2004-2007 TRX400FA/FGA Rancher Repair Service Manual PDF

This Official 2004 2005 2006 2007 Honda TRX400FA/FGA FourTrax Rancher ATV Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2004-2007 Honda TRX400FA and TRX400FGA ATVs. 

Table of Contents 

General Information 
Technical Feature 
Frame, Body Panels, Exhaust System 
Maintenance 
Engine 
Lubrication System 
Fuel System 
Engine Removal, Installation 
Cylinder Head, Valve, Camshaft 
Cylinder, Piston 
Centrifugal Clutch 
Alternator, Starter Clutch 
Sub-Transmission, Gearshift Linkage 
Crankshaft, Automatci Transmission 
Chassis 
Front Wheel, Suspension, Steering 
Rear Wheel, Suspension 
Brake System 
Fron Driving Mechanism 
Rear Driving Mechanism 
Electrical 
Battery, Charging System 
Ignition System 
Electric Starter 
Lights, Meters, Switches 
Selectable 4wd System 
Hondamatic 
Wiring Diagram 
Troubleshooting 
Index 

INDEX: 

ACCESSORY SOCKET 
AIR CLEANER 
AIR CLEANER HOUSING 
AIR CLEANER HOUSING DRAIN HOSE 
ALTERNATOR CHARGING COIL 
ALTERNATOR STATOR 
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS 
ANGLE SENSOR 
AUTOMATIC TRANSMISSION 

BATTERY 
BATTERY/CHARGING SYSTEM SPECIFICATIONS 
BODY PANEL LOCATIONS 
BRAKE FLUID 
BRAKE FLUID REPLACEMENT/AIR BLEEDING 
BRAKE LIGHT SWITCH 
BRAKE PEDAL 
BRAKE SHOES WEAR 
BRAKE SYSTEM 
BRAKE SYSTEM SPECIFICATIONS 

CABLE & HARNESS ROUTING 
CAMSHAFT INSTALLATION 
CAMSHAFT REMOVAL 
CARBURETOR ASSEMBLY 
CARBURETOR CHOKE 
CARBURETOR DISASSEMBLY/INSPECTION 
CARBURETOR HEATER/AIR TEMPERATURE SWITCH 
CARBURETOR INSTALLATION 
CARBURETOR REMOVAL 
CASE BEARING REPLACEMENT 
CENTRIFUGAL CLUTCH 
CENTRIFUGAL CLUTCH SPECIFICATIONS 
CHARGING SYSTEM INSPECTION 
COMBINATION METER/REAR VEHICLE SPEED SENSOR (VSS) 
COMPONENT LOCATION 
BATTERY/CHARGING SYSTEM 
BRAKE SYSTEM 
CENTRIFUGAL CLUTCH 
ELECTRIC STARTER 
HONDAMATIC 
IGNITION SYSTEM 
LIGHTS/METERS/SWITCHES 
SELECTABLE 4WD SYSTEM 
CONTROL MOTOR 
CRANKCASE ASSEMBLY 
CRANKCASE BEARING REPLACEMENT 
CRANKCASE SEPARATION 
CRANKSHAFT/AUTOMATIC TRANSMISSION SPECIFICATIONS 
CRANKSHAFT/BALANCER 
CYLINDER COMPRESSION 
CYLINDER HEAD ASSEMBLY 
CYLINDER HEAD COVER ASSEMBLY/ INSTALLATION 
CYLINDER HEAD COVER REMOVAL/ DISASSEMBLY 
CYLINDER HEAD DISASSEMBLY 
CYLINDER HEAD INSTALLATION 
CYLINDER HEAD REMOVAL 
CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS 
CYLINDER/PISTON INSTALLATION 
CYLINDER/PISTON REMOVAL 
CYLINDER/PISTON SPECIFICATIONS 

