Honda Trx 500 Parts

8/16/2019 Honda Trx 500 Parts

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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

4 2003 American Honda Motor Co., Inc. JULY, 2003


5/148

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


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


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


(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







TRX500FA’02 2002

No.

COLOR CODE

BASE COLOR

R232

Patriot red

R232

G152

Adventure

green

G152

Y151

Starburst

yellow

Y151R

A

RE

A


1 CAP, HANDLE COVER 53206-HM8-000 ZA ZA ZA


(LOWER)

61302-HN0-A00 ZA ZA ZA


(UPPER)

61301-HN0-A00 ZC ZC ZC

4 COVER ASSY., L. ENGINE SIDE 11325-HN2-000 ZA ZA ZA


(WOL)

83650-HN2-000 ZA ZA ZA

6 COVER ASSY., R. ENGINE SIDE 11315-HN2-000 ZA ZA ZA


(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







TRX500FA’03 2003

No.

COLOR CODE

BASE COLOR

R232

Patriot red

R232

G152

Adventure

green

G152

Y151

Starburst

yellow

Y151R

A

RE

A




(LOWER)



(UPPER)




(WOL)

83650-HN2-000 ZA ZA ZA

6 COVER ASSY., R. ENGINE SIDE 11315-HN2-000 ZA ZA ZA


(WOL)

83550-HN2-000 ZA ZA ZA








15 FENDER, FR. (WOL) 61100-HN2-000 ZB ZA ZC16 FENDER, RR. (WOL) 80100-HN2-000 ZB ZA ZC



19 LABEL, COLOR 87565-HN2-830 ZA ZB ZC
















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COLOR TABLE







TRX500FA’04 2004

No.

COLOR CODE

BASE COLOR

R232

Patriot red

R232

G152

Adventure

green

G152

Y151

Starburst

yellow

Y151R

A

RE

A




(LOWER)



(UPPER)




(WOL)


6 COVER ASSY., R. ENGINE SIDE 11315-HN2-A00 ZA ZA ZA


(WOL)









15 FENDER, FR. (WOL) 61100-HN2-000 ZB ZA ZC16 FENDER, RR. (WOL) 80100-HN2-A00 ZB ZA ZC



19 LABEL, COLOR 87565-HN2-A00 ZA ZB ZC















35 WHEEL SUB-ASSY., FR. 44650-HN8-000 ZA ZA ZA


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COLOR TABLE







TRX500FGA’04 2004

No.

COLOR CODE

BASE COLOR

R232

Patriot red

R232

G152

Adventure

green

G152

Y151

Starburst

yellow

Y151R

A

RE

A




(LOWER)



(UPPER)




(WOL)


6 COVER ASSY., R. ENGINE SIDE 11315-HN2-A00 ZA ZA ZA


(WOL)


8 COVER, BATTERY BOX 80311-HN2-000 ZA ZB 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



19 LABEL, COLOR 87565-HN2-A10 ZB ZA ZC


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









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


18/148

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


19/148

CYLINDER HEAD

JULY, 2003 2003 American Honda Motor Co., Inc. 1-3


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-1

Engine

Serial Number


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


20/148

CAMSHAFT


HN24E0200


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-2

Engine

Serial Number


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


21/148

CAMSHAFT



2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-2

Engine

Serial Number


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


22/148

CAM CHAIN


HN24E0300ZA


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-3

Engine

Serial Number


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


23/148

CYLINDER


HN24E0400A


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-4

Engine

Serial Number


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


24/148

WATER PUMP


HN24E0500A


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-5

Engine

Serial Number


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


25/148

OIL TANK


HN24E0600A


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-6

Engine

Serial Number


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


26/148

OIL TANK


HN24E0600A


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-6

Engine

Serial Number


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


27/148

FRONT CRANKCASE COVER


HN24E0700A


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-7

Engine

Serial Number


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


28/148

FRONT CRANKCASE COVER


HN24E0700A


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-7

Engine

Serial Number





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


29/148

CLUTCH


HN24E0800


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-8

Engine

Serial Number


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


30/148

OIL PUMP


HN24E0900A


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-9

Engine

Serial Number


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


31/148

REAR CRANKCASE COVER


HN24E1000B


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-10

Engine

Serial Number


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







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


32/148

REAR CRANKCASE COVER


HN24E1000B


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-10

Engine

Serial Number


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


33/148

ALTERNATOR


HN24E1100


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-11

Engine

Serial Number


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


34/148

STARTER GEAR


HN24E1200


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-12

Engine

Serial Number


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


35/148

STARTER MOTOR


HN24E1300A


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-13

Engine

Serial Number


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


36/148

CRANKCASE


HN24E1400A


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-14

Engine

Serial Number


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


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


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


37/148

CRANKCASE



2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-14

Engine

Serial Number


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


38/148

CRANKSHAFT • PISTON


HN24E1500


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-15

Engine

Serial Number


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


39/148

HONDAMATIC


HN24E1600B


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-16

Engine

Serial Number


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


40/148

TRANSMISSION


HN24E1700


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-17

Engine

Serial Number


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


41/148

TRANSMISSION



2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-17

Engine

Serial Number


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


42/148

GEARSHIFT FORK


HN24E1800


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-18

Engine

Serial Number


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


43/148

FINAL SHAFT


HN24E1900


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-19

Engine

Serial Number


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


44/148

RECOIL STARTER


HN24E2000


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-20

Engine

Serial Number


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


45/148

RECOIL STARTER



2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-20

Engine

Serial Number


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


46/148

CARBURETOR


HN24E2100D


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-21

Engine

Serial Number


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


47/148

CARBURETOR



2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-21

Engine

Serial Number


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


48/148

CARBURETOR


HN24E2100D


2 =TRX500FA’02

3 =TRX500FA’03

4 =TRX500FA’04

E-21

Engine

Serial Number


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 --

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Honda Trx 500 Parts