2014-2016 Honda Rancher 420 (TRX420) Service & Repair Manual

HOW TO USE THIS MANUAL A Few Words About Safety Service Information The service and repair infonnalion contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehi cl e or create an unsafe condition. Th is manual describes the proper methods and procedures for perfomnng service, maintenance and repairs. Some procedures reqUire the use of specially designed tools and dedicated eqUipment Any person who intends to use a replacement part. service procedure or a 1001 that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer 's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or overslghl while servicing a vehicle can result in faulty operation, damage to the vehi cl e, or injury to others. For Your Safety AWARNING Improper service Of repairs can create an unsafe condition that can cause your customer to be seriously hurt or killed. Follow the procedures and precautions in th iS manual and other service malerials carefully Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommend Ihat you do not attempt to perform the procedures described in th is manual. Some of the most important general service safety precautions are given below. However. we cannot warn yo u of every conceIvable hazard Ihat can arise in performing service or repair procedures. Only yo u can decide whether or not you should perform a given task. AWARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed . Follow the procedures and precaullOns in thiS manual carefulty. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are weanng appropriate clothing and uSing safety equipment. When performing any service task. be especially careful of the following: Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts. and the skills required to perform the tasks safely and completely. Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind. pry Of work around pressu ri zed air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. Use other protective wear when necessary. for example gloves or safety shoes. Handling hot or sharp parts can cause severe bums or cuts. Before you grab something thalloaks like it can hurt you, stop and put on gloves. Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hOist or a j ack , make sure that It is always securely supported. Use jack slands. Make sure the engine is ott before you begin any servicing procedures unless the instruction lells you to do otherwise. This will help eliminate several potential hazards: Carbon monoxide poiSOning from engine exhaust. Be sure there IS adequate ventilation whenever you run Ihe engine. • Bums from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If Ihe instruction tells you to run the engine, be sure your hands, fingers and Cloth ing are out of the way. Gasoline vapors and hydrogen gases from batteries are explOS ive. To reduce the possibility of a fire or explosion. be careful when working around gasoline or bafteries. Use only a nonflammable soivent, not gasoline, to clean parts. Never drain or store gasoline in an open container. Keep alf cigarettes. sparks and flames away from the battery and all fuel-related parts.

HOW TO USE THIS MANUAL How To Use This Manual ThIS manual describes the servIce procedures for the TRX420TM1fTE1/FM1fFM2JFE1/FA1/FA2fFASlFA6. Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Section 4 through 25 describe parts of the vehicle, grouped according to locahon Follow the Maintenance Schedule (section 3) recommendations to ensure thaI the vehIcle IS In peak operatrng condition and the emISSion levels are wlthm the standards set by the U.S Environmental Protection Agency (EPA). California Air Resources Board (CARB) and EnVironment Canada. Pelforrrllng the first scheduled maintenance is very important It compensates for the Initial wear that occurs during the break-in penod Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. Refer to the troubleshooting in each section according to the malfunction or symptom . In case of an engine trouble, refer to PGM-FI section troubleshooting first. Your safety, and the safety of others, is very Important. To help you make Informed decisions we have provided safety messages and other information throughout this manual Of course, it IS nol practical or possible to warn you about all the hazards associated with servicing this vehide. You must use your own good judgement. You Will find Important safety information in a vanety of forms inCluding; Safety Labels - on the vehide • Safety Messages - preceded by a safety alert symbol ! and one of three signal words, DAN GER, WARNING, or CAUTION These signal words mean : tN-49m3;' You WILL be KtLLED or SERIOUSLY HURT If you don't follow instructions. mWiw w ij You CAN be KILLED or SERIOUSLY HURT If you don't follow InstructIOns. NMldlm. You CAN be HURT if you don't follow instructions. • Instructions - how to service this vehide correctly and safely As you read this manual, you will find information that is preceded by a NOm- symbol. The purpose of this message is to help prevent damage to your vehide, other property, or the environment.

