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Table Of Contents - Honda Fourtrax Rancher AT 2004 Service Manual

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Owner's manual (64 pages)

Table Of Contents

Table of Contents

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Table of Contents

A Few Words About Safety2

Service Information2

Important Safety Precautions2

General Information5

Table Of Contents5

Model Identification6

General Specifications9

Lubrication System Specifications11

Fuel System Specifications11

Cylinder Headivalve/ Camshaft Specifications12

Cylinder/Piston Specifications12

Centrifugal Clutch Specifications12

Alternator/Starter Clutch Specifications13

Sub-Transmission Specifications13

Crankshaft/Automatic Transmission Specifications13

Brake System Specifications14

Front Driving Mechanism Specifications15

Ignition System Specifications15

Electric Starter Specifications15

Lights/Meters/Switches Specifications16

Standard Torque Values17

Engine & Frame Torque Values17

Lubrication & Seal Points23

Cable & Harness Routing28

Emission Control Systems43

Source Of Emissions43

Exhaust Emission Control System43

Crankcase Emission Control System43

Emission Control Information Label44

Label (U.s.a. Only)44

Technical Feature45

Gps Navigation Meter46

General Description46

Global Positioning System (Gps)46

Structure/Function47

Automatic Clock Adjustment47

Frame/Body Panels/Exhaust System49

Troubleshooting50

Torque Values50

Body Panel Locations51

Seat/Side Cover52

Tank Side Covers And Tank Top Cover52

Front Luggage Carrier54

Rear Luggage Carrier58

Center Mudguard59

Exhaust System62

Maintenance Schedule68

Throttle Operation69

Carburetor Choke70

Air Cleaner Housing Drain Hose72

Reusing A Spark Plug73

Replacing A Spark Plug73

Valve Clearance74

Engine Oil Filter78

Engine Idle Speed78

Drive Shaft Boots79

Rear Final Gear Case Oil And Differential Oil79

Differential Oil80

Brake Shoes Wear82

Skid Plate, Engine Guard84

Spark Arrester85

Swingarm Bearings85

Nuts, Bolts, Fasteners86

Steering Shaft Holder Bearing86

Steering System87

Lubrication System89

Lubrication System Diagram90

Lubrication System Service Information91

Lubrication System Torque Values91

Lubrication System Tools92

Lubrication System Troubleshooting94

Oil Pressure Check95

Front Crankcase Cover96

Oil Pressure Relief Valve Inspection96

Relief Valve Inspection97

Oil Feed Pipe Inspection98

Bearing Replacement99

Oil Cooler Removal107

Cooling Fan Removal108

Cooling Fan Oisassembly109

Cooling Fan Assembly110

Cooling Fan Installation111

Oil Cooler Installation112

Fuel System System Components116

Fuel System Service Information117

Fuel System Torque Values117

Fuel System Tool117

Fuel System Troubleshooting118

Engine Cranks But Won't Start118

Lean Mixture118

Engine Stalls, Hard To Start, Rough Idling118

Air Cleaner Housing Removal/Installation119

Sub-Air Cleaner Removal120

Sub-Air Cleaner Cleaning120

Carburetor Removal121

Sub-Air Cleaner Installation121

Carburetor Disassembly/Inspection122

Starting Enrichment (Se) Valve122

Hoses, Cable And Carburetor Heater123

Vacuum Chamber124

Float And Jets125

Air Cut-Off Valve127

Carburetor Body Cleaning127

Carburetor Assembly128

Carburetor Installation134

Pilot Screw Adjustment137

Idle Drop Procedure137

High Altitude Adjustment138

High Altitude Pilot Screw Opening138

Standard Main Jet138

Fuel Strainer Screen Cleaning141

Fuel System Installation142

Engine Removal/Installation145

Engine Removal/Installation Components146

Engine Removal/Installation Service Information147

Engine Removal/Installation Specifications147

Engine Removal/Installation Torque Values147

Engine Removal148

Engine Installation151

Gearshift Lever Free Play Adjustment156

Cylinder Head/Valve/Camshaft159

Cylinder Head/Valve/Camshaft System Components160

Cylinder Head/Valve/Camshaft Service Information161

Cylinder Head/Valve/Camshaft Torque Values161

Cylinder Head/Valve/Camshaft Tools162

Cylinder Head/Valve/Camshaft Troubleshooting163

