2004-2007 Rancher 400 AT (TRX400FA / TRX400FGA) Service Repair Manual (Highly Detailed FSM, Preview)

A Few Words About Safety Service Information J ! .. , The selVlCE! and repair inlormatlQn contained in thIS manual is intended for use by qualified, professional techrllcians. Attempting serv.ce or repairs WIthout the proper tramlng. tools, and eqUipment oould cause injury to you or others. h could also damage Ihe vehiCle or create an unsafe condition This manual deSCri bes the proper methods and procedures lor performing service, maintenance, and repair'S. Some procedures reqUire the use of specialty designed tools and dedicated eqUipment. Any person who Intends to use a replacement part, servICe procedure or a tool thaI IS not recommended by Honda, must delermlne the riSks 10 their personal safety and the safe operation of the vehicle. If you need to replace a part, use genuine Honda pans with !he correc1 part number or an equIValent pan . We strongly recommend that you do not use replacement parts of I nferior quality . For Your Customer 's Safety Proper servICe and maintenance are essential 10 the customer's safety and the reliability of the \lehlcle. Any error or oversight while servicing a vehicle can result In faulty operation, damage to the vehicle, or Injury to others. For Your Safety Because this manual is Intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g . Hot parfS.-wear gloves). If you have not received shop safety training or do not feel confident about your knOWledge of safe servicing pracbce, we recommended that you do not attempt to perform the procedures described in this manual Some of the most important general service safety precautions are given below. However, we cannot warn you 01 evety conceivable hazard that can arise in performing servICe and repair procedures Only you can dedde whether or not you should pertorm a given task. Important Safety Precautions AWARNING Improper service or repairs can create an unsafe condition that can cause your customer or others \0 be seriously hurt or killed, Fol low the procedures and precautions In this manual and other service materials I . precautJons or lolled. Follow the procedures and precautions In this manual carefully Make sure you have a clear understanding of all baSIC shop safety practices and that you are weaTlng appropriate clothing and uslOQ safety equipment. When performing any service task, be especially careful of the foI lowlng: o Read all of the Instructions belere you begin, and make sure you have the tools. the replacement or repair parts, and the skiJts required to perform the tasks safely and completely. o Protect your eyes by using proper salety glasses, goggles or lace shields any time you hammer, dnU, grind, pry or work around pressurized air or liquids, and springs or other slored-energy components. If there is any doubt, pu1 on eye protection. o Use other protective ~ when necessary, for e)(ample gloves or salety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before.,~b something that looks like it can hurt YOU . stop and put on gloves • Proted yoursaH~thers 'l¥henever you have the vehicle up In the aI r. AIry time you lift the vehicle, either with a hoist or a Jack.. make su re ~t il ls alwayS Secu rely supported. Use jad< stands. Make sure the engine IS oH before you begin any seTVlCing procedures, unless the Instruction tells you to do otherwise. ThIs will help eliminate several potentIa! hazards: o Carbon monoxide potsonlng from engine exhaust. Be sure there IS adequate ventilallon whenever you run the engine. o Burns from hoi parts or coolant. lei the engine and exhaust system cOO before working In those areas. o Injury from fl"IOIIing parts If the InstructlOfl telis you to run the engine be sure your hands lingers and clothing are out of the way Gasoline vapors and hydrogen gases from batteries are explosive To reduce the posslbltity of a fire Of exptosion, be careful when working around gaSOline or batteries. • Use only a nonflammable solvent, not gasoline. to clean paris. • Never drain or store gasoline in an open container. • Keep all cigarettes. sparks and flames away from the battery and all fuel-related parts. '-

