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Rancher AT 2004
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Honda Fourtrax Rancher AT 2004 Service Manual
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:
Owner's manual
(64 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
A few Words about Safety
Service Information
Important Safety Precautions
Contents
Symbols
Table of Contents
General Information
Service Rules
Model Identification
General Specifications
Lubrication System Specifications
Fuel System Specifications
CYLINDER HEADIVALVE/ CAMSHAFT Specifications
Cylinder/Piston Specifications
Centrifugal Clutch Specifications
Alternator/Starter Clutch Specifications
SUB-TRANSMISSION Specifications
Crankshaft/Automatic Transmission Specifications
Brake System Specifications
FRONT DRIVING MECHANISM Specifications
Ignition System Specifications
Electric Starter Specifications
Lights/Meters/Switches Specifications
Standard Torque Values
Engine & Frame Torque Values
Lubrication & Seal Points
Cable & Harness Routing
Crankcase Emission Control System
Exhaust Emission Control System
Source of Emissions
Emission Control Systems
Emission Control Information Label
LABEL (U.S.A. Only)
Technical Feature
General Description
Global Positioning System (GPS)
Gps Navigation Meter
Automatic Clock Adjustment
Compass
Structure/Function
Frame/Body Panels/Exhaust System
Service Information
Torque Values
Troubleshooting
Body Panel Locations
Seat/Side Cover
Tank Side Covers and Tank Top Cover
Front Bumper
Front Fender
Front Luggage Carrier
Rear Luggage Carrier
Center Mudguard
Rear Fender
Toolbox
Exhaust Pipe
Exhaust System
Muffler
Maintenance
Service Information
Maintenance Schedule
Fuel Line
Throttle Operation
Air Cleaner
Carburetor Choke
Air Cleaner Housing Drain Hose
Spark Plug
Replacing a Spark Plug
Reusing a Spark Plug
Valve Clearance
Engine Oil
Level Check
Oil Change
Engine Idle Speed
Engine Oil Filter
Drive Shaft Boots
Rear Final Gear Case Oil and Differential Oil
Differential Oil
Brake Fluid
Front Brake
Brake Shoes Wear
Brake System
Rear Brake
Skid Plate, Engine Guard
Suspension
Spark Arrester
Swingarm Bearings
Nuts, Bolts, Fasteners
Steering Shaft Holder Bearing
Wheels/Tires
Steering System
Lubrication System
Lubrication System Diagram
Lubrication System Service Information
Lubrication System Torque Values
Lubrication System Tools
Lubrication System Troubleshooting
Oil Pressure Check
Front Crankcase Cover
Oil Pressure Relief Valve Inspection
Relief Valve Inspection
Oil FEED PIPE INSPECTION
Bearing Replacement
OIL Pump
Oil Cooler Removal
Cooling Fan Removal
Cooling Fan Oisassembly
Cooling Fan Assembly
Cooling Fan Installation
Oil Cooler Installation
Fuel System
Fuel System System Components
Fuel System Service Information
Fuel System Tool
Fuel System Torque Values
Engine Cranks but Won't Start
Engine Stalls, Hard to Start, Rough Idling
Fuel System Troubleshooting
Lean Mixture
Air Cleaner Housing Removal/Installation
Sub-Air Cleaner Cleaning
Sub-Air Cleaner Removal
Carburetor Removal
Sub-Air Cleaner Installation
Carburetor Disassembly/Inspection
Starting Enrichment (Se) Valve
Hoses, Cable and Carburetor Heater
Vacuum Chamber
Float and Jets
Primer Knob
Air Cut-Off Valve
Air Joint
Carburetor Body Cleaning
Carburetor Assembly
Float Level
Carburetor Installation
Idle Drop Procedure
Pilot Screw Adjustment
High Altitude Adjustment
High Altitude Pilot Screw Opening
Idle Speed
Standard Main Jet
Fuel Tank
Fuel Strainer Screen Cleaning
Fuel System Installation
Engine Removal/Installation
Engine Removal/Installation Components
Engine Removal/Installation Service Information
Engine Removal/Installation Specifications
Engine Removal/Installation Torque Values
Engine Removal
Engine Installation
Gearshift Lever Free Play Adjustment
Cylinder Head/Valve/Camshaft
Cylinder Head/Valve/Camshaft System Components
Cylinder Head/Valve/Camshaft Service Information
Cylinder Head/Valve/Camshaft Torque Values
Cylinder Head/Valve/Camshaft Tools
Compression too High
Compression too Low
Cylinder Head/Valve/Camshaft Troubleshooting
Excessive Smoke
Cylinder Compression
Cylinder Head Cover Removal/Disassembly
Cylinder Head Removal
Rocker Arm/Shaft