Compression Too Low163

Compression Too High163

Excessive Smoke163

Cylinder Compression164

Cylinder Head Cover Removal/Disassembly164

Cylinder Head Removal166

Rocker Arm/Shaft166

Cylinder Head Disassembly167

Cylinder Head168

Valve Spring168

Valve/Valve Guide169

Valve Guide Replacement170

Valve Seat Inspection/Refacing171

Camshaft Removal173

Cam Follower176

Cam Chain Tensioner176

Camshaft Installation177

Cylinder Head Assembly179

Cylinder Head Installation180

Cylinder Head Cover Assembly/Installation182

Cylinder/Piston185

System Components186

Cylinder/Piston Service Information187

Cylinder/Piston Torque Value187

Cylinder/Piston Troubleshooting187

Cylinder/Piston Removal188

Piston Disassembly188

Cylinder Inspection189

Piston/Piston Ring190

Cylinder Stud Bolt Replacement191

Connecting Rod191

Cylinder/Piston Installation192

Centrifugal Clutch195

Centrifugal Clutch Component Location196

Centrifugal Clutch Service Information197

Centrifugal Clutch Torque Values197

Centrifugal Clutch Tools197

Centrifugal Clutch Troubleshooting198

Clutch Slips When Accelerating198

Clutch Will Not Disengage198

Clutch Operation Feels Rough198

Centrifugal Clutch Removal199

Centrifugal Clutch Inspection200

One-Way Clutch200

Weight Lining/Weight Spring/Clutch Spring201

Alternator/Starter Clutch207

Alternator/Starter Clutch System Components208

Alternator/Starter Clutch Service Information209

Alternator/Starter Clutch Torque Values209

Alternator/Starter Clutch Troubleshooting209

Recoil Starter209

Recoil Starter Removal210

Recoil Starter Disassembly210

Recoil Starter Assembly212

Alternator Stator215

Alternator Cover Removal215

Stator And Ignition Pulse Generator Removal/Installation216

Alternator Cover Installation216

Flywheel/Starter Clutch218

Starter Clutch Disassembly/Inspection219

Starter Clutch Assembly220

Sub-Transmission/Gearshift/Linkage223

Sub-Transmission/Gearshift Linkage Troubleshooting227

Rear Crankcase Cover Removal228

Sub-Transmission/Gearshift229

Sub-Transmission/Gearshift Linkage234

Output Shaft236

Reverse Idle Gear236

Shift Fork And Shaft236

Crankshaft/Automatic Transmission239

Crankshaft/Automatic Transmission System Components240

Crankshaft/Automatic Transmission Service Information241

Crankshaft/Automatic Transmission Torque Values241

Crankshaft/Automatic Transmission Tools241

Automatic Transmissio242

Crankshaft/Automatic Transmission Troubleshooting243

Oil Level Inspection243

Oil Pressure Test243

Crankcase Separation245

Oil Strainer Cleaning247

Breather Separator Replacement247

Automatic Transmission248

Crankshaft/Balancer249

Crankshaft And Balancer Installation251

Crankcase Bearing Replacement252

Rear Crankcase252

Front Crankcase253

Crankcase Assembly254

Front Wheel/Suspension/Steering257

Front Wheel/Suspension/Steering Components258

Front Wheel/Suspension/Steering Service Information259

Front Wheel/Suspension/Steering Specifications259

Front Wheel/Suspension/Steering Torque Values259

Front Wheel/Suspension/Steering Tools260

Front Wheel/Suspension/Steering Troubleshooting261

Hard Steering261

Steers One Side Or Does Not Track Straight261

Front Wheel Wobbling261

Handlebar Removal262

Handlebar Installation264

Throttle Housing266

Wheel Hub/Knuckle271

Ball Joint Replacement275

Front Shock Absorber278

Suspension Arm279

Steering Shaft282

Rear Wheel/Suspension289

Rear Wheel/Suspension Components290

Rear Wheel/Suspension Service Information291

Rear Wheel/Suspension Specifications291

Rear Wheel/Suspension Torque Values291

Rear Wheel/Suspension Tools292

Rear Wheel/Suspension Troubleshooting293

Rear Wheel Wobbling293

Steers To One Side Or Does Not Track Straight293

Soft Suspension293

Rear Shock Absorber294

Pivot Bearing Replacement295

Swingarm Removal296

Brake System Service Information305

Brake System Torque Values305

Brake System Tools306

Brake System Troubleshooting306

Poor Brake Performance306

Front Brake Lever Hard306

Brake Fluid Replacement/Air Bleeding307

Brake Fluid Draining307

