 4 90401-437-000 0768051
16 WASHER, SEALING (6MM)........................ 1 2 3 4 4G -------- -------- 5 90441-706-000 0163600
17 O-RING (57X2.5) ........................................ 1 2 3 4 4G -------- -------- 2 91308-500-000 0213355
18 BOLT, STUD (8X25).................................... 1 2 3 4 4G -------- -------- 2 92900-08025-0B 1715747
19 SCREW, PAN (5X25) .................................. 1 2 3 4 4G -------- -------- 2 93500-05025-0G 0477471
20 PIN, KNOCK (12X16) .................................. 1 2 3 4 4G -------- -------- 2 94301-12160 0165316
21 BOLT, FLANGE (6X20) .............................. 1 2 3 4 4G -------- -------- 6 95701-06020-00 2105815
22 BOLT, FLANGE (6X22) .............................. 1 2 3 4 4G -------- -------- 2 95701-06022-00 2105823
23 BOLT, FLANGE (6X25) .............................. 1 2 3 4 4G -------- -------- 4 95701-06025-00 210583124 BOLT, FLANGE (6X30) .............................. 1 2 3 4 4G -------- -------- 4 95701-06030-00 2401222
25 BOLT, FLANGE (6X70) .............................. 1 2 3 4 4G -------- -------- 3 95701-06070-00 2427284
26 SPARK PLUG (IJR6A9) .............................. 1 2 3 4 4G -------- -------- (1) 98069-5691U 6443170
SPARK PLUG (VX20BC) (NGK) ................ 1 2 3 4 4G -------- -------- (1) 98069-5692U 6443188
SPARK PLUG (IJR7A9) .............................. 1 2 3 4 4G -------- -------- 1 98069-5791U 6443196
SPARK PLUG (VX22BC) (NGK) ................ 1 2 3 4 4G -------- -------- 1 98069-5792U 6443204
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CAMSHAFT
1-4 2003 American Honda Motor Co., Inc. JULY, 2003 1-C2
HN24E0200
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-2
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 SEAL, VALVE STEM .................................. 1 2 3 4 4G -------- -------- 4 12209-KL4-005 1777879
2 HOLDER B, CAMSHAFT ............................ 1 2 3 4 4G -------- -------- 1 12212-HN2-P00 6433692
3 CAMSHAFT ................................................ 1 2 3 4 4G -------- -------- 1 14100-HN2-P00 6433833
4 PLATE, CAMSHAFT HOLDER.................... 1 2 3 4 4G -------- -------- 1 14104-HN2-000 6441505
5 FOLLOWER, CAM ...................................... 1 2 3 4 4G -------- -------- 2 14421-HM7-000 4686606
6 ARM, VALVE ROCKER (IN)........................ 1 2 -------- -------- 1 14431-HN2-000 6441521
ARM, IN. VALVE ROCKER ........................ 3 4 4G -------- -------- 1 14431-HN8-000 7168529
7 ARM, VALVE ROCKER (EX) ...................... 1 2 -------- -------- 1 14432-HN2-000 6441539
ARM, EX. VALVE ROCKER........................ 3 4 4G -------- -------- 1 14432-HN8-000 7168537
8 ROD, PUSH ................................................ 1 2 3 4 4G -------- -------- 2 14440-HN2-000 64415479 SHAFT, ROCKER ARM .............................. 1 2 3 4 4G -------- -------- 2 14451-HN2-000 6441554
10 VALVE, IN. .................................................. 1 2 3 4 4G -------- -------- 2 14711-HN2-000 6433841
11 VALVE, EX. ................................................ 1 2 3 4 4G -------- -------- 2 14721-HN2-000 6433858
12 SPRING, VALVE (OUTER) ........................ 1 2 3 4 4G -------- -------- 4 14751-HN2-000 6433866
13 SPRING, VALVE (INNER) .......................... 1 2 3 4 4G -------- -------- 4 14761-HN2-000 6433874
14 RETAINER, VALVE SPRING...................... 1 2 3 4 4G -------- -------- 4 14771-107-020 0214726
15 SEAT, VALVE SPRING .............................. 1 2 3 4 4G -------- -------- 4 14775-HN2-000 6433882
16 COTTER, VALVE ........................................ 1 2 3 4 4G -------- -------- 8 14781-HA0-770 2419612
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CAMSHAFT
JULY, 2003 2003 American Honda Motor Co., Inc. 1-5
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-2
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
17 SCREW, TAPPET ADJ. .............................. 1 2 3 4 4G -------- -------- 4 90012-426-000 0768499
18 NUT, TAPPET ADJ. .................................... 1 2 3 4 4G -------- -------- 4 90206-250-000 0040139
19 O-RING (1.5X9.5)........................................ 1 2 3 4 4G -------- -------- 2 91306-MG3-000 1592013
O-RING (1.5X9.5)........................................ 1 2 3 4 4G -------- -------- 2 91306-105-690 1445741
20 PIN A, DOWEL (8X10) ................................ 1 2 3 4 4G -------- -------- 2 94301-08100 0081711
21 BOLT, FLANGE (6X60) .............................. 1 2 3 4 4G -------- -------- 2 95701-06060-00 2791119
22 BOLT, FLANGE (6X65) .............................. 1 2 3 4 4G -------- -------- 2 95701-06065-08 2602233
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CAM CHAIN
1-6 2003 American Honda Motor Co., Inc. JULY, 2003 1-C3
HN24E0300ZA
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-3
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 PLATE, OIL SEPARATE ............................ 1 2 3 4 4G -------- -------- 1 11140-HN2-003 6441331
2 GASKET, TENSIONER HOLE .................... 1 2 3 4 4G -------- -------- 1 12194-HC5-740 3813581
3 CHAIN, CAM (104L) (DAIDO) .................... 1 2 3 4 4G -------- -------- 1 14401-HN2-003 6441513
4 TENSIONER, CAM CHAIN.......................... 1 2 3 4 4G -------- -------- 1 14510-HN2-003 6441562
5 COLLAR, TENSIONER (6X9)...................... 1 2 3 4 4G -------- -------- 1 14515-KF0-000 1417070
6 LIFTER ASSY., TENSIONER...................... 1 2 3 4 4G -------- -------- 1 14520-HA0-771 2419588
7 GUIDE A, CAM CHAIN................................ 1 2 3 4 4G -------- -------- 1 14621-HN2-000 6441570
8 BOLT, FLANGE (6X13) .............................. 1 2 3 4 4G -------- -------- 1 90002-HA7-670 2112019
9 WASHER, DRUM STOPPER...................... 1 2 3 4 4G -------- -------- 1 90417-360-000 0341099
10 WASHER, SEALING (6MM)........................ 1 2 3 4 4G -------- -------- 1 90442-397-000 068761611 BOLT, FLANGE (6X12) .............................. 1 2 3 4 4G -------- -------- 2 95701-06012-00 2105799
12 BOLT, FLANGE (6X22) .............................. 1 2 3 4 4G -------- -------- 1 95701-06022-00 2105823
13 BOLT, FLANGE (6X25) .............................. 1 2 3 4 4G -------- -------- 2 96001-06025-00 2105989
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CYLINDER
