2004 Honda TRX400FA FourTrax Rancher AT Service Repair Manual.pdf
- 2. 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 8ISUta thaI the veOide Is in peaIt operating cond>tion and the emISSion kNels are wit!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 1 0 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 Hyou 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
- 3. 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.
- 4. L 1. GENERAL INFORMATION SERVICE RULES ............................................ 1-2 MODELIDENTIFICATION····-·········_·········_····· 1-2 GENERAL SPECIFICATIONS ·········_··············· 1-5 LUBRICATION SYSTEM SPECIFICATIONS · 1-7 FUEL SYSTEM SPECiFiCATIONS················· 1-7 CYLINDER 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 WHEEl/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 CONTROLINFORMATlON LABEL (U.S.A. only) ····································· 1-40 - 1-1
- 5. 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 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. 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; After '04 similar: 1-2 I I i
- 6. 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 number 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
- 7. 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
- 8. 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 Air filtration h""oo"""",,,,,_--1---:;. Engine dry weight CARBURETOR Carburetor type L ______-L Throttle bore Double wishbone 150 mm (5.9 in) Double tube Trailing 150 mm (5.9 in) Double tube AT24 x 8-12 * * AT24 x 10-11 * * 12x6.0AT 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 cml (24.2 cu-in) 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
- 9. GENERAL INFORMATION ITEM SPECIFICATIONS DRIVE TRAIN Clutch system Centrifugal, wet Transmission HQNOAMATIC (automatic; non-stage speed) with sub-transmission (constant mesh) Primary reduction 1.048 (65f62) Secondary reduction 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; Automatic and Manual (ESP; 5 speeds) A (Reverse) , -mode (fixed low ratio) ELECTRICAL Ignition system DC-COI (Direct current-Capacitor discharge ignition) Starting system Electric starter motor and emergency recoil starter Charging system Triple phase output alternator Regulator/rectifier SeA shorted, triple phase full wave rectifica- tion Lighting system Banery 1-6
- 10. GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS i i pressure pump rotor FUEL SYSTEM SPECIFICATIONS I denum additives) 4-stroke oil and Canada). or Honda 4-stroke oil (Canada only), or an equivalent motor oil API service classification: SG or Higher except oils labeled as energy conserv- ing on the circular API service label JASO T 903 : MA i ; 1-7
- 11. GENERAL INFORMATION CYLINDER HEADIVALVE/CAMSHAFT SPECIFICATIONS ITEM STANDARD r-&~,li nder compression at 450 rpm 736 kPa (7.5 kgf/cm", 107 psi) Valve clearance IN 0.15 (0.006) EX 0.15 10.006) Valve, Valve stem 0.0. IN 5.475 - 5.490 (0.2156 - 0.2161) valve guide EX 5.455 5.470 (0.2148 0.2154) Valve guide 1.0. INlEX 5.500 5.512 (0.2165 - 0.2170) Stem-te-guide clearance f---;N 0.010 - 0.037 (0.0004 - 0.0015) EX 0.030 0.057 (0.0012 0.0022) Valve guide projection IN 15.8 16.0 (0.62 0.63 above cylinder head EX 15.8 16.0 (0.62 0.63) rvalve seat width INlEX 1.0 - 1.1 (0.039 0.043) Valve spring Free length Inner 37.8 (1.49) Outer 42.7 (1.68) Rocker arm Arm 1.0. IN/EX 12.000 12.018 (0:4724 - 0.4731) Shaft 