Brake Fluid Filling307

Brake Bleeding308

Front Master Cylinder309

Brake Hose/Brake Pipe/Breather Hose Inspection309

Front Brake Shoes/Drum314

Brake Drum Removal314

Brake Shoe Replacement315

Water Seal Inspection316

Water Seal Replacement316

Front Brake Panel Inspection317

Brake Drum Installation317

Front Wheel Cylinder/Brake Panel318

Brake Panel Assembly328

Front Driving Mechanism333

Front Driving Mechanism System Components334

Front Driving Mechanism Service Information335

Front Driving Mechanism Torque Values335

Front Driving Mechanism Tools336

Front Driving Mechanism Troubleshooting338

Consistent Noise During Cruising338

Gear Noises While Running338

Abnormal Noises When Turning338

Front Drive Shaft339

Differential Removal346

Differential Disassembly Inspection348

Propeller Shaft Inspection348

Operation Check349

Backlash Inspection349

Differential Case Disassembly350

Bearing Inspection351

Gear Tooth Contact Pattern Check351

Differential Inspection352

Differential Disassembly353

Differential Components Inspection354

Differential Housing/Face Cam/Cam Followers354

Side Cone Spring355

Pinion Gear Removal355

Case Bearing Replacement356

Differential Bearing356

Pinion Needle Bearing357

Differential Assembly358

Pinion Gear Installation359

Differential Case Assembly361

Propeller Shaft Assembly362

Differential Installation363

Rear Driving Mechanism367

Rear Driving Mechanism Service Information369

Rear Driving Mechanism Specifications369

Rear Driving Mechanism Torque Values369

Rear Driving Mechanism Tools370

Rear Driving Mechanism Troubleshooting372

Excessive Noise372

Wobble Or Vibration In Vehicle372

Rear Axle Removal373

Final Drive Removal375

Final Drive Disassembly/Inspection377

Final Gear Case Disassembly378

Final Gear Case Bearing Replacement382

Ring Gear Bearing382

Final Drive Assembly384

Ring Gear Clearance Inspection385

Final Gear Case Assembly386

Final Drive Installation387

Rear Axle Installation388

Battery/Charging System391

Battery/Charging System Component Location392

Battery/Charging System Diagram392

Battery/Charging System Service Information393

Battery/Charging System Specifications393

Battery Testing393

Battery/Charging System Troubleshooting394

Battery Is Damaged Or Weak394

Battery Removal/Installation395

Battery Voltage Inspection395

Battery Charging396

Charging System Inspection398

Current Leakage Inspection398

Charging Voltage Inspection398

Alternator Charging Coil399

Regulator/Rectifier399

Wire Harness Inspection399

Battery Line400

Charging Coil Line400

Ignition System401

Component Location402

Ignition System Service Information403

Ignition System Specification403

Ignition System Torque Values403

Ignition System Tools403

Ignition System Troubleshooting404

No Spark At Spark Plug404

Ignition System Inspection405

Ignition Coil Primary Peak Voltage405

Ignition Pulse Generator Peak Voltage406

Ignition Coil Removal/Installation407

Ignition Timing408

Electric Starter409

Electric Starter Component Location410

Electric Starter System Diagram410

Electric Starter Service Information411

Electric Starter Troubleshooting412

Starter Motor Does Not Turn412

Starter Relay Switch Inspection413

Starter Motor Turns Engine Slowly413

Starter Motor Turns, But Engine Does Not Turn413

Starter Motor414

Starter Motor Assembly417

Starter Relay Switch420

Operation Inspection420

Circuit Inspection420

Lights/Meters/Switches423

Lights/Meters/Switches Component Location424

Lights/Meters/Switches Service Information425

Lights/Meters/Switches Torque Values425

Lights/Meters/Switches Tool425

Headlight Bulb Replacement426

Tail/Brake Light427

Bulb Replacement427

Accessory Socket428

Ignition Switch429

Handlebar Switch430

Carburetor Heater Air Temperature Switch431

Carburetor Heater Inspection431

Air Temperature Switch Inspection432

Combination Meter Rear Vehicle Speed Sensor (Vss)433

Power/Ground Line Inspection433

Speedometer/Rear Vss433

Power Input Line433

Combination Meter Removal/Installation434

