2004-2007 TRX400FA/FGA Rancher Repair Service Manual

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

2004-2007 TRX400FA/FGA Rancher Repair Service Manual PDF