JULY, 2003 2003 American Honda Motor Co., Inc. 1-7
HN24E0400A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-4
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 CYLINDER .................................................. 1 2 3 4 4G -------- -------- 1 12100-HN2-000 6441414
2 GASKET, CYLINDER.................................. 1 2 3 4 4G -------- -------- 1 12191-HN2-000 6433668
3 PIN, KNOCK (12X16) .................................. 1 2 3 4 4G -------- -------- 4 94301-12160 0165316
4 BOLT, FLANGE (6X30) .............................. 1 2 3 4 4G -------- -------- 4 95701-06030-00 2401222
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WATER PUMP
1-8 2003 American Honda Motor Co., Inc. JULY, 2003 1-C4
HN24E0500A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-5
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 WATER PUMP ............................................ 1 -------- 8003606 1 19200-HN2-000 6434229
WATER PUMP ............................................ 1 2 3 4 4G -------- -------- 1 19200-HN2-010 6589519
2 COVER, WATER PUMP.............................. 1 2 3 4 4G -------- -------- 1 19220-HN2-000 6441786
3 GASKET, WATER PUMP COVER.............. 1 2 3 4 4G -------- -------- 1 19226-HN2-000 6434237
4 HOSE, WATER PUMP ................................ 1 2 3 4 4G -------- -------- 1 19322-HN2-000 6434252
5 HOSE, WATER BYPASS............................ 1 2 3 4 4G -------- -------- 1 19323-HN2-000 6434260
6 JOINT, WATER .......................................... 1 2 3 4 4G -------- -------- 1 19523-HN2-000 6441810
7 BOLT, FLANGE (6X30) (CT200) ................ 1 2 3 4 4G -------- -------- 2 90003-HN2-000 6442974
8 BOLT, FLANGE (6X12) (CT200) ................ 1 2 3 4 4G -------- -------- 1 90013-883-000 0636845
9 WASHER, SEALING (6.5MM) .................... 1 2 3 4 4G -------- -------- 1 90463-ML7-000 240868010 O-RING........................................................ 1 2 3 4 4G -------- -------- 2 91303-KV3-780 6591465
11 O-RING (37X2.4) (ARAI) ............................ 1 2 3 4 4G -------- -------- 1 91305-KT7-003 3353216
12 CLIP, TUBE ................................................ 1 2 3 4 4G -------- -------- 2 95002-41000-08 0660829
13 CLIP, TUBE (D12.5) .................................... 1 2 3 4 4G -------- -------- 2 95002-41250-08 0665257
14 BOLT, FLANGE (6X55) .............................. 1 2 3 4 4G -------- -------- 3 95701-06055-00 2533834
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OIL TANK
JULY, 2003 2003 American Honda Motor Co., Inc. 1-9
HN24E0600A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-6
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 SCREEN, OIL FILTER (KOYO) .................. 1 2 3 4 4G -------- -------- 1 15421-HC4-005 2724730
2 CAP, OIL TANK .......................................... 1 2 3 4 4G -------- -------- 1 15651-HN2-000 6441679
3 DIPSTICK, OIL ............................................ 1 2 3 4 4G -------- -------- 1 15660-HN2-000 6441687
4 TANK, FR. OIL ............................................ 1 2 3 4 4G -------- -------- 1 15710-HN2-000 6433981
5 TANK, RR. OIL ............................................ 1 2 3 4 4G -------- -------- 1 15721-HN2-000 6433999
6 PLATE, OIL TANK ...................................... 1 2 3 4 4G -------- -------- 1 15730-HN2-000 6434005
7 JOINT, RR. OIL TANK ................................ 1 2 3 4 4G -------- -------- 1 15771-HN2-000 6441695
8 SENSOR ASSY., THERMOSTAT OIL(TOYO).................................................... 1 2 3 4 4G -------- -------- 1 37750-HC4-751 3820537
9 BOLT, FLANGE (8X176) ............................ 1 2 3 4 4G -------- -------- 1 90017-PP6-000 3028073
10 WASHER, SEAL.......................................... 1 2 3 4 4G -------- -------- 1 90401-HA8-000 1974609
WASHER, SEAL.......................................... 1 2 3 4 4G -------- -------- 1 90401-HC4-750 3522505
11 O-RING (11.7X1.9) (KEIHIN) ...................... 1 2 3 4 4G -------- -------- 1 91303-P6H-003 5210570
12 O-RING (28X3)............................................ 1 2 3 4 4G -------- -------- 1 91307-MK5-000 2902443
13 O-RING (18.5X2.4) (ARAI) .......................... 1 2 3 4 4G -------- -------- 2 91311-MB0-003 1260850
14 O-RING (8.4X2.4)........................................ 1 2 3 4 4G -------- -------- 1 91316-MJ8-003 1768746
15 BOLT, DRAIN PLUG (12MM)...................... 1 2 3 4 4G -------- -------- 1 92800-12000 0053975
16 BOLT, HEX. (5X12) .................................... 1 2 3 4 4G -------- -------- 4 93101-05012-0A 6443139
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OIL TANK
1-10 2003 American Honda Motor Co., Inc. JULY, 2003 1-C5
HN24E0600A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-6
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
17 WASHER, DRAIN PLUG (12MM)................ 1 2 3 4 4G -------- -------- 1 94109-12000 0171868
18 BOLT, FLANGE (6X35) .............................. 1 2 3 4 4G -------- -------- 12 95701-06035-00 2105864
19 BOLT, FLANGE (8X100) ............................ 1 2 3 4 4G -------- -------- 3 95701-08100-00 2533875
20 BOLT, FLANGE (8X110) ............................ 1 2 3 4 4G -------- -------- 1 95701-08110-08 2891059
-
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FRONT CRANKCASE COVER
JULY, 2003 2003 American Honda Motor Co., Inc. 1-11
HN24E0700A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-7
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 COVER, FR. CRANKCASE ........................ 1 2 3 4 4G -------- -------- 1 11330-HN2-000 6433627
2 CLAMP, CONTROL MOTOR ...................... 1 2 3 4 4G -------- -------- 1 11333-HN2-000 6433635
3 BOLT, VALVE SETTING ............................ 1 2 3 4 4G -------- -------- 1 11334-HN2-000 6441356
4 BOLT, FEED PIPE SETTING...................... 1 2 3 4 4G -------- -------- 1 11335-HN2-000 6441364
5 SPRING, ORIFICE VALVE.......................... 1 2 3 4 4G -------- -------- 1 11336-HN2-000 6441372
6 VALVE, RELIEF .......................................... 1 2 3 4 4G -------- -------- 1 11337-HN2-000 6441380
7 SEAL, RUBBER .......................................... 1 2 3 4 4G -------- -------- 1 15152-HN2-000 6441596
8 COVER, OIL FILTER .................................. 1 2 3 4 4G -------- -------- 1 15411-HN2-000 6441646