Cylinder Head Disassembly
Cylinder Head
Valve Spring
Valve/Valve Guide
Valve Guide Replacement
Valve Seat Inspection/Refacing
Camshaft Removal
Push Rod
Cam Chain Tensioner
Cam Follower
Camshaft Installation
Cylinder Head Assembly
Cylinder Head Installation
Cylinder Head Cover Assembly/Installation
Cylinder/Piston
System Components
Cylinder/Piston Service Information
Cylinder/Piston Specifications
Cylinder/Piston Torque Value
Cylinder/Piston Troubleshooting
Cylinder/Piston Removal
Piston Disassembly
Cylinder Inspection
Piston/Piston Ring
Connecting Rod
Cylinder Stud Bolt Replacement
Cylinder/Piston Installation
Centrifugal Clutch
Centrifugal Clutch Component Location
Centrifugal Clutch Service Information
Centrifugal Clutch Specifications
Centrifugal Clutch Tools
Centrifugal Clutch Torque Values
Centrifugal Clutch Troubleshooting
Clutch Operation Feels Rough
Clutch Slips When Accelerating
Clutch will Not Disengage
Centrifugal Clutch Removal
Centrifugal Clutch Inspection
Clutch Drum
One-Way Clutch
Weight Lining/Weight Spring/Clutch Spring
Crankshaft
Alternator/Starter Clutch
Alternator/Starter Clutch System Components
Alternator/Starter Clutch Service Information
Alternator/Starter Clutch Specifications
Alternator/Starter Clutch Torque Values
Alternator/Starter Clutch Troubleshooting
Recoil Starter
Recoil Starter Disassembly
Recoil Starter Removal
Recoil Starter Assembly
Alternator Cover Removal
Alternator Stator
Alternator Cover Installation
Stator and Ignition Pulse Generator Removal/Installation
Flywheel/Starter Clutch
Starter Clutch Disassembly/Inspection
Starter Clutch Assembly
Sub-Transmission/Gearshift/Linkage
Troubleshooting
System Components
Sub-Transmission/Gearshift Linkage Troubleshooting
Rear Crankcase Cover Removal
Sub-Transmission/Gearshift
Sub-Transmission/Gearshift Linkage
Output Shaft
Reverse Idle Gear
Shift Fork and Shaft
Crankshaft/Automatic Transmission
Troubleshooting
Crankshaft/Automatic Transmission System Components
Crankshaft/Automatic Transmission Service Information
Crankshaft/Automatic Transmission Specifications
Crankshaft/Automatic Transmission Tools
Crankshaft/Automatic Transmission Torque Values
Automatic Transmissio
Crankshaft/Automatic Transmission Troubleshooting
Oil Level Inspection
Oil Pressure Test
Crankcase Separation
Breather Separator Replacement
Oil Strainer Cleaning
Automatic Transmission
Crankshaft/Balancer
Crankshaft and Balancer Installation
Crankcase Bearing Replacement
Rear Crankcase
Front Crankcase
Crankcase Assembly
Front Wheel/Suspension/Steering
Front Wheel/Suspension/Steering Components
System Components
Front Wheel/Suspension/Steering Service Information
Front Wheel/Suspension/Steering Specifications
Front Wheel/Suspension/Steering Torque Values
Front Wheel/Suspension/Steering Tools
Front Wheel Wobbling
Front Wheel/Suspension/Steering Troubleshooting
Hard Steering
Steers One Side or Does Not Track Straight
Handlebar Removal
Handlebar Installation
Throttle Housing
Front Wheel
Tires
Tire Repair
Wheel Hub/Knuckle
Ball JOINT REPLACEMENT
Front Shock Absorber
Suspension Arm
Steering Shaft
Tie-Rod
Rear Wheel/Suspension
Rear Wheel/Suspension Components
System Components
Rear Wheel/Suspension Service Information
Rear Wheel/Suspension Specifications
Rear Wheel/Suspension Torque Values
Rear Wheel/Suspension Tools
Rear Wheel Wobbling
Rear Wheel/Suspension Troubleshooting
Soft Suspension
Steers to One Side or Does Not Track Straight
Rear Shock Absorber
Rear Wheel
Pivot Bearing Replacement
Swingarm Removal
Brake System Service Information
Brake System Specifications
Brake System Torque Values
Brake System Tools
Brake System Troubleshooting
Front Brake Lever Hard
Poor Brake Performance
Brake Fluid Draining
Brake Fluid Filling
Brake Fluid Replacement/Air Bleeding
Brake Bleeding
Brake Hose/Brake Pipe/Breather Hose Inspection
Front Master Cylinder
Brake Drum Removal
Front Brake Shoes/Drum
Brake Shoe Replacement
Water Seal Inspection
Water Seal Replacement
Brake Drum Installation
Front Brake Panel Inspection
Front Wheel Cylinder/Brake Panel
Brake Panel Assembly
Front Driving Mechanism
Front Driving Mechanism System Components
Front Driving Mechanism Service Information
