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2007-2010 ; 2@ HONDA Cray pE/FMITE/TM/FPE/FPM FourTrax Rancher® A Few Words About Safety Service Information “The service and repair information contained in this manual is intended for use by qualified, professional technicians, ‘Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also amage the vehicle or create an unsate condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle It you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality For Your Customer's Safety AWARNING Proper service and maintenance are essential to the cusiomer’s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle Improper service or repairs can create an in fauity operation, damage tothe vehicle, or injury to others. Lnsafe conattion that can cause your customer ‘can result in faulty operation, damage . rey or others to be seriously hurt or killed. For Your Safety Follow the procedures and precautions in this Because this manual is intended for the professional service technician, we manual and other service materials caretuly do not provide warnings about many basic shop safety practices (e.g. Hot — parts-wear gives). If you have nat received shop safety training or do not feel confident about your knowledge of sale servicing practice, we CNN recommended that you de not attempt to perform the procedures described” Falure to properly tollow instructons. and in this manual Precautions can cause you to be seriously hurt ‘Some of the most important general service safety precautions are given or liat below. However, we cannot warn you of every conceivable hazard that can Follow the procedures and precautions inthis ‘arise in pertorming service and repair procedures. Only you can decide manual careful ‘whether or not you should perform a given task Important Safety Precautions ‘Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially caretul ofthe folowing: * Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely * Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, dil, orind, pry or work around pressurized air or liquids, and springs or other stored-eneray components. If there is any doubt, put on eye protection. * Use other protective wear when necessary, for example gloves or safely shoes. Handling hot or sharp parts can cause severe bburns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. * Protect yourself and cthers whenever you have the vehicle up in the air. Any time you it the vehicle, ether witha hoist or a jack, ‘make sure that itis always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise ‘This will help eliminate several potential hazards * Carbon monoxide poisoning from engine exhaust, Be sure there is adequate ventilation whenever you run the engine. * Burns from hot parts or coolant. Let the ngine and exhaust system cool before working in those areas. *Inlury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and cothng are out ofthe way Gascinevaors and hystogen gases tom bates ae explosive ordcn the are exclosive To reduce the psstlity of a fre o explosion, be atl whon working around gasoline or batteries, ‘ ee eee * Use only a nonflammable solvent, not gasoline, to clean parts. ‘+ Never drain or store gasoline in an open container. * Keep all cigarettes, sparks and flames away from the battery and all fuel-elated parts, HOW TO USE THIS MANUAL CONTENTS TlSeauvbeaet her enter GENERAL INFORMATION pak Cperating condlion and ihe exssion TECHNICAL FEATURES Protection Agency (EA) Cavtomia Ae Resourene Bost Bruin gene (EM) FRAME/BODY PANELS/EXHAUST SYSTEM [IE CGumporeites oro Paal wear Wat ome Got, fe: bean MAINTENANCE EI Sector + ad 4 spi oth whole aie. Sesion 3 Nutimias