9 ELEMENT, OIL FILTER .............................. 1 2 3 4 4G -------- -------- 1 15412-KEA-003 6441653
10 SEAT, OIL FILTER SPRING ...................... 1 2 3 4 4G -------- -------- 1 15414-300-000 019013211 SPRING, FILTER ELEMENT SETTING...... 1 2 3 4 4G -------- -------- 1 15415-413-000 0493619
12 BOLT, OIL FILTER CENTER...................... 1 2 3 4 4G -------- -------- 1 15420-HN2-000 6441661
13 VALVE, CHECK .......................................... 1 2 3 4 4G -------- -------- 1 15473-300-300 0190165
14 SPRING, CHECK VALVE............................ 1 2 3 4 4G -------- -------- 1 15474-300-310 0190173
15 PIN, SPRING SETTING .............................. 1 2 3 4 4G -------- -------- 1 15477-300-300 0190181
16 PIPE, FEED ................................................ 1 2 3 4 4G -------- -------- 1 26631-HN2-000 6441935
17 MOTOR ASSY., CONTROL........................ 1 2 3 4 4G -------- -------- 1 31300-HN2-003 6434534
18 BOLT, FLANGE (6X32) (NSHF).................. 1 2 3 4 4G -------- -------- 2 90004-GHB-690 4774196
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FRONT CRANKCASE COVER
1-12 2003 American Honda Motor Co., Inc. JULY, 2003 1-C6
HN24E0700A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-7
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
19 BOLT, FLANGE (6X50) (NSHF).................. 1 2 3 4 4G -------- -------- 5 90004-GHB-730 4774220
20 BOLT, FLANGE (6X75) (NSHF).................. 1 2 3 4 4G -------- -------- 6 90004-GHB-780 4822151
21 BOLT, FLANGE (6X95) (NSHF).................. 1 2 3 4 4G -------- -------- 2 90004-GHB-820 6434757
22 BOLT, SEALING (10MM) ............................ 1 2 3 4 4G -------- -------- 1 90083-PL3-000 2909851
23 BOLT, SPECIAL (10X13) ............................ 1 2 3 4 4G -------- -------- 1 90101-VD6-003 3250057
24 WASHER, OIL BOLT (10.2X15X1.4) .......... 1 2 3 4 4G -------- -------- 2 90545-MC0-000 1117951
WASHER, OIL BOLT .................................. 1 2 3 4 4G -------- -------- 2 90545-300-000 0189902
25 BEARING, RADIAL BALL (6303SP)............ 1 2 3 4 4G -------- -------- 1 91009-HA0-004 1824713
26 OIL SEAL (13X22X5) .................................. 1 2 3 4 4G -------- -------- 1 91204-KE8-003 1768662
27 O-RING (7.7X2.3) (ARAI) ............................ 1 2 3 4 4G -------- -------- 1 91301-PC9-003 135240028 O-RING (75X2.5) ........................................ 1 2 3 4 4G -------- -------- 1 91301-107-000 0213306
29 O-RING (15X2.5) ........................................ 1 2 3 4 4G -------- -------- 1 91302-377-000 0386995
30 O-RING, MOTOR ........................................ 1 2 3 4 4G -------- -------- 1 91351-HM8-A51 6857502
31 O-RING (22.1X2) ........................................ 1 2 3 4 4G -------- -------- 1 91305-679-003 1455021
O-RING (22X1.9) (ARAI) ............................ 1 2 3 4 4G -------- -------- 1 91355-MB0-003 1251578
32 PIN A, DOWEL (8X14) ................................ 1 2 3 4 4G -------- -------- 2 94301-08140 0069310
33 BOLT, FLANGE (6X22) .............................. 1 2 3 4 4G -------- -------- 2 95701-06022-00 2105823
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CLUTCH
JULY, 2003 2003 American Honda Motor Co., Inc. 1-13
HN24E0800
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-8
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 PLATE, DRIVE ............................................ 1 2 3 -------- -------- 1 22350-HN2-000 6441828
PLATE, DRIVE ............................................ 4 4G -------- -------- 1 22350-HN2-A00 7516289
2 SPRING, CLUTCH DRIVE.......................... 1 2 3 4 4G -------- -------- 6 22451-HN2-300 6441836
3 WEIGHT SET, CLUTCH.............................. 1 2 3 4 4G -------- -------- 1 22535-HN2-305 6434286
4 SPRING, CONE DISK ................................ 1 2 3 4 4G -------- -------- 1 22714-HN2-000 6441844
5 CLUTCH OUTER ........................................ 1 2 3 -------- -------- 1 23110-HN2-000 6434294
CLUTCH OUTER ........................................ 4 4G -------- -------- 1 23110-HN2-A00 7516297
6 NUT, LOCK (20MM) .................................... 1 2 3 4 4G -------- -------- 1 90235-HM7-000 4713384
7 WASHER (66X124X1.0).............................. 1 2 3 -------- -------- 1 90406-HN2-000 6443055
WASHER (66X124X1.0).............................. 4 4G -------- -------- 1 90406-HN2-A00 75168678 WASHER (66X107X1.6).............................. 1 2 3 -------- -------- 1 90407-HN2-000 6443063
WASHER (66X107X1.6).............................. 4 4G -------- -------- 1 90407-HN2-A00 7516875
9 WASHER, THRUST (29X40X2) .................. 1 2 3 4 4G -------- -------- 1 90457-HN2-000 6443071
10 WASHER, THRUST (20MM) ...................... 1 2 3 4 4G -------- -------- 1 90459-KB4-670 1187772
11 CIRCLIP (7MM) .......................................... 1 2 3 4 4G -------- -------- 6 90605-HM8-000 5309141
12 CLUTCH, ONE-WAY .................................. 1 2 3 4 4G -------- -------- 1 91101-HN2-003 6434922
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OIL PUMP
1-14 2003 American Honda Motor Co., Inc. JULY, 2003 1-C7
HN24E0900A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-9
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 PUMP ASSY., OIL ...................................... 1 2 3 4 4G -------- -------- 1 15100-HN2-000 6433890
2 ROTOR A, OIL PUMP (INNER) .................. 1 2 3 4 4G -------- -------- 1 15122-HN2-003 6433908
3 ROTOR A, OIL PUMP (OUTER) ................ 1 2 3 4 4G -------- -------- 1 15123-HN2-003 6433916
4 ROTOR C, OIL PUMP (INNER) .................. 1 2 3 4 4G -------- -------- 1 15124-HN2-003 6433924
5 ROTOR C, OIL PUMP (OUTER) ................ 1 2 3 4 4G -------- -------- 1 15125-HN2-003 6433932
6 ROTOR B, OIL PUMP (INNER) .................. 1 2 3 4 4G -------- -------- 1 15126-HN2-003 6433940
7 ROTOR B, OIL PUMP (OUTER) ................ 1 2 3 4 4G -------- -------- 1 15127-HN2-003 6433957
8 SPROCKET, OIL PUMP DRIVEN (19T)...... 1 2 3 4 4G -------- -------- 1 15133-HN2-000 6441588
10 COLLAR, SPECIAL .................................... 1 2 3 4 4G -------- -------- 1 15234-HN2-000 6441612