Front Driving Mechanism Specifications
Front Driving Mechanism Torque Values
Front Driving Mechanism Tools
Abnormal Noises When Turning
Consistent Noise During Cruising
Front Driving Mechanism Troubleshooting
Gear Noises While Running
Front Drive Shaft
Differential Removal
Differential Disassembly Inspection
Propeller Shaft Inspection
Backlash Inspection
Operation Check
Differential Case Disassembly
Bearing Inspection
Gear Tooth Contact Pattern Check
Differential Inspection
Differential Disassembly
Differential Components Inspection
Differential Housing/Face Cam/Cam Followers
Ring Gear
Pinion Gear Removal
Side Cone Spring
Case Bearing Replacement
Differential Bearing
Pinion Needle Bearing
Differential Assembly
Pinion Gear Installation
Differential Case Assembly
Propeller Shaft Assembly
Differential Installation
Rear Driving Mechanism
System Components
Rear Driving Mechanism Service Information
Rear Driving Mechanism Specifications
Rear Driving Mechanism Torque Values
Rear Driving Mechanism Tools
Excessive Noise
Oil Leak
Rear Driving Mechanism Troubleshooting
Wobble or Vibration in Vehicle
Rear Axle Removal
Final Drive Removal
Final Drive Disassembly/Inspection
Final Gear Case Disassembly
Final Gear Case Bearing Replacement
Ring Gear Bearing
Final Drive Assembly
Ring Gear Clearance Inspection
Final Gear Case Assembly
Final Drive Installation
Rear Axle Installation
Battery/Charging System
Battery/Charging System Component Location
Battery/Charging System Diagram
Battery Testing
Battery/Charging System Service Information
Battery/Charging System Specifications
Battery Is Damaged or Weak
Battery/Charging System Troubleshooting
Battery Removal/Installation
Battery Voltage Inspection
Battery Charging
Charging System Inspection
Charging Voltage Inspection
Current Leakage Inspection
Alternator Charging Coil
Regulator/Rectifier
Wire Harness Inspection
Battery Line
Charging Coil Line
Ground Line
Ignition System
Component Location
Ignition System Service Information
Ignition System Specification
Ignition System Tools
Ignition System Torque Values
Ignition System Troubleshooting
No Spark at Spark Plug
Ignition Coil Primary Peak Voltage
Ignition System Inspection
Ignition Pulse Generator Peak Voltage
Ignition Coil Removal/Installation
Ignition Timing
Electric Starter
Electric Starter Component Location
Electric Starter System Diagram
Electric Starter Service Information
Electric Starter Specifications
Electric Starter Troubleshooting
Starter Motor Does Not Turn
Starter Motor Turns Engine Slowly
Starter Motor Turns, but Engine Does Not Turn
Starter Relay Switch Inspection
Starter Motor
Starter Motor Assembly
Circuit Inspection
Operation Inspection
Starter Relay Switch
Diode
Lights/Meters/Switches
Lights/Meters/Switches Component Location
Lights/Meters/Switches Service Information
Lights/Meters/Switches Specifications
Lights/Meters/Switches Tool
Lights/Meters/Switches Torque Values
Headlight Bulb Replacement
Bulb Replacement
Tail/Brake Light
Accessory Socket
Ignition Switch
Socket
Handlebar Switch
Carburetor Heater Air Temperature Switch
Carburetor Heater Inspection
Air Temperature Switch Inspection
Combination Meter Rear Vehicle Speed Sensor (Vss)
Power Input Line
Power/Ground Line Inspection
Speedometer/Rear Vss
Combination Meter Removal/Installation
Oil Temperature Indicator System Inspection
Oil Temperature Sensor Cooling Fan
Cooling Fan System Inspection
Cooling Fan Does Not Stop
Oil TEMPERATURE SENSOR INSPECTION
Gps Receiver
GPS Indicator Blinks
GPS Receiver Connector Check
GPS Receiver Ground Line Inspection
GPS Receiver Input Voltage Inspection
GPS Receiver Backup Voltage Inspection
Gps Receiver Replacement
Gps Start·up Time Is Taking too Long
GPS System Reset
Brake Light Switch
Rear Brake Pedal
Front Brake Switch
Rear Brake Lever
Front Brake Lever
Selectable 4Wd System
Selectable 4Wd System Component Location
Selectable 4Wd System System Diagram
Selectable 4Wd System Service Information
Selectable 4Wd System Troubleshooting
Selectable 4Wd System Self-Diagnostic Function
Front VSS Connector Inspection
Front VSS Input Line Inspection
Front VSS Line Inspection
Front VSS Line Short Circuit Inspection
Front VSS Mechanical Inspection