HOW TO USE THIS MANUAL This service manual deSCfiOOs the SllfVice procedures lor the TRX400FA/TRX-4OOFGA. Follow !he Maimenance Schedule (Sectioo 4) recommendations 10 8I\SUta thaI the veOide Is in peaIt operating cond>tion and the emISSion kNels are wi t!l,n!he slanOO.(lS set by !he Calilomlll Air Resources Board. PerIooning the first &eheduled maintenance Is very il\"flOf1llnl. 'I COITIpIIflS8les!of the Initial wear thai occtJlS during Ihe bfellk-In pefiod . Sec:IIon$ 1 end 4 awtv 10 the whole vehicle. 5ecI1on 3 illl.$lrales ptocedures lor remtlY8V1ns1aJllllion 01 components thaI may be required 10 perform selVice described in the following sectioos. Section Slhrough 25 descOOe parts althe vehicle, grouped according 1o """"'" F~ the seclion you want on this page. then turn 1o the table 01 contents on !he HISI page 01 the sactlon. Most sectioos start with an assembly or system Hluslrallon. seMce Inlormatior! and troubleshooting lor the SOCOOn. The subsequent pag&s giYe deUliled procedure. II you are fIOIlamiliar WIth tlus vehicle, go 10 section 2 Technical Feature. ~ )IOU don1 know the soorcu or the trOUble. go 10 soolion 26 TroubIe5hootlng. Your safely, and the salety 0/ oth8fs, Is very important. To heIp)lOU mak8 lntormed d9cisions we haY!! provided safety messages and other information throughout thIS manual , 04 OOUI'!)e, it is I"(lt pmctical or pOSSible to wern you about all the /laZarUs associated with sefVicing this vehicle. You must LiSe your own good Judgement. You wiH lind Imporlant safi!1y InIormalion In a variety of IoIms lneIuding: • Safety Labels -00 the vehicle • Safely Messages - preceded by 8 safety alert symbol It sod one 01 tlwee sgnallYOrUs, DANGER, WARNING, or CAUTION These signal words mean: fi.4i~[M;i ~RTV;;I~ :,,~~DI~~~SLY You CAN be KILLED or SERIOUSlY HURT IDb"Wt'! !f! :J H you don'l follow instructions. tiM'm.U' :'~s~ HURT H you don" IoIIow • Instruo;t;o.ns _ how 10 service Itlis vehICle correctly and aaJely At> )IOU read this manual, )IOU win find inlormatJon thai is preceded by a DlOt'iiXl symboi, The purpose 01 Itlis message is to help prevent damage to)'OUr vehicle, olh&r property, or the erwironm&n1 , w z a z w -' .. ~ ~ W -' W CONTENTS GENERAL INFORMATION TECHNICAL FEATURE MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVALI1NSTALLATION CYLINDER HEADNALVEICAMSHAFT CYLINDER/PISTON CENTRIFUGAL CLUTCH ALTERNATOR/STARTER CLUTCH SUB-TRANSMISSION/GEARSHIFT LINKAGE CRANKSHAFT/AUTOMATIC TRANSMISSION FRONT WHEEUSUSPENSIDN/STEERING REAR WHEEUSUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM REAR DRIVING MECHANISM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER L1GHTSlMETERSISWITCHES SELECTABLE 4WD SYSTEM HONDAMATIC WIRING DIAGRAM TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. eI Replace the partes) with new one(s) before assembly. 78 Use recommended engine oil, unless otherwise specified. ~ Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1). UU;~ Use multi-purpose grease (lithium based multi-purpose grease NLGt #2 or equivalent) . • Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). ~ Example: Molykote® BR-2 plus manufactured by Dow Corning U.SA Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A. ~ Honda Moly 60 (U.S.A. only) Aocol ASP manufactured by Aocol Limited, UK Aocol Paste manufactured by Sumico Lubricant. Japan ;1iSiiI Use silicone grease. ca Apply a locking agent. Use a middle strength locking agent unless otherwise specified. ",- Apply sealant. I Use DOT 4 brake fluid. Use the recommended brake ftuid unless otherwise specified. .. Use Fork or Suspension Fluid .

L 1. GENERAL INFORMATION SERVICE RULES ............................................ 1-2 MODELIDENTIFICATION····-·········_·········_····· 1-2 GENERAL SPECIFICATIONS·········_··············· 1-5 LUBRICATION S YST EM SPECIFICATIONS · 1-7 FUEL SYSTEM SPECiFiCATIONS················· 1-7 CY LINDER HEADIVALVE/ CAMSHAFT SPECiFiCATIONS········································ ... 1-8 CYLINDER / PISTON SPECIFICATIONS ·--······ 1-8 CENTRIFUGAL CLUTCH SPECIFICATIONS · 1-8 ALTERNATOR/ STARTER CLUTCH SPECIFICATIONS·······_·········_·········_··············· 1-9 SUB-TRANSMISSION SPECiFiCATIONS· ·· ·· 1-9 CRANKSHAFT/AUTOMATIC TRANSMISSION SPECiFiCATIONS··········································· 1-9 FRONT WHEE l/ SUSPENSION / STEERING SPECIFICATIONS····-···································· 1-10 REAR WHEEL/SUSPENSION SPECiFiCATIONS········································· 1-10 BRAKE SYSTEM SPECIFICATIONS·············1-10 FRONT DRIVING MECHANISM SPECiFiCATIONS·········································· 1-11 REAR DRIVING MECHANISM SPECiFiCATIONS········································· ·1 - 11 BATTERY/ CHARGING SYSTEM SPECIFICATIONS ·· ....................................... ·1-11 IGNITION SYSTEM SPECIFICATIONS ········ 1-11 ELECTRIC STARTER SPECIFICATIONS ······1-11 LIGHTS/ METERS/ SWITCHES SPECiFiCATiONS······························· ··········· 1-12 STANDARD TORQUE VALUES ···················1-13 ENGINE & FRAME TORQUE VALUES ········1-13 LUBRICATION & SEAL POINTS ···· ·· ············ 1-19 CABLE & HARNESS ROUTING ···················1-24 EMISSION CONTROL SYSTEMS ·· ········· ····· 1-39 EMISSION CONTROLINFORMA TlON LABEL (U .S.A. only) ·················· ·· ················· 1-40 - 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don 't meet Honda's design specifications may cause damage to the vehicle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plat es when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified t orque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. lubricate any sliding surfaces before reassembly. 7. After reassembly. check all parts for proper installation and operation. 8. Route all electrical wires as show in the Cable and Harness Routing (page 1·24). MODEL IDENTIFICATION '04 shown; Aft er '04 si mil ar: 1-2 I I i