11 RUBBER, OIL PUMP SEAL ........................ 1 2 3 4 4G -------- -------- 1 15236-HN2-000 644163812 CHAIN, OIL PUMP DRIVE (50L) (DAIDO) .. 1 2 3 4 4G -------- -------- 1 15401-HN2-003 6433965
13 O-RING (16X2.1) ........................................ 1 2 3 4 4G -------- -------- 1 91309-PX4-003 3301793
14 BOLT, FLANGE (6X14) .............................. 1 2 3 4 4G -------- -------- 1 95701-06014-00 2410884
15 BOLT, FLANGE (6X75) .............................. 1 2 3 4 4G -------- -------- 3 95701-06075-00 3794765
16 BOLT, FLANGE (6X80) .............................. 1 2 3 4 4G -------- -------- 1 95701-06080-08 2953016
17 BOLT, FLANGE (6X90) .............................. 1 2 3 4 4G -------- -------- 4 95701-06090-08 3871845
18 ROLLER (4X15.8) ...................................... 1 2 3 4 4G -------- -------- 3 96220-40158 0345066
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REAR CRANKCASE COVER
JULY, 2003 2003 American Honda Motor Co., Inc. 1-15
HN24E1000B
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-10
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 COVER, RR. CRANKCASE ........................ 1 2 3 4 4G -------- -------- 1 11340-HN2-000 6433643
2 COVER, ALTERNATOR.............................. 1 2 3 4 4G -------- -------- 1 11350-HN2-000 6441398
3 INSULATOR, SPEED SENSOR.................. 1 2 3 4 4G -------- -------- 1 11358-HN2-010 6873152
4 GASKET, ALTERNATOR COVER.............. 1 2 3 4 4G -------- -------- 1 11396-HN2-000 6433650
5 SWITCH ASSY., CHANGE.......................... 1 2 3 4 4G -------- -------- 1 35759-HN2-013 6590087
6 SENSOR SET, SPEED .............................. 1 2 -------- -------- 1 37010-HN2-305 68731603 -------- 8125506 1 37010-HN2-305 6873160
7 BOLT, FLANGE (6X22) (NSHF).................. 1 2 3 4 4G -------- -------- 2 90004-GHB-660 4774162
8 BOLT, FLANGE (6X25) (NSHF).................. 1 2 3 4 4G -------- -------- 3 90004-GHB-670 4774170
9 BOLT, FLANGE (6X32) (NSHF).................. 1 2 3 4 4G -------- -------- 2 90004-GHB-690 4774196
10 BOLT, FLANGE (6X40) (NSHF).................. 1 2 3 4 4G -------- -------- 9 90004-GHB-710 4774212
11 BOLT, FLANGE (6X50) (NSHF).................. 1 2 3 4 4G -------- -------- 1 90004-GHB-730 4774220
12 BOLT, FLANGE (6X85) (NSHF).................. 1 2 3 4 4G -------- -------- 5 90004-GHB-800 6374946
13 CAP (14MM)................................................ 1 2 3 4 4G -------- -------- 1 90084-KY2-000 3117728
14 WASHER, SEALING (6MM)........................ 1 2 3 4 4G -------- -------- 3 90441-706-000 0163600
15 OIL SEAL (32X52X8) .................................. 1 2 3 4 4G -------- -------- 1 91201-HM7-003 4688719
16 O-RING (13.8X2.5) ...................................... 1 2 3 4 4G -------- -------- 1 91303-377-000 0499525
17 O-RING (18.3X2.4) (NOK) .......................... 1 2 3 4 4G -------- -------- 1 91321-PF4-004 2129211
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REAR CRANKCASE COVER
1-16 2003 American Honda Motor Co., Inc. JULY, 2003 1-C8
HN24E1000B
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-10
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
18 O-RING (17.0X2.5) (ARAI) .......................... 1 2 3 4 4G -------- -------- 1 91333-KE5-003 1873231
O-RING (17X2.5) ........................................ 1 2 3 4 4G -------- -------- 1 91333-567-010 0412213
19 PIN A, DOWEL (8X14) ................................ 1 2 3 4 4G -------- -------- 4 94301-08140 0069310
20 BOLT, FLANGE (6X16) .............................. 1 2 3 4 4G -------- -------- 2 95701-06016-00 2410892
21 BEARING, RADIAL BALL (6000) ................ 1 2 3 4 4G -------- -------- 1 96100-60000-00 0671297
22 SENSOR ASSY., SPEED............................ 3 8125507 -------- 1 37700-HN2-024 75164204 4G -------- -------- 1 37700-HN2-024 7516420
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ALTERNATOR
JULY, 2003 2003 American Honda Motor Co., Inc. 1-17
HN24E1100
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-11
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 CLUTCH OUTER, STARTING .................... 1 2 3 4 4G -------- -------- 1 28125-HN2-003 6434518
2 CLUTCH, ONE-WAY .................................. 1 2 3 4 4G -------- -------- 1 28126-HN0-A01 5746961
3 GENERATOR, PULSE (TOYO) .................. 1 2 3 4 4G -------- -------- 1 30300-HA0-033 2956373
4 FLYWHEEL ................................................ 1 2 3 4 4G -------- -------- 1 31110-HN2-003 6441992
5 STATOR...................................................... 1 2 3 4 4G -------- -------- 1 31120-HN2-003 6442008
6 BOLT, SOCKET (8X12) .............................. 1 2 3 4 4G -------- -------- 6 90010-HN2-000 6442982
7 BOLT, SOCKET (6X34) .............................. 1 2 3 4 4G -------- -------- 3 90012-KR8-000 6442990
8 BOLT, SOCKET (5X12) .............................. 1 2 3 4 4G -------- -------- 2 90089-KR0-000 2909083
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STARTER GEAR
1-18 2003 American Honda Motor Co., Inc. JULY, 2003 1-C9
HN24E1200
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-12
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 GEAR, STARTER DRIVEN (70T)................ 1 2 3 4 4G -------- -------- 1 28110-HN2-000 6441984
2 SHAFT, STARTER REDUCTION................ 1 2 3 4 4G -------- -------- 1 28130-HM7-000 4687604
3 GEAR C, STARTER REDUCTION.............. 1 2 3 4 4G -------- -------- 1 28131-HM7-000 4687612
4 SHAFT A, STARTER REDUCTION............ 1 2 3 4 4G -------- -------- 1 28133-HA0-770 2419828
5 GEAR, STARTER REDUCTION (43T/18T) 1 2 3 4 4G -------- -------- 1 28140-HN0-A00 5746979
6 WASHER (32X45X3) .................................. 1 2 3 4 4G -------- -------- 1 90401-HM7-000 4688594
7 WASHER, THRUST (12MM) ...................... 1 2 3 4 4G -------- -------- 1 90451-GF6-000 1824556
8 BEARING, NEEDLE (32X37X26)................ 1 2 3 4 4G -------- -------- 1 91061-HM7-003 4688693
9 CIRCLIP (OUTER) (15MM) ........................ 1 2 3 4 4G -------- -------- 1 94510-15000 0171892
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STARTER MOTOR
JULY, 2003 2003 American Honda Motor Co., Inc. 1-19
HN24E1300A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-13
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 CLIP, HOSE ................................................ 1 2 3 4 4G -------- -------- 1 19626-HN2-000 6434278
