🏷️ Basic Information Identification Make: Honda Model: Rancher 400 (TRX400) Model Variants Covered: TRX400, TRX400FA (Automatic), TRX400FGA (Automatic with IRS) Model Years Covered: 2004, 2005, 2006, 2007 Codes Chassis Code: TRX400 👋 Introduction Market Position Positioning: The Honda Rancher 400, also known as the FourTrax 400, was a popular and versatile utility ATV known for its reliability and capability across various terrains. This manual targets owners and technicians seeking comprehensive information for maintaining and repairing these machines. Competitive Analysis Competitors: Competed with other 400cc-class utility ATVs from manufacturers like Yamaha (Grizzly 350/400), Suzuki (KingQuad 300/400), and Polaris (Sportsman 400). Key Features Features Of Atv: Available in 2WD and 4WD configurations, with some models featuring Independent Rear Suspension (IRS). Known for its robust engine, comfortable seating, and capable utility features. Manual Value Proposition: This manual provides the essential technical data and procedural guidance to perform a wide range of maintenance and repair tasks, empowering users to maintain their Rancher 400 effectively and economically. 📋 Manual Details Coverage Areas Coverage: Complete service, repair, maintenance, and troubleshooting for all model variations of the 2004-2007 Honda Rancher 400 ATVs. Includes full teardown and rebuild procedures. Page Count Page Count: 515 pages Manual Type Manual Type: Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, including piston, rings, cylinder, crankshaft, connecting rod, valves, camshaft, valve clearance adjustment, timing, lubrication system, cooling system (radiator, coolant), starter motor, flywheel, stator, ignition system (spark plug, coil, CDI), fuel system (carburetor, fuel pump, PGM-FI for applicable models). Transmission: Complete transmission rebuild for both manual and automatic transmission (AT) variants, including gearshift mechanism, clutch, primary reduction gear, drive train, shafts, and associated components. Covers fluid changes and maintenance. Suspension: Front and rear suspension systems, including forks, struts, linkage, swingarm, shocks, springs, and associated hardware. Covers adjustment, maintenance, and repair. Electrical: Complete electrical system, including battery, charging system (rectifier/regulator), lighting (headlights, taillights, indicators), ignition system, starter system, switches, wiring harnesses, fuses, and error code diagnostics. Bodywork: Body panels, fenders, plastics, seat, handlebars, and associated trim. Covers removal, installation, and replacement. Brakes Brakes: Hydraulic brake system, including master cylinders, calipers, brake lines, brake pads, brake rotors, parking brake, and bleeding procedures. Covers inspection, service, and replacement. Procedures Included Maintenance: Scheduled maintenance, fluid changes (engine oil viscosity, coolant, brake fluid), filter replacement (oil, air), spark plug replacement, tire pressure checks, lubrication points, and general upkeep. Includes maintenance schedules. Troubleshooting: Comprehensive troubleshooting guides for common and uncommon issues, including no spark, starting problems, engine misfires, electrical faults, transmission issues, and braking problems. Includes diagnostic procedures and error code explanations. Repair Overhaul: Detailed step-by-step instructions for complete teardown and rebuild of all major vehicle components, including engine, transmission, suspension, and braking systems. Includes procedures for component replacement and overhaul. Installation: Instructions for installing various parts and accessories, as well as procedures for reassembling components after repair or overhaul. Technical Depth Depth: Extensive technical depth, covering everything from basic maintenance and adjustments to complete engine and transmission rebuilds. Includes detailed diagnostic procedures, torque specifications, and schematics. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, printable pages with clear diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Features Searchability: Fully searchable PDF with clickable chapters for easy navigation. Usage Rights: No restrictions on printing or saving/burning to disc. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, OHV, air-cooled, single-cylinder Displacement: 397 cc Bore X Stroke: 85 mm x 70 mm Compression Ratio: 8.5:1 Performance Horsepower: Approx. 27 HP (Varies slightly by year/model) Torque: Approx. 23 lb-ft (Varies slightly by year/model) Fuel System Fuel Delivery: Carburetor (Keihin 37mm CV for most models), PGM-FI (Fuel Injection) on certain later automatic models. Fuel Type: Unleaded gasoline, 87 octane or higher recommended. Lubrication Oil Type: Honda GN4 10W-40 4-stroke motorcycle oil recommended. SAE 10W-30 or 10W-40 also acceptable. Oil Capacity: Approx. 2.0 US qt (1.9 L) with filter change. Cooling System Cooling Method: Air-cooled Ignition Ignition Type: CDI (Capacitor Discharge Ignition) Spark Plug Recommended Spark Plug: NGK CR7EH-9 or equivalent. 🔧 Transmission Standard Transmission Type: 5-speed manual with reverse (standard on TRX400/TRX400FGA), Torque Converter Automatic (AT) transmission (standard on TRX400FA). Optional Optional Transmission: Not applicable, variants are factory equipped. Features Drive System: Shaft drive Final Drive: O-ring sealed chain Transmission Fluid Transmission Fluid Type: SAE 80 hypoid gear oil recommended for shaft drive. 📐 Dimensions Exterior Overall Length: Approx. 77.4 inches (1966 mm) Overall Width: Approx. 45.1 inches (1145 mm) Overall Height: Approx. 42.2 inches (1072 mm) Wheelbase: Approx. 49.2 inches (1250 mm) Weights Dry Weight: Approx. 570 lbs (259 kg) Curb Weight: Approx. 595 lbs (270 kg) (with all fluids) Capacities Fuel Tank Capacity: 3.0 US gallons (11.5 L), including 0.7 US gal (2.6...