0 .0 . INfEX 11.964 - 11.984 (0.4710 - 0.4718) Arm-Io·shaft clearance INlEX 0.016 - 0.054 (0.0006 0.0021) - Camshaft and Cam lobe height IN 35.9795 36.2195 (1.41651 1.42600) cam follower r Cam follower 0.0. EX 35.9245 - 36.1654 (1.41435 -1.42383) INfEX 22.467 22.482 (0.8845 - 0.8851) Follower bore 1.0. INfEX 22.510 22.526 (0.8862 0.8868) Follower-to-bore clear- INIEX 0.028 - 0.059 (0.0011 0.0023) anca Cylinder head warpage - CYLINDER/PISTON SPECIFICATIONS piston pin. piston ring gap CENTRIFUGAL CLUTCH SPECIFICATIONS ,- ITEM STANDARD r-Clutch Drum 1.0. 140.0 140.2 (5.51 5.52) ~~ht lining thickness 3.0 (0.12) Clutch spring height 3.10 (0.122) r-a~tch weight spring free length 216 (0.85) Clutch drum boss 1.0. 27.000 - 27.021 (1.0630 - 1.0638) Crankshaft 0.0. at clutch drum 26.959 26.980 t1.0614 1.0622) 1-8 Unit· mm (in) SERVICE UMIT - - 5.45 (0.215) 5.43 (0.214) 5.53 (0.218) 0.12 (0.005) 0.14 (0.006) - 1.4 (0.06) 37.04 (1.458~ 41.85 (1.648) 12.05 (O.474) 11.92 (0.46!~ 0.08 (0.003) _ 35.84 (1.411) 35.79 (1.409) 22.46 (0.884) 22.54 (0.8~P- 0.07 (0.003) 0.10 (0.004) Unit- mm (in) SERVICE UMI''':..:..:c 140.4 (5.53) 2.0 (0.08) 3.00 (0.118) 22.5 (0.89) 27.05 (1.065) 26.93 (1.060)
- 12. GENERAL INFORMATION ALTERNATOR/STARTER CLUTCH SPECIFICATIONS driven boss SUB-TRANSMISSION SPECIFICATIONS r R,.v.c,.. idle gear drive gear CRANKSHAFT/AUTOMATIC TRANSMISSION SPECIFICATIONS Unit- mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Aunout 0.05 (0.002) Big end side clearance 0.05 0.65 (0.002 - 0.026) 0.8 (0.03) Big end radial clearance 0,006 0.D18 (0.0002 - 0.0007) 0.05 (0.002) 1-9
- 13. GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ITEM STANDARD Minimum tire tread depth Cold tire pressure Standard 25 kPa (0.25 kgf/cm • 3.6 psi) Minimum 22 kPa (0.22 kgf/cm • 3.2 psi) Maximum 28 kPa (0.28 kgf/cm • 4.0 psi) With cargo 25 kPa (0.25 kgf/cm • 3.6 psi) Tie-rod distance between the ball joints 347.5 ± 1 mm (13.68 ± 0.4 in) To. Toe-out: 18 ± 15 mm (11/18 ± 9/16 in) REAR WHEEL/SUSPENSION SPECIFICATIONS ITEM STANDARD Minimum tire tread depth Cold tire pressure Standard 25 kPa (0.25 kgf/cm', 3.6 psi) Minimum 22 kPa (0.22 kgf/cm ,3.2 psi) Maximum 28 kPa (0.28 kgf/cm , 4.0 psi) With cargo 25 kPa (0.25 kgf/cm , 3.6 psi) BRAKE SYSTEM SPECIFICATIONS ITEM Dcum I.D. 160.0 )6.30) Bcoke pooel . - 14.0 f-O=ReaccCC:;;; bCO" C:;-- Dcum I.D. ~ 160.0 (6.30) Bcoke lev", fee, pl.y 15-¥oi 1-10 SERVICE LIMIT 4.0 mm (0.16 in) SERVICE LIMIT 4.0 mm (0.16 in) 161 '-34) ) 0.4 J.02) - 161.0 (6.34) -
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- 15. GENERAL INFORMATION FRONT DRIVING MECHANISM SPECIFICATIONS REAR DRIVING MECHANISM SPECIFICATIONS ITEM STANDARD Rear axle Axle runout Final drive Oil capacity h ,draining 85 em (2.9 US OZ, 3.0 Imp azl f--" At disassembly 100 em (3.4 US OZ, 3.5 Imp oz) Recommended oil Hypoid gear oil SAE #80 Gear backlash 0.05 0.25 (0.002 0.010) Backlash difference Ring gear-ta-stop pin clearance 0.3 0.6 (0.01 0.02) SATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM Battery Capacity Current leakage Voltage Fully charged (20"C/68°F) Needs charging Charging cur- Normal rent Quick Alternator I- Capacity Charging coil resistance (20°C/68°F) IGNITION SYSTEM SPECIFICATIONS ELECTRIC STARTER SPECIFICATIONS ITEM Starter motor brush length 12.5 (0.49) S PECIRCAnONS 12V 12 Ah 1 rnA max. 13.0-13.2 V Below 12.3 V 1.4 Ai5 10 h 6.0 All.0 h 0.32 kWI5,OOO rpm 0.1 1,On STANDARD Unit' mm (in) SERVICE UMlT 3.0 (0.12) 0.4 (0.02) 0.2 (0.01) - Unit: mm {in) SERVICE LIMIT 9.010.35) 1-11