2 MOTOR ASSY., STARTER ........................ 1 2 3 -------- -------- 1 31200-HN2-003 6434526
MOTOR ASSY., STARTER (MITSUBA)...... 4 4G -------- -------- 1 31200-HN2-A01 7516313
3 TERMINAL SET, BRUSH(USE FOR MITSUBA STARTER MOTORSM-13) .................................................... 1 2 3 4 4G -------- -------- 1 31201-KS5-901 2541951
4 SPRING, CARBON BRUSH........................ 1 2 3 4 4G -------- -------- 2 31204-KS5-901 2541969
5 BOLT, SETTING.......................................... 1 2 3 4 4G -------- -------- 2 31205-MN4-008 2605087
6 HOLDER SET, BRUSH .............................. 1 2 3 4 4G -------- -------- 1 31206-MN4-008 2605095
7 RING............................................................ 1 2 3 4 4G -------- -------- 2 31207-KS5-901 2541985
8 NUT-WASHER (6MM) ................................ 1 2 3 4 4G -------- -------- 2 90071-MB0-000 1243534
9 WASHER, STEEL PLATE .......................... 1 2 3 4 4G -------- -------- 2 90122-MN4-008 2605483
10 O-RING (24.4X3.1) (ARAI) .......................... 1 2 3 4 4G -------- -------- 1 91309-425-003 1113422
O-RING (24.4X3.1)...................................... 1 2 3 4 4G -------- -------- 1 91312-MG7-003 2618221
11 O-RING........................................................ 1 2 3 4 4G -------- -------- 3 91320-MB0-000 1292184
12 BOLT, FLANGE (6X25) .............................. 1 2 3 4 4G -------- -------- 2 95801-06025-00 2105906
13 BRACKET, FR............................................. 1 2 3 4 4G -------- -------- 1 31210-HM7-003 4769352
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CRANKCASE
1-20 2003 American Honda Motor Co., Inc. JULY, 2003 1-C10
HN24E1400A
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-14
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 CRANKCASE, FR. ...................................... 1 2 3 4 4G -------- -------- 1 11100-HN2-000 6433601
2 CRANKCASE, RR. ...................................... 1 2 3 4 4G -------- -------- 1 11200-HN2-000 6433619
3 SEAL, RUBBER .......................................... 1 2 3 4 4G -------- -------- 1 15152-HN2-000 6441596
4 STRAINER, OIL .......................................... 1 2 3 4 4G -------- -------- 1 15153-HN2-000 6441604
5 JOINT, SPECIAL ........................................ 1 2 3 4 4G -------- -------- 1 15235-HN2-000 6441620
6 SCREEN, OIL FILTER (KOYO) .................. 1 2 3 4 4G -------- -------- 1 15421-MN1-671 2690196
8 SENSOR ASSY., ANGLE............................ 1 -------- -------- 1 38800-HN2-000 6442164
SENSOR ASSY., ANGLE............................ 1 2 3 4 4G -------- -------- 1 38800-HN2-005 6761621
9 BOLT, FLANGE (6X40) (NSHF).................. 1 2 3 4 4G -------- -------- 9 90004-GHB-710 4774212
10 BOLT, FLANGE (6X55) (NSHF).................. 1 2 3 4 4G -------- -------- 4 90004-GHB-740 477423811 BOLT, FLANGE (6X65) (NSHF).................. 1 2 3 4 4G -------- -------- 1 90004-GHB-760 4774246
12 BOLT, FLANGE (6X80) (NSHF).................. 1 2 3 4 4G -------- -------- 2 90004-GHB-790 4831715
13 BOLT, STUD (10X252.5) ............................ 1 2 3 -------- -------- 4 90032-HN2-000 6443006
BOLT, STUD (10X252.5) ............................ 4 4G -------- -------- 4 90032-HN2-A00 7516842
14 BOLT, SOCKET (5X14) .............................. 1 2 3 4 4G -------- -------- 2 90049-KBH-000 6434765
15 OIL SEAL (6X13X5) (ARAI) ........................ 1 2 3 4 4G -------- -------- 1 91202-GF9-003 6443113
16 O-RING (9.8X1.9)........................................ 1 2 3 4 4G -------- -------- 1 91301-PM5-A01 2710820
O-RING (9.8MM) ........................................ 1 2 3 4 4G -------- -------- 1 91302-PJ4-000 2426435
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CRANKCASE
JULY, 2003 2003 American Honda Motor Co., Inc. 1-21
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-14
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
16 O-RING (9.6X1.9) (ARAI) ............................ 1 2 3 4 4G -------- -------- 1 91302-PJ4-004 2143055
O-RING (9.8X1.9)........................................ 1 2 3 4 4G -------- -------- 1 91305-PE2-003 1869478
17 O-RING (11.8X2.4)...................................... 1 2 3 4 4G -------- -------- 1 91302-ZE9-003 2461705
O-RING (11.8X2.4)...................................... 1 2 3 4 4G -------- -------- 1 91320-MJ6-003 2023935
18 O-RING (14.8X2.4) (ARAI) .......................... 1 2 3 4 4G -------- -------- 2 91303-KF0-003 1521087
O-RING (14.8X2.4) (NOK) .......................... 1 2 3 4 4G -------- -------- 2 91356-MA6-005 1377704
19 O-RING (5.5X1.4)........................................ 1 2 3 4 4G -------- -------- 1 91319-ME5-003 1377399
20 O-RING (25X2.4) (NOK).............................. 1 2 3 4 4G -------- -------- 1 91321-P0X-003 4326757
21 BOLT, DRAIN PLUG (12MM)...................... 1 2 3 4 4G -------- -------- 1 92800-12000 005397522 WASHER, DRAIN PLUG (12MM)................ 1 2 3 4 4G -------- -------- 1 94109-12000 0171868
23 PIN A, DOWEL (6X10) ................................ 1 2 3 4 4G -------- -------- 1 94301-06100 0294256
24 PIN A, DOWEL (8X14) ................................ 1 2 3 4 4G -------- -------- 2 94301-08140 0069310
25 BOLT, FLANGE (6X14) .............................. 1 2 3 4 4G -------- -------- 2 95701-06014-00 2410884
26 BOLT, FLANGE (6X80) .............................. 1 2 3 4 4G -------- -------- 1 95701-06080-08 2953016
27 WASHER, PLAIN (5MM) ............................ 1 2 3 4 4G -------- -------- 2 94101-05000 0059055
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CRANKSHAFT • PISTON
1-22 2003 American Honda Motor Co., Inc. JULY, 2003 1-C11
HN24E1500
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-15
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 CRANKSHAFT ............................................ 1 2 3 4 4G -------- -------- 1 13000-HN2-000 6433759
2 RING SET, PISTON (STD).......................... 1 2 3 4 4G -------- -------- 1 13010-HN2-003 6433767
RING SET, PISTON (OS 0.25).................... 1 2 3 4 4G -------- -------- (1) 13011-HN2-003 6433775
RING SET, PISTON (0.5) ............................ 1 2 3 4 4G -------- -------- (1) 13012-HN2-003 6433783
3 PISTON ...................................................... 1 2 3 4 4G -------- -------- 1 13101-HN2-000 6433791