HOW TO USE THIS MANUAL 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. I Replace the partes) with new one(s) before assembly. Use Ihe recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). I Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more 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 Milsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Coming U.S.A. Honda Moly 60 (U.SA only) Rocol ASP manufactured by Rocol Limited. U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a medium strength locking agent unless otherwise speCified. Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use fork or suspension fluid.

...J « u 0:: .... u W ...J W C Z « z « 0:: .... W > 0:: c W z (!) z w CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE PGM-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM CYLINDER HEADNALVE CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE (Except FA models) DUAL CLUTCH TRANSMISSION (FA models) ALTERNATOR/STARTER CLUTCH CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING II) REAR WHEEL/SUSPENSION II) ~ BRAKE SYSTEM :I: u FRONT DRIVING MECHANISM (Except TM1ITEl models) REAR DRIVING MECHANISM BATTERY/CHARGING SYSTEM ~ ~========================================== U LIGHTS/METERS/SWITCHES ~ ~========================~~========~==== U ELECTRIC SHIFT PROGRAM (ESP: TE1/FEl models) ~ ~====================~==============~==== ELECTRIC POWER STEERING (EPS: FM2/FA2/FA6 models) WIRING DIAGRAMS INDEX

1. GENERAL INFORMATION SERVICE RULES··································· 1-2 LUBRICATION & SEAL POINTS .. .. ........ 1-21 MODEL IDENTIFICATION ...................... . 1-3 CABLE & HARNESS ROUTING ............. 1-24 SPECiFiCATIONS .. ·· .. · .... ·· .... · ........ · .. · .. ·· 1-5 EMISSION CONTROL SySTEMS .......... · 1-38 TORQUE VALUES .. .................... ........ · 1-14 1-1

GENERAL INFORMATION SERVICE RULES 1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don', meet Honda's design specifications may cause damage to the vehicle. 2. Use the speciallools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolls, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings. cotter pins, and lock plates when reassembling. 5. When lightening bolts or nuts, begin with the larger diameter or inner bolt fi rst. Then tighten to the speCified torque diagonally in incremental sleps 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 shown in the Cable & Hamess routing (page 1-24). 9. Do not bend or twist control cables. Damaged control cables will not operates smoothly and may stick or bind. 10.00 not tow your A TV behind a car or other vehicle. ABBREVIATION Throughout this manual, the following abbreviation are used to idenlify the respective parts or systems. 1-2

GENERAL INFORMATION MODEL IDENTIFICATION This manual covers 9 types of TRX420 models: Model name TMl TEl FMl FM2 FEl FAl FA2 FAS FA G Manual transmission 0 0 0 0 0 - Dual clutch transmission 0 0 0 0 2WD 0 0 4WD 0 0 0 0 0 0 0 Left foot operated gearshift 0 0 0 ESP 0 0 EPS 0 0 0 Recoil starter ('14 Canada type) 0 0 0 Recoil starter (After ' 14 Canada type) 0 0 0 0 0 0 Independent rear suspension 0 0 Rear hydraulic disc brake 0 0 Be sure to refer to the procedure thai pertains to the appropriate version of the TRX420. FA2 mo del shown: SERIAL NUMBERS/LABELS The Vehicle Identification Number (VIN) [1] is stamped on the front side of the frame under the front fender. ~ __ [11 The engine serial number [1J is stamped on the left side ofthe rear crankcase. [1 1·3

GENERAL INFORMATION The throttle body identification number is stamped on the lower side of the throttle body. The color label [1J is attached on the left front frame down pipe. When ordering color-coded parts. always specify the designated color code. 1·4 The safety certification label [1] is attached on the left front frame down pipe, -fiC;V":N~ [1[ The vehicle emission control information label is attached on the left front frame pipe. - U.S.A. and Canada types [1] - Canada type only [2] [11 [21

2014-2016 Honda Rancher 420 (TRX420) Service & Repair Manual

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