- 16. GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS 8,'b ;~ 12V - 2115 W ,2 I KW5'; ; ; LEI r- ~mel"lighl LED,12 F,,, lain -i§-A I . 13 - 15<> 1-12
- 17. GENERAL INFORMATION STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE N·m (kgf'm, Ibf.ft) FASTENER TYPE N'm (kgf·m. Ibf·ft) 5 mm bolt and nul 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5) 8 mm bolt and nut 22 (2.2. 16) 6 mm flange bolt (8 mm head; small 10 (1.0, 7) head) 10 mm bolt and nut 34 (3.5, 25) 6 mm flange bolt (8 mm head; large 12 (1.2, 9) flange) 12 mm bolt and nut 54 (5.5, 40) 6 mm flange bolt (10 mm head) and 12 (1.2, 9) nut 8 mm flange bolt and nut 26 (2.7, 20) 10 mm flange bolt and nut 39 (4.0, 29) ENGINE & FRAME TORQUE VALUES • Torque specifications listed below are for important fasteners. • Others should be tightened to standard torque values listed above. NOTE: 1. Apply locking agent to the threads. 2. Apply engine oil to the threads and seating surface. 3. Apply grease to the threads and seating surface. 4. Lock nut: replace with a new one. 5. Stake. 6. Self-lock nut; replace with a new one. 7. Castle nut: tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hole. 8. U-nut. ENGINE MAINTENANCE Engine oit drain bolt ITEM Engine oit filter center bolt Timing hole cap Spark plug Tappet adjusting hole cap Valve adjusting screw lock nut LUBRICATION SVSTEM ITEM Front crankcase cover socket bolt Oil feed pipe setting cap bolt Oil pump assembly bolt FUEl SYSTEM ITEM Carburetor insulator band screw Throttle position (TP) sensor mounting screw CVLlNDER HEAOIVALVE/ CAMSHAFT ITEM Cylinder head flange cap nut Cam dlain tensioner pivot bolt Q'TV 1 1 1 1 2 2 Q'TV 4 1 1 Q'TV f- 2 2 Q'TV 4 1 THREAD TORQUE REMARKS DIA. (mml N'm (kgf·m, lbf.ftl 12 25 (2.5, 18) 20 18 (1.8, 13) 14 10 (1.0, 7) 12 22 (2.2, 16) 30 20 (2.0, 14) 6 17 (1.7,12) THREAD TORQUE REMARKS DIA.(mm) N·m (kg"m, Ibf.ft) 10 34 (3.5, 25) 20 18 (1.8,13) 5 6 (0.6, 4.3) THREAD TORQUE REMARKS DIA. (mm) N'm (kgf'm, Ibf.ft) 5 4 (0.4, 2.9) 5 4 (0.4, 2.9) NOTE 1 THREAD TORQUE REMARKS DIA. (mm) N'm (kgf·m. Ibf.ft) 10 39 (4.0, 29) NOTE 2 6 12 (1.2, 9) NOTE 1 1-13
- 18. GENERAL INFORMATION CYLINDER/PISTON ITEM Q'TY THREAD TORQUE REMARKS DlA. (mmJ N'm (kgf·m. Ibf.ftJ Cylinder stud bolt 4 10 12(1.2,9) See page , . 15 CENTRIFUGAL CLUTCH ITEM Q'TY THREAD TORQUE REMARKS OIA. (mml N'm Ikgf·m. Ibf.ftJ Centrifugal clutch lock nut 1 20 118(12.0, 87) NOTE 2, 4, 5 Primary driven gear socket bolt 4 6 17 11.7. 12) NOTE 2 ALTERNATOR/STARTER CLUTCH ITEM Q'TY THREAD TORQUE REMARKS OIA. {mmJ N·m (kgf·m. Ibf.ft) Recoil starter driven pulley bolt 1 12 108 (11.0, 80) NOTE 2 Starter one-way clutch socket bolt 6 8 3013. 1,22) NOTE 1 Alternator stator mounting bolt 3 6 10 (1.0, 7) Ignition pulse generator mounting bolt 2 5 6 (0.6, 4.3) SUB·TRANSMISSION ITEM Q'TY THREAD TORQUE REMARKS OIA. lmmJ N'm (kgf'm, Ibf.ftl Gearshift stopper cap bolt 1 18 18 (1.8, 13) Neutral/DrivelReverse switch 3 10 1311.3,9) Gearshift fork lock nut ('04:) 1 10 35 (3.6, 26) NOTE 1 Gearshift fork lock nut (After '04:) 1 10 39 (4.0, 29) NOTE 1 CRANKSHAFT/AUTOMATIC TRANSMISSION ITEM Q'TY THREAD TORQUE REMARKS DIA. (mmJ N'm (kgf'm, Ibf.ft) Angle sensor mounting bolt 2 5 6 (0.6, 4.3) NOTE 1 Angle sensor bracket bolt 2 6 10 (1.0, 7) LIGHTS/METERS/ SWITCHES ITEM Q'TY THREAD TORQUE REMARKS DlA. (mm) N·m (kgf'm, Ibf.ft) Oil thermosensor 1 12 18 (1.8, 13 1-14