LUBRICATION SYSTEM ps ane Soren ALeeiin GaN) ls ane - . COOLING SYSTEM Ha Eris arte wapope te weston en wn wa — See ee eee ENGINE RENOVALANGTALLATION [ e fae ve ciated posacaes me Te newenet CYLINDER HEADIVALVE CYLINDER/PISTON | 10 CLUTCH/GEARSHIFT LINKAGE El ALTERNATOR/STARTER CLUTCH EE Jeulmate armed scons aw have pond sey massages {ANKCASE/TRANSMISSION/CRANKSHAFT/ BPN paca portblewsnyosuonslvolaaiareded | (—-—SALANCER FRONT WHEEL/SUSPENSION/STEERING EZ ean we Errno St) sn myo em re ro REAR WHEEL/SUSPENSION Ea "Shed ince sonal words DANGER WAAING, 6 CAUTION. BRAKE SYSTEM Ea or “ou WILL be KILLED or SERIOUSLY FRONT DRIVING MECHANISM yeu teow boven FMF EJFPM/FPE models} BX iit eed tow tc REAR DRIVING MECHANISM ED wg. wom vros ant tow | | parTERVcHARGING svsTEM SRE len nail ia icy IGNITION SYSTEM ED (as oe te recone te meee ve tw ELECTRIC STARTER gt | LIGHTS/METERS/SWITCHES E / ELECTRIC SHIFT PROGRAM _(ESP: TE/FE/FPE models / ELECTRIC POWER STEERING —— _ (EPS: FPMIFPE models} EI WIRING DIAGRAMS El “Tnoustesioomne ENGINE Sion? WF you dont know the source of the trouble, go to seston 26 | Ifyou are not fariar wth this woh, rad Tectia! Features in | “Teubleshootng. | CHASSIS. ELECTRICAL 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. 2 Foplace the part(s) with new one(s) before assembly. :) Use the recommended engine oil, unless otherwise specified. Use molybdenum oll solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). Use molybdenum disuifide grease (containing more than 3% molybdenum disuifide, NGI #2 or equivalent) Example: Molykote® BR-2 plus manulactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan a Use mult-purpose grease (lithium based mult-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning US.A. AEX Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, UK. ocol Paste manufactured by Sumico Lubricant, Japan Aa Use silicone grease. Apply a locking agent. Use a medium strength locking agent unless otherwise specified. om sem Apply sealant. A Use DOT 4 brake ui Use the recommended brake uid uness otherwise spected Use fork or suspension fluid 1. GENERAL INFORMATION SERVICE RULES ~ MODEL IDENTIFICATION GENERAL SPECIFICATIONS. LUBRICATION SYSTEM SPECIFICATIONS: FUEL SYSTEM (PGM-FI SPECIFICATIONS COOLING SYSTEM SPECIFICATIONS --- 112 CYLINDER HEAD/VALVE SPECIFICATIONS CYLINDER/PISTON SPECIFICATIONS 113 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS --- ALTERNATOR/STARTER CLUTCH ‘SPECIFICATIONS -. CRANKCASE/TRANSMISSION/CRANK- ‘SHAFT/BALANCER SPECIFICATIONS ---- FRONT WHEEL/SUSPENSION/STEERING essen 115, SPECIFICATIONS. REAR WHEEL/SUSPENSION ‘SPECIFICATIONS BRAKE SYSTEM SPECIFICATIONS ----- 1-15 FRONT DRIVING MECHANISM SPECIFICA- TIONS (FM/FE/FPM/FPE models) ------~ 1-15 REAR DRIVING MECHANISM ‘SPECIFICATIONS - “1-16 BATTERY/CHARGING SYSTEM ‘SPECIFICATIONS - 1-16 IGNITION SYSTEM SPECIFICATIONS - 1-16 ELECTRIC STARTER SPECIFICATIONS ---- LIGHTS/METERS/SWITCHES SPECIFICATIONS STANDARD TORQUE VALUES. ENGINE & FRAME TORQUE VALUES-~ 1-18 LUBRICATION & SEAL POINTS -~ 1:24 CABLE & HARNESS ROUTING (‘07 - 08 model} 1-28 CABLE & HARNESS ROUTING (After ‘08 model) “1-87 EMISSION CONTROL SYSTEMS «==+--- 1-71 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. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the vehicle, Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 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. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly, After reassembly, check all parts for proper installation and operation. Route all electrical wires as shown in the Cable & Harness routing (page 1-28). ABBREVIATION Throughout this manual, the following abbreviation are used to identify the respective parts or systems. ‘bbrev. term CKP sensor ‘crankshaft Posi ico Uiquid Crystal Dic Data Link Connector — ore Diagnostic Trouble Code 4 PCM (TE/FEIFPE models) | Powertrain Control Module ~ ECM (TWEMIFPM mo: Engine Control Module ECT sensor Engine Coolant Temperature sensor “EEPROM Electicaly Erasable Programmable Read Only Memory EPS Electric Power Steeri oo ESP Electric Shift Program 1 Fuel Pump “Honda Diagnostic System Idle Air Control Valve Intake Air Temperature senor Manifold Absolute Pressure sensor ~ Malfunction Indicator Lamp Programmed Fuel Injection Vehicle Speed sensor [4 Wheel Drive GENERAL INFORMATION MODEL IDENTIFICATION ‘This manual covers 4 types of TRX420 models: + TM - 2WDiLeft foot operated gearshift ‘TE ~ 2WDiElectric shift program (ESP) FM - 4WDiLeft foot operated gearshift + FE~ aWDiElectric shift program (ESP) + FPM - 4WDiLeft foot operated gearshiftElectric Power Steering (EPS) ‘+ FPE —4WDiElectric shift program (ESP)/Electric Power Steering (EPS) (Co Be sure to refer to the procedure that pertains to the appropriate version of the TAX420 ‘TRX420FE model shown: © SERIAL NUMBERS ‘The Vehicle Identification Number (VIN) is stamped on the front side of [— the frame through the front fender. GENERAL INFORMATION The engine serial number is stamped on the left side of the rear erankease. ENGINE SERIAL NUMBER ‘The throttle body identification number is stamped on the upper side of the throttle body, ‘THROTTLE BODY IDENTIFICATION NUMBER LABELS ‘07: The name plate (U.S.A. type) or safety certification label (Canada type) is attached on the left front frame down pipe. NAME PLATE (U.S.A) SAFETY CERTIFICATION LABEL (Cenada) After ‘07: The name plate (U.S.A. type) or safety certification label ~ (Canada type) is attached on the right front frame down pipe. NAME PLATE (U.S.A,) ‘SAFETY CERTIFICATION LABEL (Canada) GENERAL INFORMATION ‘The color label is attached on the left frame pipe under the seat. When ordering color-coded parts, always specify the designated color code. ‘07: The vehicle emission control information label is attached on the right front frame pipe. “08: The vehicle emission control information label is attached on the left front frame pipe. After ‘08: The vehicle emission control information label is attached on the left front frame pipe. MISSION CONTROL INFORMATI El (ON LABEL USA. only: - 7 { EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION LABEL (Canada type only} ~ EMISSION CONTROL INFORMATION LABEL (U.S.A. and Canada types) EMISSION CONTROL INFORMATION LABEL (Canada type only) GENERAL INFORMATION GENERAL SPECIFICATIONS TRX420TM/TE DIMENSIONS FRAME ENGINE ew Overall iength Overall with Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Curb weight Maximum weight capacity Frame type Front suspension Front whee! travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Roar rim size Front tire brand. Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity ‘o7: After ‘07: Fuel tank reserve capacity ‘07: After ‘07: Cylinder arrangement Bore and stroke Displacement Compression ratio ‘07-08: After ‘08 Valve train Intake valve opens ‘07 ~ 08: After ‘08: closes ‘07 ~“08: After ‘08: Exhaustvaive opens ‘07 - 08: After ‘08: closes ‘07 ~ 08: After ‘08: Lubrication system il pump type Cooling system Air filtration Engine dry weight T™: Te: SPECIFICATIONS 2,055 mim (80.9 in} 4,172 mm (46.1 in} 4,148 mm (482 in} 1,256 mm (49.4 in) 847 mm (33.3 in) 880 mm (84.8 in) 823 mm (32.4 in} TM: 246 mm (13.6 in} TE: $86 mm {13.2 in) 165 mm (6.5in) TM: 248 kg (547 tbs) TE: 249 kg (549 Ibs) 220 kg (485 tbs) Double cradie Double wishbone 4160 mm (6.3in) Double tube Swingarm (w 160 mm (6.3in) Double tube