Oil Temperature Sensor Cooling Fan435

Oil Temperature Indicator System Inspection435

Cooling Fan System Inspection437

Cooling Fan Does Not Stop438

Oil Temperature Sensor Inspection439

Gps Receiver440

Gps Indicator Blinks441

Gps Receiver Connector Check441

Gps Receiver Input Voltage Inspection441

Gps Receiver Ground Line Inspection441

Gps Receiver Replacement442

Gps Start·up Time Is Taking Too Long442

Gps System Reset442

Gps Receiver Backup Voltage Inspection442

Brake Light Switch443

Front Brake Lever443

Rear Brake Lever443

Rear Brake Pedal443

Front Brake Switch444

Selectable 4Wd System445

Selectable 4Wd System Component Location446

Selectable 4Wd System System Diagram446

Selectable 4Wd System Service Information447

Selectable 4Wd System Troubleshooting447

Selectable 4Wd System Self-Diagnostic Function447

Front Vss Connector Inspection448

Front Vss Input Line Inspection448

Front Vss Line Inspection448

Front Vss Line Short Circuit Inspection449

Front Vss Mechanical Inspection449

Failure Reproduction449

Rear Vss Connector Inspection450

Rear Vss Input Line Inspection450

Rear Vss Line Inspection450

Rear Vss Line Short Circuit Inspection451

Rear Vss Mechanical Inspection451

System Voltage452

Front Final Clutch System452

Ecm Power Input Line Inspection452

Front Final Clutch Line Open Circuit Inspection453

Front Final Clutch Line Short Circuit Inspection453

Front Final Clutch Inspection453

Rear Vehicle Speed Sensor (Vss)454

Hondamatic Component Location458

Hondamatic Service Information459

Hondamatic Torque Values459

Hondamatic Tool459

Hondamatic Connector Location460

Hondamatic Circuit Diagram461

Before Starting Troubleshooting462

Retrieval/Erasure Of Problem Code463

Problem Code Blink Duration464

To Erase The Problem Code464

Erasure Confirmation Blink Duration464

Initial Setiing Procedure465

Hondamatic Troubleshooting Chart468

Ignition Pulse Generator System469

Ground Cable Connection Inspection470

Ignition Pulse Generator Line Inspection470

Ignition Pulse Generator Peak Voltage Inspection470

System Failure Reproduction470

Vehicle Speed Sensor System471

Vss Line Inspection472

Rear Vss Installation Condition472

Wire Harness Continuity Inspection472

Gear Position Switch System473

Gear Position Switch Connection Inspection473

Gear Position Switch Line Inspection473

Throttle Position (Tp) Sensor System474

Tp Sensor Resistance474

Tp Sensor Installation Condition475

Tp Sensor Input Voltage Inspection475

Tp Sensor Line Inspection475

Angle Sensor System (Motor Lock)476

Angle Sensor Connection Inspection476

Initial Setting Procedure477

Esp Shift Switch Operation Inspection477

Control Motor Power Input Line Inspection477

Control Motor Ground Line Inspection478

Control Motor Line Inspection478

Control Motor Circuit Inspection478

Control Motor Inspection479

Automatic Transmission Operation Inspection479

Angle Sensor Resistance Inspection480

Angle Sensor Line Inspection480

Angle Sensor System481

Esp Shift Switch Inspection485

Mode Select Switch System (Auto And Esp)486

Mode Select Switch Connection Inspection486

Mode Select Switch Line Inspection486

Ecm Voltage Converter Circuit, Ecm Fail-Safe Relay Circuit, Ecm Cpu487

Mode Select Switch Inspection487

Ecm Motor Driver Circuit488

Ecm/Control Motor Connection Inspection488

But No Code Is Retrievable490

Problem Not Detected By Ecm491

Meter Connection Inspection491

Drive/Neutral/Reverse Switch494

Esp Shift Switch495

Mode Select Switch496

Throttle Position (Tp) Sensor497

Input Voltage497

Angle Sensor498

Sensor Input Voltage498

Sensor Resistance499

Control Motor500

Sensor Preload500

Engine Control Module (Ecm)502

Wiring Diagrams503

Engine Does Not Start Or Is Hard To Start507

Engine Lacks Power508

Poor Performance At Low And Idle Speed510

Poor Performance At High Speed511

Poor Handling511

Steering Is Heavy511

Any Wheel Is Wobbling511

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Table of Contents

Troubleshooting

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