Failure Reproduction
Rear VSS Line Inspection
Rear VSS Input Line Inspection
Rear VSS Connector Inspection
Rear VSS Line Short Circuit Inspection
Rear VSS Mechanical Inspection
System Voltage
Front Final Clutch System
ECM Power Input Line Inspection
Front Final Clutch Line Open Circuit Inspection
Front Final Clutch Line Short Circuit Inspection
Front Final Clutch Inspection
Rear Vehicle Speed Sensor (Vss)
Hondamatic
Hondamatic Component Location
Hondamatic Tool
Hondamatic Torque Values
Hondamatic Service Information
Hondamatic Connector Location
Hondamatic Circuit Diagram
Before Starting Troubleshooting
Retrieval/Erasure of Problem Code
Problem Code Blink Duration
To Erase the Problem Code
Erasure Confirmation Blink Duration
Initial Setiing Procedure
Hondamatic Troubleshooting Chart
Ignition Pulse Generator System
Ignition Pulse Generator Peak Voltage Inspection
System Failure Reproduction
Ignition Pulse Generator Line Inspection
Ground Cable Connection Inspection
Vehicle Speed Sensor System
VSS Line Inspection
Rear VSS Installation Condition
Wire Harness Continuity Inspection
Gear Position Switch System
Gear Position Switch Connection Inspection
Gear Position Switch Line Inspection
Throttle Position (TP) Sensor System
TP Sensor Resistance
TP Sensor Installation Condition
TP Sensor Input Voltage Inspection
TP Sensor Line Inspection
Angle Sensor Connection Inspection
Angle Sensor System (Motor Lock)
ESP Shift Switch Operation Inspection
Control Motor Power Input Line Inspection
Initial Setting Procedure
Control Motor Ground Line Inspection
Control Motor Line Inspection
Control Motor Circuit Inspection
Control Motor Inspection
Automatic Transmission Operation Inspection
Angle Sensor Resistance Inspection
Angle Sensor Line Inspection
Angle Sensor System
Ecm Eeprom
ESP Shift Switch Inspection
Mode Select Switch Line Inspection
Mode Select Switch System (Auto and ESP)
Mode Select Switch Connection Inspection
ECM Voltage Converter Circuit, ECM Fail-Safe Relay Circuit, ECM CPU
Mode Select Switch Inspection
ECM Motor Driver Circuit
Ecm/Control Motor Connection Inspection
But no Code Is Retrievable
Problem Not Detected by Ecm
Meter Connection Inspection
Drive/Neutral/Reverse Switch
ESP Shift Switch
Mode Select Switch
Throttle Position (Tp) Sensor
Input Voltage
Sensor Input Voltage
Angle Sensor
Sensor Resistance
Control Motor
Sensor Preload
Engine Control Module (Ecm)
Wiring Diagrams
Engine Does Not Start or Is Hard to Start
Engine Lacks Power
Poor Performance at Low and Idle Speed
Poor Performance at High Speed
Poor Handling
Steering Is Heavy
Any Wheel Is Wobbling
Index
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Owner's Manual
Table of
Contents
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Table of Contents
Troubleshooting
Troubleshooting
50
Lubrication system troubleshooting
94
Fuel System Troubleshooting
118
Cylinder head/valve/camshaft troubleshooting
163
Cylinder/Piston service information
187
Centrifugal clutch troubleshooting
198
Alternator/starter clutch service information
209
Sub-transmission/gearshift/linkage
223
Sub-transmission/gearshift linkage troubleshooting
227
Crankshaft/automatic transmission
239
Crankshaft/automatic transmission troubleshooting
243
Front wheel/suspension/steering troubleshooting
261
Rear wheel/suspension troubleshooting
293
Brake system tools
306
Front driving mechanism troubleshooting
338
Rear driving mechanism troubleshooting
372
Battery/charging system troubleshooting
394
Ignition system troubleshooting
404
Electric starter troubleshooting
412
Selectable 4wd system service information
447
Before Starting Troubleshooting
462
Hondamatic troubleshooting chart
468
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This manual is also suitable for:
Fourtrax rancher at gpscape 2004
Trx400fga 2004
Fourtrax rancher at 2005
Trx400fa 2005
Trx400fga 2005
Fourtrax rancher at gpscape 2005
...
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Trx400fa 2006
Fourtrax rancher at 2006
Trx400fga 2006
Fourtrax rancher at gpscape 2006
Trx400fa 2007
Fourtrax rancher at 2007
Trx400fga 2007
Fourtrax rancher at gpscape 2007
Trx400fa 2004
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