AT24 x 8412 ++ AT24 x 10-11 + 12x80 AT 1c 75 AT MS77 (Maxxis) M978 (Maxxis) Hydraulic dise brake Mechanical drum brake 638° 25.1 mm (0.88 in) 2 1327 liters (3.62 US gal, 3.01 Imp gal) 133 liters (3.51 US gal, 293 Imp gal) 28 liters (0.74 US gal, 0.82 Imp gal) 26 liters (0.69 US gal, 0.57 Imp gal) Single cylinder, longitudinally installed 86.5 x71.5 mm (3.41 x 281 in) 420 om? (25.6 cu-in) 98:1 a9: ‘OHV 6° BTDC (at 1 mm lt) 7 BTDC (at 1 mm lift) 45° ABDC (at 1 mm lif) 32° ABDC (at 1 mm lif) 45° BBDC (at 1 mm lift) 35° ABDC (at 1 mm lif} 2 ATDC (at 1 mm lif) 4 ATDC (at 1 mm lif) Forced pressure and wet sump Trochoid Liquid cooled Oiled double urethane foam ing type) “07 ~ ‘08: 48.6 kg (1071 tbs) ‘After ‘08: 48.5 kg (106.9 Ibs) “07 ~ "08: 49.6 kg (109.3 lbs) ‘After ‘08: 49.5 kg (109.1 Ibs) GENERAL INFORMATION Tem ‘SPECIFICATIONS FUEL DELIVERY | Type PGM-Fl (Programmed Fuel Injection) SYSTEM Throttle bore 34mm (1.3 in) DRIVE TRAIN Clutch system Centrifugal and multi-plate, wet Clutch operation system Automatic Transmission Constant mesh, §-speeds with reverse Primary reduction 2.103 (61/29) Secondary reduction 1.818 (40/22) Final reduction 3,183 (41/13) © Gear ati, 1 Sesy tana) 2nd 2.235 (38/17) 3rd 1.871 (33/21) ath 1.178 (33/28) sth 0.848 (28/33) Reverse 4,831 (46/14 x 25/17) © Gearshift pattern R-N-1-2-3-4-5 TM: Lett foot operated return system TE: Electric shift (left hand operated) return sys- tem ELECTRICAL Tanition system Full transistorized ignition Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase full wave rectif Lighting system Battery GENERAL INFORMATION ‘TRX420FM/FE eM srciricarions 1@ DIMENSIONS | Overall length 055 mm (605 in} Overall width 1,172 mm (46.1 in) Overall height 41/148 mm (48.1 in) Wheelbase 1/249 mm (49.2 in} Front troad ‘840 mm (33.1 in} Rear tread £880 mm (34.6 in} Seat height 822 mm (32.4 in) Footpeg height FM: 345 mm (13.6 in) FE: 395 mm (13.2) Ground clearance 165 mm (65 in} Curb weight FM: ‘07-08 USA. and Canada: 266 kg (586 Ibs) Alter 08 U.S.A. 265 kg (584 Ibs) Fe: ‘07 ~ 08: 267 kg (589 Ibs) ‘After '08: 265 kg (586 Ibs) Maximum weight capacity 220 kg (485 ibs) FRAME rame Doubie cradle Front suspension Double wishbone Front wheel travel 160 mm (63 in) Front damper Double tube Rear suspension ‘Swingarm (trailing type) Rear wheel travel 160 mm (6.3 in) Rear demper Double tube | Front tte size AT24 x 8-12 #4 Rear tre size ‘AT24 x 10-11 3 Front rim size 12x80 AT Rear rim size 11x75 AT From tire brand (M377 (Maxxis) Rear tire brand M978 (Maxxis) Front brake Hydraulic dise brake Rear brake Mechanical drum brake Caster angle 2 Trail length ‘07-08 | 9.5mmi0.37 in) After‘08: | 9 mm (11/32 in) ‘camber angle o Fuel tank capacity ‘0 137 liters (3.62 US gal, 3.01 Imp gal) Afer‘o7: | 13.3 liters (3.51 US gal, 2.93 imp gal) Fuel tank reserve capacity 07 28 lters (0.74 US gal, 0.62 Imp gal) | © _After‘07: _ | 2.6 ters (0.69 US gal, 0.57 Imp gal) _ ENGINE T igie cylinder, longitudinally installed Bore and stroke 86.5 x 71.5 mm (3.41 x 2.81 in) Displacement 420 cm? (25.6 cu-in) Compression ratio ‘7-08 =| ga: Alier‘0& =| 9.921 Valve train onV Intake valve opens. ‘07 6° BTDC (at 1 mm lift) After ‘08 7° BTDC (at 1 mm lit) closes ‘07 '08: 45° ABDC (at 1 mm lift) After ‘08: 32° ABDC (at 1 mm lift) Exhaustvalve opens ‘07 ~'08: 45° BBDC (at 1 mm lift) After‘08: 35° BBDC (at 1 mm lift) closes 2° ATDC (at 1 mm lift) 4 ATDC (at 1 min lft) Lubrication system Forced pressure and wet sump. Oil pump type Trochoid Cooling system Liquid cooled Air filtration Oiled double urethane foam Engine dry weight FM: “07 ~ ‘0B: 49.0 kg {108.0 Ibs) After ‘08: 48.9 kg (1078 tbs) Fe (07 ~ ‘08: 49.9 kg (110.0 Ibs) After ‘08: 49.8 kg (109.8 Ibs)