2007- 2012 HONDA TRX420 RANCHER 420 Repair Service Manual

HOW TO USE THIS MANUAL Thfs servfCEI manual d8scntles lI1e SIIr"IlCe proc::e<luras lor the TRX420TMfTElFMfFElFPMlFPE Fojlow th.a Mamlenance Schedule (Section 4) feeommendah::)nS \0 l!flSure ItIallhe vehICle Is ;n peak operalil1Q cond~lon and the emission levels are llirthln Iha standards set by !he U,S. Enworlmenlal Protection Agoocy (EPA). Cal l/orma Air Resources Board (CARB) and Enwonman! Cal'\3.da (Ee) Perlormlr.g tilt! lirs! scheduled maln\enaoc8 IS very important 11 compensates lor 1he ,Moa l wea, lhat OCCurS dUring the Dreak·in period. Sectl(lrlS 1 and 4 apply to the whole vehICle. Secl.on 3 lIIuslrat!)S procedures tor remlWaVonstanation 01 compooanls Ihal may be required to perform servICe described In the folloWing sections, sections 5 through 24 deSCribe pariS 01 the vehicle, groupOO according 10 location FIfId Ihe sechon yoo want on lI1is page, then tum \0 the tabia of 00<11eniS on the lirst page 01 \I1(l &eClion Most seclioos start with an assembly or system IlIuslrBhon, servICe information and troubleshooting lor the section. The subsequ8f1t pages give detailed procedure If you are not familiar With this \fQhocJe . read Technical Features in Section 2. If you don1 know lI1e source 01 the 'rouble, go to sectlOl1 26 TroubJeshootmg. Your safety. and the safety of others. is 'lOry I mportant. To help you make Informed deciSions we haw prwided safety messages and O1OOr inlormatloo throughollllh1s manual. O! course. it IS nOl practical or possible to warn you about all the ha..<:ards associated with serw;mg thiS vehiCle You must use your own good judgemen1. You will lind importimt salety Information in a variety of forms mooing. • Safety Labels - on the vehicle • Safety Messages - preceded by a safety alert symbol i and one of three signal words, DANGER. WARNING, or CAUTION These slgnaf words mean: You WILL be KILLED or SERIOUSLY n'l;lWW' HURT ilyou don'tlof low instructIOnS . fflWiWiN. eijiii[ 'V' You CAN be KILLED or SERIOUSLY HURT II you don't fol low InStlUCIlOns . You CAN be HURT il you don't follow instructions. • Instruct!(lns - how to service thiS vehocle corre<:tly and safely As you read thIS manual. you WIll find informat,on thaI is preceded by a IJiOlUJ symbol The purpose ot th,s message Is to help prevent damage to your vehICle, other property. or the enViloomen1. w z a z w <J) u; <J) .. :I: U ..J .. !,1 a: t; w ..J W CONTENTS GENERAL INFORMATION TECHNICAL FEATURES FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM (PGM-FI) COOLING SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVE CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE REAR WHEEUSUSPENSION BRAKE SYSTEM REAR DRIVING MECHANISM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERs/SWITCHES TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to Ihese symbols, it would be explained specifically in the text without the use of the symbols. 111 Replace the parl(s) with new one(s) before assembly. -, Use the recommended engine oil, unless otherwise specified. 7J Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a rat io of 1:1). _..iiiiii1 .. Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing mote than 3% molybdenum disulfide, NlGI #2 or equivalent). ~ Example: Molykole® BR-2 plus manufactured by Dow Corning U.S.A. 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) Rocol ASP manufactured by Roeol Limited, U.K. Rocol Paste manufactured by Sumico lubricant , Japan .AiSiII Use si licone grease. 1m Apply a Iocfo;ing agent. Use a medium strength locking agent unless otherwise specified. ",@Ell Apply sealant. • Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified . .. Use fork or suspension fluid.