DIFFERENTIAL ASSEMBLY 
DIFFERENTIAL DISASSEMBLY/INSPECTION 
DIFFERENTIAL INSTALLATION 
DIFFERENTIAL REMOVAL 
DIODE 
DRIVE SHAFT BOOTS 
DRIVE/NEUTRAL/REVERSE SWITCH 

ELECTRIC STARTER SPECIFICATIONS 
EMISSION CONTROL INFORMATION LABEL (USA only) 
EMISSION CONTROL SYSTEMS 
ENGINE & FRAME TORQUE VALUES 
ENGINE IDLE SPEED 
ENGINE INSTALLATION 
ENGINE OIL 
ENGINE OIL FILTER 
ENGINE REMOVAL 
ESP SHIFT SWITCH 
EXHAUST SYSTEM 

FINAL DRIVE ASSEMBLY 
FINAL DRIVE DISASSEMBLY/INSPECTION 
FINAL DRIVE INSTALLATION 
FINAL DRIVE REMOVAL 
FINAL GEAR CASE BEARING REPLACEMENT 
FLYWHEEL/STARTER CLUTCH 
FRONT BRAKE MASTER CYLINDER 
FRONT BRAKE SHOES/DRUM 
FRONT BRAKE SWITCH 
FRONT CARRIER/BUMPER/FRONT FENDER 
FRONT CRANKCASE COVER 
FRONT DRIVE SHAFT 
FRONT DRIVING MECHANISM SPECIFICATIONS 
FRONT SHOCK ABSORBER 
FRONT WHEEL 
FRONT WHEEL CYLINDER/BRAKE PANE 
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS 
FUEL LINE 
FUEL SYSTEM SPECIFICATIONS 
FUEL TANK 

GENERAL SPECIFICATIONS 
GPS NAVIGATION METER (GPS type) 
GPS RECEIVER 

HANDLEBAR 
HANDLEBAR SWITCH 
HEADLIGHT 
HIGH ALTITUDE ADJUSTMENT 
HONDAMATIC 
BEFORE STARTING TROUBLESHOOTING 
CIRCUIT DIAGRAM 
CONNECTOR LOCATION 
DIAGNOSTIC TROUBLESHOOTING 

IGNITION COIL 
IGNITION SWITCH 
IGNITION SYSTEM INSPECTION 
IGNITION SYSTEM SPECIFICATIONS 
IGNITION TIMING 
INITIAL SETTING PROCEDURE 

LIGHTS/METERS/SWITCHES SPECIFICATIONS 
LUBRICATION & SEAL POINTS 
LUBRICATION SYSTEM DIAGRAM 
LUBRICATION SYSTEM SPECIFICATIONS 

MAINTENANCE SCHEDULE (04 06) 
MAINTENANCE SCHEDULE (After 06) 
MODE SELECT SWITCH 
MODEL IDENTIFICATION 

NUTS, BOLTS, FASTENERS 

OIL COOLER 
OIL PRESSURE CHECK 
OIL PUMP 

PILOT SCREW ADJUSTMENT 
POWERTRAIN CONTROL MODULE (PCM) 

REAR AXLE INSTALLATION 
REAR AXLE REMOVAL 
REAR BRAKE 
REAR CRANKCASE COVER 
REAR DRIVING MECHANISM SPECIFICATIONS 
REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL 
REAR LUGGAGE CARRIER/REAR FENDER 
REAR SHOCK ABSORBER 
REAR VEHICLE SPEED SENSOR (VSS) 
REAR WHEEL 
REAR WHEEL/SUSPENSION SPECIFICATIONS 
RECOIL STARTER 
REGULATOR/RECTIFIER 