PISTON (OS 0.25) ...................................... 1 2 3 4 4G -------- -------- (1) 13102-HN2-000 6433809
PISTON (0.5) .............................................. 1 2 3 4 4G -------- -------- (1) 13103-HN2-000 6433817
4 PIN, PISTON .............................................. 1 2 3 4 4G -------- -------- 1 13111-HN2-000 6433825
5 SHAFT, BALANCER.................................... 1 2 3 4 4G -------- -------- 1 13420-HN2-000 6441497
6 CLIP, PISTON PIN (1.2X20)........................ 1 2 3 4 4G -------- -------- 2 90601-KA5-000 10283987 KEY, SPECIAL WOODRUFF (25X18) ........ 1 2 3 4 4G -------- -------- 1 90741-ZE2-000 2027159
8 BEARING, RADIAL BALL RSH (6203)........ 1 2 3 4 4G -------- -------- 2 91003-HA7-672 2105096
9 BEARING, RADIAL BALL (32X80X17.5) .... 1 2 3 4 4G -------- -------- 1 91004-HN2-003 6434856
10 BEARING, RADIAL ROLLER (40X80X18).. 1 2 3 4 4G -------- -------- 1 91010-HN2-003 6434872
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HONDAMATIC
JULY, 2003 2003 American Honda Motor Co., Inc. 1-23
HN24E1600B
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-16
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 HONDAMATIC UNIT .................................. 1 -------- -------- 1 26000-HN2-010 6589931
HONDAMATIC UNIT .................................. 1 2 3 -------- -------- 1 26000-HN2-020 7066368
MATIC UNIT, HONDA ................................ 4 4G -------- -------- 1 26000-HN2-A00 7516305
2 GEAR, PRIMARY DRIVEN (70T)................ 1 2 3 4 4G -------- -------- 1 26221-HN2-000 6441927
3 SHAFT, ANGLE SENSOR .......................... 1 2 3 4 4G -------- -------- 1 27431-HN2-000 6441943
4 GEAR, MOTOR DRIVE .............................. 1 2 3 4 4G -------- -------- 1 27511-HN2-000 6441968
5 SHAFT, MOTOR DRIVE.............................. 1 2 3 4 4G -------- -------- 1 27526-HN2-000 6441976
6 BOLT, SOCKET (6MM) .............................. 1 2 3 4 4G -------- -------- 4 90002-HN5-670 6473110
7 BEARING, RADIAL BALL (6813) (NTNCORP.).................................................... 1 2 3 4 4G -------- -------- 1 91007-HN2-004 6443089
8 BEARING, RADIAL BALL (22X52X13)........ 1 2 3 4 4G -------- -------- 1 91014-HN2-003 6434898
9 O-RING (19.20X1.90) .................................. 1 2 3 4 4G -------- -------- 1 91301-P7X-003 5619002
10 PIN A, DOWEL (8X14) ................................ 1 2 3 4 4G -------- -------- 1 94301-08140 0069310
11 BOLT, FLANGE (6X35) .............................. 1 2 3 4 4G -------- -------- 3 95701-06035-00 2105864
12 BOLT, FLANGE (6X60) .............................. 1 2 3 4 4G -------- -------- 1 95701-06060-00 2791119
13 BOLT, FLANGE (6X105) ............................ 1 2 3 4 4G -------- -------- 1 95701-06105-00 5374327
14 PIN, DOWEL (7X12).................................... 1 2 3 4 4G -------- -------- 1 94303-07120 6591507
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TRANSMISSION
1-24 2003 American Honda Motor Co., Inc. JULY, 2003 1-C12
HN24E1700
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-17
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 MAINSHAFT (18T/24T) .............................. 1 2 3 4 4G -------- -------- 1 23211-HN2-000 6434302
2 COUNTERSHAFT ...................................... 1 2 3 4 4G -------- -------- 1 23221-HN2-000 6434310
3 GEAR, LOW (45T) ...................................... 1 2 3 4 4G -------- -------- 1 23411-HN2-000 6434328
4 SHIFTER, REVERSE COUNTERSHAFTLOW GEAR ............................................ 1 2 3 4 4G -------- -------- 1 23412-HN2-000 6434336
5 COLLAR, REVERSE SHIFT (LOW)............ 1 2 3 4 4G -------- -------- 1 23413-HN2-000 6434344
6 BUSH, SPLINE (25MM) .............................. 1 2 3 4 4G -------- -------- 1 23414-HA0-000 1820877
7 GEAR, HIGH (38T)...................................... 1 2 3 4 4G -------- -------- 1 23431-HN2-000 6434351
8 SHIFTER, GEAR (HIGH) ............................ 1 2 3 4 4G -------- -------- 1 23432-HN2-000 6441851
9 COLLAR, SHIFTER (HIGH) ........................ 1 2 3 4 4G -------- -------- 1 23433-HN2-000 6441869
10 BUSH, REVERSE GEAR (HIGH)................ 1 2 3 4 4G -------- -------- 1 23454-HN2-000 6441877
11 GEAR, FINAL DRIVE .................................. 1 2 3 4 4G -------- -------- 1 23621-HM7-000 4687281
12 GEAR, REVERSE IDLE (14T/29T).............. 1 2 3 4 4G -------- -------- 1 23721-HN2-000 6434385
13 SHAFT, REVERSE IDLE ............................ 1 2 3 4 4G -------- -------- 1 23731-HN2-000 6434393
14 GEAR, COUNTERSHAFT REVERSE (28T) 1 2 3 4 4G -------- -------- 1 23751-HN2-000 6434401
15 WASHER, SPECIAL (20MM) ...................... 1 2 3 4 4G -------- -------- 1 90451-HM7-000 4688610
16 WASHER (14.2MM) .................................... 1 2 3 4 4G -------- -------- 2 90451-115-000 0309013
17 WASHER, THRUST (20MM) ...................... 1 2 3 4 4G -------- -------- 1 90454-751-000 2093151
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TRANSMISSION
JULY, 2003 2003 American Honda Motor Co., Inc. 1-25
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-17
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
18 WASHER C, THRUST (25MM) .................. 1 2 3 4 4G -------- -------- 1 90459-357-000 0322255
19 RING, DOUBLE COIL (INNER) .................. 1 2 3 4 4G -------- -------- 4 90613-969-003 1543362
20 CLIP (32.5MM) ............................................ 1 2 3 4 4G -------- -------- 4 90616-969-000 1519792
21 BEARING, RADIAL BALL (6204) ................ 1 2 3 4 4G -------- -------- 1 91001-GM4-033 4328506
22 BEARING, RADIAL BALL (6006) ................ 1 2 3 4 4G -------- -------- 1 91003-HN2-004 6434831
23 BEARING, RADIAL BALL SPL (6203U)...... 1 2 3 4 4G -------- -------- 1 91006-HN2-003 6434864
24 BEARING, RADIAL BALL (6204U SPL.)(KOYO).................................................... 1 2 3 4 4G -------- -------- 1 91011-HN2-004 6443097
25 BALL, STEEL (#7) (7/32) ............................ 1 2 3 4 4G -------- -------- 54 96211-07000 0633032
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GEARSHIFT FORK
1-26 2003 American Honda Motor Co., Inc. JULY, 2003 1-C13
HN24E1800
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-18