1. GENERAL INFORMATION SERVICE RULES · .. · .. ··································· 1-2 MODEL IDENTIFICATION .... · ...................... 1-3 GENERAL SPECIFICATIONS ...................... 1-6 LUBRICATION SYSTEM SPECIFICATIONS .. · .... · .......... ·· .. · .. · .. ·· ........ 1-12 FUEL SYSTEM IPGM· FI) SPECIFICATIONS ·.... · .. ·· .. · .. · .. · ............ ·.... ·· 1-12 COOLING SYSTEM SPECIFICATIONS .... 1-12 CYLINDER HEADIVALVE SPECIFICATIONS · .. · ............ .. ..... .. .. ........... 1-13 CYLINDER/ PISTON SPECIFICATIONS .... 1·13 CLUTCH/ GEARSHIFT LINKAGE SPECIFICATIONS ··· .... ·· .. · .. · .. ··· .. ·.... · .... · .. · .. 1·14 ALTERNATOR /S TARTER CLUTCH SPECIFICATIONS .. · .... · .............................. 1-14 CRANKCASE/TRANSMISSION/CRANK· SHAFT/ BALANCER SPECIFICATIONS .... 1-14 FRONT WHEEL/ SUSPENSION/ STEERING SPECIFICATIONS ·............ · ............. .......... . 1-15 REAR WHEEL/ SUSPENSION SPECIFICATIONS ...................................... 1-15 BRAKE SYSTEM SPECIFICATIONS ........ 1-15 FRONT DRIVING MECHANISM SPECIFICA- TIONS IFM/FE/ FPM/ FPE models) .......... 1-15 REAR DRIVING MECHANISM SPECIFICATIONS .......... .. ......................... 1-1 6 BAITERY/CHARGING SYSTEM SPECIFICATIONS ..................................... 1-16 IGNITION SYSTEM SPECIFICATIONS .... 1-16 ELECTRIC STARTER SPECIFICATIONS ................ .. ................... 1-16 LIGHTS/ METERS/SWITCHES SPECIFICATIONS ..................................... 1-16 STANDARD TORQUE VALUES .............. · 1-18 ENGINE & FRAME TORQUE VALUES .... 1-18 LUBRICATION & SEAL POINTS ........ ...... 1-24 CABLE & HARNESS ROUTING 1'07 - '08 model) ...................................... · 1-28 CABLE & HARNESS ROUTING IAfter ' 08 model) ..................... .. ..... ... .. ..... 1-47 EMISSION CONTROL SYSTEMS ............ 1-71 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 lools 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 plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. lubricate any sliding surfaces before reassembly. 7. Aher reassembly. check all parts for proper installation and operation. 8. Route all electrical wires as shown in the Cable & Harness routing (page 1-28). ABBREVIATION Throughout this manual, the following abbreviation are used to identify the respective parts or systems. 1-2

MODEL IDENTIFICATION This manual covers 4 types of TRX420 models: • TM - 2WD/ left foot operated gearshift • TE - 2WD/Electric shift program (ESP) • FM - 4WD/Left foot operated gearshift • FE - 4WD/Electric shift program (ESP) • FPM - 4WD/left foot operated gearshift/Electric Power Steering (EPS) • FPE - 4WD/Eleciric shift program (ESP)lElectric Power Steering ( EPS) Be sure to refer to the procedure that pertains to the appropriate version of the TRX420. TR X420FE model shown: SERIAL NUMBERS GENERAL INFORMATION The Vehicle Identification Number (VIN) is stamped on the front side of ~------------------, the frame through the front fender. ) c \ VIN 1-3