The model identification label is located on the frame down tube. The frame serial number is stamped on the front side of the frame . The engine serial numbe r is stamped on the left side of the rear crankcase. The carburetor identification number is stamped on the leh side of the carburetor body. GENERAL INFORMATION 1-3

GENERAL INFORMATION The color label is attached on the cross member of the frame under the seal. When ordering color coded parts, alwavs specify the designated color code. 1-4 -

GENERAL SPECIFICATIONS DIMENSIONS ITEM Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight Curb weight GENERAL INFORMATION SPECIFICATIONS 2,031 mm (SO.O in) 1,114 mm (43.9 in) 1,157 mm (45.6 in) 1,246 mm (49. 1 in) 850 mm (33.5 in) 860 mm (33.9 in) 824 mm (32.4 in) 336 mm (13.2 in) 184 mm (7.2 in) 254 kg (560 Ibs) 265 kg (583 Ibs) '--- ..-"",, ___ --1_ Maximum weight capacity I FRAME Frame type _ ______ ~2~2~O~kg{~5~lb~'I ~-------- Double cradle Front suspension Front wheel travel Front damper Rear suspension Rear wheet travel Rear damper Front tire size Rear lire size Front rim sile Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity h"'''''",-___ --1---;. Fuel tank reserve capacity ENGINE Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes lubrication system Oil pump type Cooling system Ai r filtration h"" oo"""",,,,,_--1---:;. En g ine dry weight CARBURETOR Carburetor type L ______ -L Throttle bore Double wishbone 150 mm (5.9 in) Doub le tube Tra iling 150 mm (5.9 in) Double tube AT24 x 8-12 * * AT24 x 10- 11 * * 1 2x6.0AT 11 x 7.5 AT Bridgestone Sridgestone Hydraulic drum brake (Dual leading) Mechanical drum brake 4" 17 mm (0.7 in) 0.10 14.5 titers (3.83 US gal, 3.19 Imp gal) ____ 1-:3~.~B~Ii~" ~ ''''s: (lOO US gal, 0.84 Imp gal) Single cylinder, longitudinally installed 85 X 70 mm (3 .35 X 2.76 in) at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift 397 cm l (24.2 cu-i n) 9.1 : 1 OHV 7" STDC 42" ABDC 8" BBDC 39" ATDC Forced pressure (dry sump) Trochoid Air cooled Oiled urethane foam 51.7 kg (114.0 Ibs) Constant Vacuum (VE type) __________ 1- 36 mm (1.4 in) '---__________ _ 1-5

GENERAL INFORMATION ITEM SPECIFICATIONS DRIVE TRAIN Clutch system Centrifugal, wet Transmission HQNOAMATIC (automatic; non -stage speed) with sub-transmission (constant mesh) Primary reduct ion 1.048 (65f62) Secondary reducti on 1.722 (31118) Final reduction Front 3.769 ( 13149 ) Rear 3.692113/48) Sub-transmission Drive 1.684 \32/19) ratio Reverse 2.021 (24119 · 32f29) Gearshift pattern Sub-transmission D-N-R o (Drivel 2-mode; Aut omatic and Manual (ESP; 5 speeds) A (Reverse) , -mode (fixed low ratio) ELECTRICAL Ignition system DC-COI (Direct current-Capacitor discharge ignition) Starting syst em Electric starter motor and eme r gency recoil starter Charging system Triple phase output alternator Regulator/rectifier SeA shorted, trip le phase full wave rectifica- tion Lighting system Banery 1-6

2004-2007 Rancher 400 AT (TRX400FA / TRX400FGA) Service Repair Manual (Highly Detailed FSM, Preview)

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