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 FORK, FR. GEARSHIFT ............................ 1 2 3 4 4G -------- -------- 2 24211-HN2-000 6434419
2 SHAFT, GEARSHIFT FORK ...................... 1 2 3 4 4G -------- -------- 1 24241-HN2-000 6434427
3 DRUM ASSY., GEARSHIFT........................ 1 2 3 4 4G -------- -------- 1 24300-HN2-000 6434435
4 CENTER, GEARSHIFT DRUM.................... 1 2 3 4 4G -------- -------- 1 24321-HN2-003 6434443
5 GEAR, DRUM SHIFTER ............................ 1 2 3 4 4G -------- -------- 1 24331-HN2-003 6434450
6 STOPPER, GEARSHIFT DRUM ................ 1 2 3 4 4G -------- -------- 1 24430-HB3-000 2135416
7 SPRING, SHIFT DRUM STOPPER ............ 1 2 3 4 4G -------- -------- 1 24435-HM7-000 4687380
8 SPINDLE, GEARSHIFT .............................. 1 2 3 4 4G -------- -------- 1 24681-HN2-000 6434468
9 ARM, GEARSHIFT...................................... 1 2 3 4 4G -------- -------- 1 24682-HN2-003 6434476
10 PLATE, CHANGE SPINDLE........................ 1 2 3 4 4G -------- -------- 1 24685-HN2-000 644188511 PIVOT, SHIFT DRUM STOPPER ARM ...... 1 2 3 4 4G -------- -------- 1 90022-MG8-000 2045862
12 WASHER, DRUM STOPPER...................... 1 2 3 4 4G -------- -------- 1 90417-360-000 0341099
13 BEARING, RADIAL BALL (6203) (KOYO) .. 1 2 3 4 4G -------- -------- 1 91012-HC5-004 2735090
14 CIRCLIP (OUTER) (12MM) ........................ 1 2 3 4 4G -------- -------- 1 94510-12000 0112847
15 BOLT, FLANGE (6X16) .............................. 1 2 3 4 4G -------- -------- 1 95701-06016-00 2410892
16 BOLT, FLANGE (8X35) .............................. 1 2 3 4 4G -------- -------- 1 95801-08035-00 2774479
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FINAL SHAFT
JULY, 2003 2003 American Honda Motor Co., Inc. 1-27
HN24E1900
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-19
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 SHAFT, FINAL ............................................ 1 2 3 4 4G -------- -------- 1 23611-HN2-000 6434369
2 GEAR, FINAL DRIVEN (40T)...................... 1 2 3 4 4G -------- -------- 1 23631-HN2-000 6434377
3 CLIP, OIL SEAL .......................................... 1 2 3 4 4G -------- -------- 1 90601-HA0-000 2088581
4 BEARING, BALL (25X52X15) (NTN CORP.) 1 2 3 4 4G -------- -------- 1 91003-PY4-004 3676111
5 BEARING, RADIAL BALL (6005) ................ 1 2 3 4 4G -------- -------- 1 91012-HN2-004 6434880
6 OIL SEAL (24X34X7) (ARAI) ...................... 1 2 3 4 4G -------- -------- 1 91201-HC5-003 2735207
OIL SEAL (24X34X7) (KOYO) .................... 1 2 3 4 4G -------- -------- 1 91201-HC5-005 2735215
7 OIL SEAL (25X61X8.5)................................ 1 2 3 4 4G -------- -------- 1 91205-HM7-003 4688727
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RECOIL STARTER
1-28 2003 American Honda Motor Co., Inc. JULY, 2003 1-C14
HN24E2000
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-20
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 STARTER ASSY., RECOIL ........................ 1 2 3 -------- -------- 1 28400-HM7-A11 5897095
STARTER ASSY., RECOIL ........................ 4 4G -------- -------- 1 28400-HM7-A51 7253487
2 CASE, RECOIL STARTER.......................... 1 2 3 -------- -------- 1 28401-HM7-A11 5897103
CASE, RECOIL STARTER.......................... 4 4G -------- -------- 1 28401-HM7-A51 7253503
3 SPRING, RECOIL STARTER...................... 1 2 3 4 4G -------- -------- 1 28402-HM7-A11 5897111
4 SPRING, FRICTION.................................... 1 2 3 -------- -------- 1 28404-HM7-003 4713186
SPRING, FRICTION.................................... 4 4G -------- -------- 1 28404-HM7-A51 7253511
5 ROPE, RECOIL STARTER ........................ 1 2 3 4 4G -------- -------- 1 28407-HM7-A11 5897129
6 REEL, RECOIL STARTER.......................... 1 2 3 4 4G -------- -------- 1 28420-HM7-A11 5897137
7 RATCHET, STARTER ................................ 1 2 3 4 4G -------- -------- 1 28422-HE0-004 30586338 SPRING, RETURN...................................... 1 2 3 -------- -------- 1 28424-HM7-A11 5897145
SPRING, RETURN...................................... 4 4G -------- -------- 1 28424-HM7-A51 7253545
9 PULLEY, RECOIL........................................ 1 2 3 4 4G -------- -------- 1 28430-HM7-000 4687653
10 PLATE, FRICTION ...................................... 1 2 3 4 4G -------- -------- 1 28431-HE0-004 3058666
11 NUT, FLANGE ............................................ 1 2 3 4 4G -------- -------- 1 28448-HM7-A11 5897152
12 KNOB, RECOIL STARTER ........................ 1 2 3 -------- -------- 1 28461-HM7-003 4687661
KNOB, RECOIL STARTER ........................ 4 4G -------- -------- 1 28461-HM7-A51 7253552
13 CLIP, SUB-WIRE ........................................ 1 2 3 4 4G -------- -------- 1 32901-MA1-000 1054113
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RECOIL STARTER
JULY, 2003 2003 American Honda Motor Co., Inc. 1-29
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-20
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
14 BOLT, SPECIAL (12MM) ............................ 1 2 3 4 4G -------- -------- 1 90081-HN5-670 6314678
15 CLIP, WIRE HARNESS .............................. 1 2 3 4 4G -------- -------- 1 90684-ZA0-601 2539138
16 O-RING (11.5X2.3)...................................... 1 2 3 4 4G -------- -------- 1 91303-679-003 2445526
17 BOLT, FLANGE (6X14) .............................. 1 2 3 4 4G -------- -------- 4 96001-06014-00 2154672
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CARBURETOR
1-30 2003 American Honda Motor Co., Inc. JULY, 2003 1-C15
HN24E2100D
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-21
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
1 GASKET SET .............................................. 1 2 3 -------- -------- 1 16010-HM7-700 4805966
GASKET SET .............................................. 4 4G -------- -------- 1 16010-HN7-003 7369325
2 GASKET SET .............................................. 1 2 3 4 4G -------- -------- 1 16010-HN2-003 6434013
3 NEEDLE SET, JET...................................... 1 2 3 4 4G -------- -------- 1 16012-HN2-003 6434021
4 FLOAT SET ................................................ 1 2 3 -------- -------- 1 16013-HN5-671 6313068