GENERAL INFORMATION The engine serial number is stamped on the left side of the rear crankcase. The throttle body identification number is stamped on the upper side of the throttle body. LABELS THROTTLE BODY IDENTIFICATION NUMBER '07; The name plate (U.S.A. type) or safety certification label (Canada I~~~:~~~~~~~~~~~~l type) is attached on the left front frame down pipe. (F 'iJ;, • .r- WJ~I'\ @ ~ \c:::1 \ & B :~ -;:!.::: 0' . c \Y. ~, . NAME PLATE (U.S.A.) ~ . SAFETY CER TIFICATION LABEL (Canada) After '07: The name plate (U.S.A. type) or safety certification label r=====~~~;i~~r~~ ' ~=l (Canada type) is attached on the right front frame down pipe. 1 !~f~~~ ' ~ ~ /~- -/-~ \ ~ ~g ~~ . NAME PLATE I~.I ~ I . SAFETY CERTIFICATION LABEL (Canada) 1-4

The color label is attached on the left frame pipe under the seat. When ordering color-coded parts, always specify the designated color code. '07: The vehicle emission control information label is attached on the right front frame pipe. '08: The vehicle emission control information label is attached on the left front frame pipe. After '08: The vehicle emission control information label is attached on the left front frame pipe. GENERAL INFORMATION U_S.A. only: ( EMISSION CONTAOL INFOAMATION LABEL EMISSION CONTAOLINFOAMATION ..... LABEL (U.S.A. and Canada types) ~ - " \ ;; EMISSI ON CONTAOLINFORMATION LABEL (Canada type only) EMISSION CONTROllNFOAMATION LABEL (U.S.A. and Canada types) 1-5

GENERAL INFORMATION GENERAL SPECIFICATIONS TRX420TM/ TE DIMENSIONS FRAME ITEM Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Curb weight Maximum weight capacity Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity SPECIFICATI ONS 2,055 mm (80.9 in) ---- --1 1,172 mm (46.1 in) 1,148 mm (45.2 in) , ,256 mm (49.4 in) 847 mm (33.3 in) 880 mm (34.6 in) 823 mrn (32.4 in) TM: 346 mm (13.6 in) TE: 336 mm (13.2 in) 165 mm (6.5 in) TM: 248 kg (547 Ibs) TE: 249 kg (549 Ibs) 220 kg (485 lbsl Double cradle Double wishbone 160 mm (6.3 in) Double tube Swingarm (trailing type) 160 mm (6.3 in) Double tube AT24xB~12 ** AT24 x 10-" ** 12xB.OAT 11 x 7.5 AT M977 (Maxxis) M978 (Maxxis) Hydraulic disc brake Mechanical drum brake 6.34° 25.1 mm (0.99 in) 0" '07' 13.7 liters (3.S2 US gal, 3.01 Imp gal) After '07: 13.3 liters (3.51 US gal, 2.93 Imp gal) '07: 2.8 liters (0.74 US gal, 0.S2 Imp gal) ENGINE Cylinder arrangement Bore and stroke Displacement Compression ratio After '07: 2.6 liters (0.S9 US gal. 0.57 Imp gal) --="'-=~-I-iS ~;~ n~ g~'e ~,~y"linder, longitudinally installed 1-6 Valve train Intake valve Exhaust valve Lubrication system Oil pump type Cooling system Air filtration Engine dry weight opens closes opens closes ' 07 - '08: After '08: '07 - '08: After '08: '07 - '08: After '08: '07 - '08: After '08: '07 - '08: After '08: TM: TE: 86.5 x 71.5 mm (3.41 x 2.81 in) 420 cm' (25.S cu-in) 9.8: 1 9.9: 1 OHV S~ BTDC (at 1 mm lift) 7~ BTDC (at 1 mm lift) 45 0 ABDC (at 1 mm tift) 32 0 ABDC (at 1 mm lift) 45 0 BBDC (at 1 mm lift) 35 ° ABDC (at 1 mm lift) 2° ATDC (at 1 mm lift) 4 0 ATDC (at 1 mm lift) Forced pressure and wet sump Trochoid liquid cooled Oiled double urethane foam '07 - '08: 48.6 kg (107.1Ibs) After '08: 48.5 kg (10S.9Ibs) '07 - '08: 49.6 kg (109.3 Ibs) After '08: 49.5 kg (109.1Ibs)

2007- 2012 HONDA TRX420 RANCHER 420 Repair Service Manual

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