SEAT/SIDE COVER 
SERVICE INFORMATION 
ALTERNATOR/STARTER CLUTCH 
BATTERY/CHARGING SYSTEM 
BRAKE SYSTEM 
CENTRIFUGAL CLUTCH 
CRANKSHAFT/AUTOMATIC TRANSMISSION 
CYLINDER HEAD/VALVE/CAMSHAFT 
CYLINDER/PISTON 
ELECTRIC STARTER 
ENGINE REMOVAL/INSTALLATION 
FRAME/BODY PANELS/EXHAUST SYSTEM 
FRONT DRIVING MECHANISM 
FRONT WHEEL/SUSPENSION/STEERING 
FUEL SYSTEM 
HONDAMATIC 
IGNITION SYSTEM 
LIGHTS/METERS/SWITCHES 
LUBRICATION SYSTEM 
MAINTENANCE 
REAR DRIVING MECHANISM 
REAR WHEEL/SUSPENSION 
SELECTABLE 4WD SYSTEM 
SUB-TRANSMISSION/GEARSHIFT LINKAGE 
SERVICE RULES 
SKID PLATE, ENGINE GUARD 
SPARK ARRESTER 
SPARKPLUG 
STANDARD TORQUE VALUES 
STARTER MOTOR 
STARTER RELAY SWITCH 
STEERING SHAFT 
STEERING SHAFT HOLDER BEARING 
STEERING SYSTEM 
SUB-AIR CLEANER 
SUB-TRANSMISSION SPECIFICATIONS 
SUB-TRANSMISSION/GEARSHIFT LINKAGE 
SUSPENSION 
SUSPENSION ARM 
SWINGARM 
SYSTEM COMPONENTS 
ALTERNATOR/STARTER CLUTCH 
CRANKSHAFT/AUTOMATIC TRANSMISSION 
CYLINDER HEAD/VALVE/CAMSHAFT 
CYLINDER/PISTON 
ENGINE REMOVAL/INSTALLATION 
FRONT DRIVING MECHANISM 
FRONT WHEEL/SUSPENSION/STEERING 
FUEL SYSTEM 
REAR DRIVING MECHANISM 
REAR WHEEL/SUSPENSION 
SUB-TRANSMISSION/GEARSHIFT LINKAGE-SYSTEM DIAGRAM 
BATTERY/CHARGING SYSTEM 
ELECTRIC STARTER 
IGNITION SYSTEM 
SELECTABLE 4WD SYSTEM 
TAIL/BRAKE LIGHT 
THROTTLE HOUSING 
THROTTLE OPERATION 
THROTTLE POSITION SENSOR 
TIE-ROD 
TIRES 
TROUBLESHOOTING 
ALTERNATOR/STARTER CLUTCH 
BATTERY/CHARGING SYSTEM 
BRAKE SYSTEM 
CENTRIFUGAL CLUTCH 
CRANKSHAFT/AUTOMATIC TRANSMISSION 
CYLINDER HEAD/VALVE/CAMSHAFT 
CYLINDER/PISTON 
ELECTRIC STARTER 
ENGINE DOES NOT START OR IS HARD TO START 
ENGINE LACKS POWER 
FRAME/BODY PANELS/EXHAUST SYSTEM 
FRONT DRIVING MECHANISM 
FRONT WHEEL/SUSPENSION/STEERING 
FUEL SYSTEM 
IGNITION SYSTEM 
LUBRICATION SYSTEM 
POOR HANDLING 
POOR PERFORMANCE AT HIGH SPEED 
POOR PERFORMANCE AT LOW AND IDLE SPEED 
REAR DRIVING MECHANISM 
REAR WHEEL/SUSPENSION 
SELECTABLE 4WD SYSTEM 
SUB-TRANSMISSION/GEARSHIFT LINKAGE-TROUBLESHOOTING CHART 
HONDAMATIC 
SELECTABLE 4WD SYSTEM 

VALVE CLEARANCE 
VALVE GUIDE REPLACEMENT 
VALVE SEAT INSPECTION/REFACING 
WHEEL HUB/KNUCKLE 

WHEELS/TIRES 
WIRING DIAGRAM 
GPS TYPE 
STANDARD TYPE 

INDEX