FLOAT SET ................................................ 4 4G -------- -------- 1 16013-HN8-003 7130040
5 CHAMBER SET, FLOAT ............................ 1 2 3 -------- -------- 1 16015-HN2-003 6434039
CHAMBER SET, FLOAT ............................ 4 4G -------- -------- 1 16015-HN2-A01 7458557
6 SCREW SET .............................................. 1 2 3 4 4G -------- -------- 1 16016-HM7-670 4686804
7 JOINT SET .................................................. 1 2 3 4 4G -------- -------- 1 16026-MR1-004 28522758 SCREW SET .............................................. 1 2 3 4 4G -------- -------- 1 16028-HM5-730 4523817
9 PLATE SET, VALVE.................................... 1 2 3 4 4G -------- -------- 1 16037-HN2-003 6434047
10 PLATE SET, STAY...................................... 1 2 3 4 4G -------- -------- 1 16038-HN2-003 6434054
11 VALVE, STARTER ...................................... 1 2 3 4 4G -------- -------- 1 16046-HN2-003 6434062
12 PUMP SET .................................................. 1 2 3 4 4G -------- -------- 1 16048-HM7-700 4805982
13 SPRING, COMPRESSION COIL ................ 1 2 3 4 4G -------- -------- 1 16050-MBH-670 5723010
14 SPACER SET, THROTTLE SENSOR ........ 1 2 3 4 4G -------- -------- 1 16060-HN2-003 6434070
15 HEATER ASSY. .......................................... 1 -------- -------- 1 16070-HN5-671 6313076
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CARBURETOR
JULY, 2003 2003 American Honda Motor Co., Inc. 1-31
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-21
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
15 HEATER ASSY. .......................................... 2 3 4 4G -------- -------- 1 16070-HN5-672 7111057
16 O-RING (1.3X4.3)........................................ 1 2 3 4 4G -------- -------- 2 16075-GHB-640 4774907
17 SCREW, PAN.............................................. 1 2 3 4 4G -------- -------- 1 16080-HC0-003 2515708
18 SCREW, PAN (5X16) .................................. 1 2 3 4 4G -------- -------- 2 16080-MT7-000 4636825
19 CARBURETOR ASSY. (VE6AB A).............. 1 -------- -------- 1 16100-HN2-003 6441703
CARBURETOR ASSY. (VE6AB B).............. 1 2 3 -------- -------- 1 16100-HN2-013 7489610
CARBURETOR ASSY. (VE6AC A) ............ 4 4G -------- -------- 1 16100-HN2-A01 7458565
20 TOP ............................................................ 1 2 3 4 4G -------- -------- 1 16107-HN2-003 6434088
21 PISTON, VACUUM...................................... 1 2 3 4 4G -------- -------- 1 16111-HN2-003 643409622 VALVE, FLOAT............................................ 1 2 3 -------- -------- 1 16155-HN2-000 6434104
VALVE, FLOAT............................................ 4 4G -------- -------- 1 16155-HN7-003 7400948
23 COVER, BODY............................................ 1 -------- -------- 1 16157-HC4-003 2730679
COVER, BODY............................................ 2 3 4 4G -------- -------- 1 16157-HN8-003 7130149
24 GASKET, FLOAT CHAMBER...................... 1 2 3 -------- -------- 1 16163-HM7-700 4806014
GASKET, FLOAT CHAMBER...................... 4 4G -------- -------- 1 16163-MEA-671 7090889
25 HOLDER, NEEDLE JET.............................. 1 2 3 4 4G -------- -------- 1 16165-HN2-003 6434112
26 HOLDER, JET ............................................ 1 2 3 4 4G -------- -------- 1 16168-HC4-003 2977262
27 COLLAR, SETTING .................................... 1 2 3 -------- -------- 1 16172-HN0-A00 5746482
COLLAR, SETTING .................................... 4 4G -------- -------- 1 16172-KEB-610 7400963
28 BINDER ...................................................... 1 2 3 4 4G -------- -------- 1 16179-HA0-003 1831569
29 BINDER(NOT AVAILABLE).................................. 1 2 3 4 4G -------- -------- 1 16179-428-670 4241816
BINDER ...................................................... 1 2 3 4 4G -------- -------- 1 16179-428-671 0684217
30 VALVE, ONE-WAY...................................... 1 2 3 4 4G -------- -------- 1 16180-HC4-003 2977270
31 TUBE, AIR VENT ........................................ 1 2 3 4 4G -------- -------- 1 16196-HN2-003 6434120
32 CLIP, PLATE .............................................. 1 2 3 4 4G -------- -------- 1 17191-MN5-740 2803427
33 SCREW, PAN (4X8) .................................... 1 2 3 4 4G -------- -------- 4 93500-04008-0H 0369017
SCREW, PAN (4X8) .................................... 1 2 3 4 4G -------- -------- 4 93500-04008-1H 1295146
34 SCREW, PAN (4X14) .................................. 1 2 3 4 4G -------- -------- 4 93500-04014-0H 0583179
SCREW, PAN (4X14) .................................. 1 2 3 4 4G -------- -------- 4 93500-04014-1H 1415462
35 SCREW-WASHER (4X12) .......................... 1 2 3 4 4G -------- -------- 2 93892-04012-08 0485953
SCREW-WASHER (4X12) .......................... 1 2 3 4 4G -------- -------- 2 93892-04012-18 1446749
36 SCREW-WASHER (5X14) .......................... 1 2 3 4 4G -------- -------- 2 93892-05014-08 0660720
SCREW-WASHER (5X14) .......................... 1 2 3 4 4G -------- -------- 2 93892-05014-18 1418912
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CARBURETOR
1-32 2003 American Honda Motor Co., Inc. JULY, 2003 1-C16
HN24E2100D
1 =TRX500FA’01 4G=TRX500FGA’04
2 =TRX500FA’02
3 =TRX500FA’03
4 =TRX500FA’04
E-21
Engine
Serial Number
Ref Description Model From To QTY Part Number H/C
37 CLIP, TUBE (B17) ...................................... 1 2 3 4 4G -------- -------- 5 95002-02079 4171690
38 CLIP, TUBE (B18) ...................................... 1 2 3 4 4G -------- -------- 1 95002-02089 4125571
39 CLIP, TUBE (B6.5) ...................................... 1 2 3 4 4G -------- -------- 1 95002-02659 4125589
40 BULK HOSE, VACUUM (3.5X1000)(3.5X140) ................................................ 1 2 3 4 4G -------- -------- 2 95005-35001-50M 4603536
41 JET, MAIN (#152)........................................ 1 2 3 4 4G -------- -------- (1) 99101-GHB-1520 4563003
JET, MAIN (#158)........................................ 1 2 3 4 4G -------- -------- 1 99101-HN2-1580 6434997
42 JET, SLOW (#45) ........................................ 1 2 3 4 4G -------- -------- 1 99104-HN2-0450 6435002
43 JET (#85) .................................................... 1 2 3 4 4G --