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2004-2007 Rancher 400 AT (TRX400FA / TRX400FGA) Service Repair Manual (Highly Detailed FSM PDF Preview) Download

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This manual covers the 2004 through 2007 model years of the FourTrax Rancher 400 AT, specifically the TRX400FA (Standard AT) and TRX400FGA (AT with GPS) variants. As a robust All-Terrain Vehicle (ATV), the Rancher 400 AT is engineered for versatility and reliability in demanding off-road conditions. It features a powerful 397cc liquid-cooled engine paired with an automatic transmission (Hondamatic) and electronically selectable 2WD/4WD system, making it suitable for work, recreation, and exploration. The fourth-generation Rancher line is recognized for its durable construction, independent double-wishbone suspension on all wheels, and the advanced integration of GPS navigation on the FGA model, enhancing its utility for various tasks. This comprehensive workshop service and repair manual provides detailed information essential for the maintenance and repair of your FourTrax Rancher 400 AT. It covers a wide array of systems including the engine, automatic transmission, drivetrain, chassis, body, and electrical components. Within its 515 pages, you will find step-by-step procedures for scheduled maintenance, tune-ups, fluid changes, complete disassembly and reassembly of major components, and systematic troubleshooting guides for common issues. The manual also includes hundreds of original photographs and illustrations, technical specifications, and wiring diagrams, empowering owners and technicians to effectively diagnose, maintain, and repair their vehicle. 🏷️ Basic Information Identification Make: Honda Model: FourTrax Rancher 400 AT Model Codes: TRX400FA, TRX400FGA Vehicle Type: ATV (All-Terrain Vehicle) Production Years Covered: 2004, 2005, 2006, 2007 Generation Generation Identifier: Fourth Generation (TRX400FA/FGA) Codes Chassis Codes: TRX400FA (Standard AT), TRX400FGA (AT with GPS) 👋 Introduction Market Position Target Audience: Owners of 2004-2007 Honda FourTrax Rancher 400 AT (TRX400FA/TRX400FGA) seeking to perform maintenance, repairs, and diagnostics. Also useful for professional technicians. Competitive Analysis Advantage: Provides dealer-level repair information at a fraction of the cost. Instant download eliminates shipping delays and costs associated with physical manuals. Comprehensive and highly detailed, covering all aspects of the vehicle. Key Features Manual Features: Hundreds of original photographs and illustrations, step-by-step procedures, complete disassembly/reassembly guides, troubleshooting sections, and technical specifications. 📋 Manual Details Coverage Areas Supported Models: 2004-2007 Honda Rancher TRX400FA (4x4 Auto Transmission), 2004-2007 Honda Rancher TRX400FGA (4x4 Auto Transmission with GPS) Page Count Total Pages: 515 Manual Type Type: Official Full Workshop Service and Repair Manual (FSM) Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine Removal/Installation, Cylinder Head/Valve/Camshaft, Cylinder/Piston, Centrifugal Clutch, Alternator/Starter Clutch, Sub-Transmission/Gearshift Linkage, Crankshaft/Automatic Transmission (Hondamatic), Front Driving Mechanism, Rear Driving Mechanism Chassis And Body: Frame, Body Panels, Exhaust System, Front Wheels/Suspension/Steering, Rear Wheels/Suspension, Brake System, Selectable 4WD System Electrical And Fuel: Fuel System, Lubrication System, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagram Procedures Included Maintenance: Scheduled Maintenance, Tune-Ups, Lubrication Schedule, Fluid Checks and Changes (Engine Oil, Gear Oil, Coolant) Repair: Complete Overhaul procedures for engine, transmission, drivetrain, suspension, brakes, and electrical components. Detailed repair instructions for specific parts and systems. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, including error code interpretation (if applicable for the era), no-spark diagnosis, starting problems, and performance issues. Technical Depth Depth: Highly Detailed, covering complete disassembly and reassembly. Suitable for novice DIY mechanics to experienced professionals. Includes hundreds of original photographs and illustrations. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable without restriction. All pages can be printed as needed. Binding Type Binding: Digital Download (PDF) Paper Type Paper Quality: N/A (Digital Format) Compatibility Operating Systems: All Versions of Windows & Mac Requirements Software Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, OHC, 4-valve, Unicam Displacement: 397cc Bore X Stroke: 85 mm x 70 mm Compression Ratio: 8.9:1 Performance Horsepower: Approximately 22-25 HP (Specific figures vary slightly by year and testing method, details within manual) Torque: Detailed torque specifications for all engine fasteners are provided in the manual. Fuel System Carburetor: 34 mm Constant Velocity (CV) Carburetor (Specific model: Keihin, details on jetting and adjustments in manual) Fuel Type: Unleaded gasoline, 86 octane minimum Lubrication System Oil Type: SAE 10W-40 API SG or higher. Specific Honda recommendations available in manual. Oil Capacity: Details on oil capacity for engine and transmission are provided. Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) with electronic advance Cooling System Cooling Method: Liquid-cooled Coolant Type: Honda Motorcycle Coolant or equivalent. Details on mixture ratio and capacity provided. 🔧 Transmission Standard Transmission Type: Automatic transmission with torque converter and electronic shifting (Hondamatic) Gear Selection: Trax (Drive), Neutral, Reverse Features Drive System: Shaft drive Selectable 4Wd: Yes, electronically selectable 2WD/4WD Transmission Fluid: Honda ATV Specific Transmission Fluid or equivalent. Manual specifies type and capacity. 📐 Dimensions Exterior Overall Length: Approximately 77.7 inches (1973 mm) Overall Width: Approximately 45.1 inches (1145 mm) Overall Height: Approximately 45.5 inches (1156 mm) Wheelbase: Approximately 50.6 inches (1285 mm) Weights Dry Weight: Approximately 560 lbs (254 kg) Curb Weight: Approximately 593 lbs (269 kg) Capacities Fuel Capacity: 3.1...
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2004-2007 Rancher 400 AT (TRX400FA / TRX400FGA) Service Repair Manual (Highly Detailed FSM PDF Preview) Download2004-2007 Rancher 400 AT (TRX400FA / TRX400FGA) Service Repair Manual (Highly Detailed FSM PDF Preview) Download2004-2007 Rancher 400 AT (TRX400FA / TRX400FGA) Service Repair Manual (Highly Detailed FSM PDF Preview) Download2004-2007 Rancher 400 AT (TRX400FA / TRX400FGA) Service Repair Manual (Highly Detailed FSM PDF Preview) Download
This manual covers the 2004 through 2007 model years of the FourTrax Rancher 400 AT, specifically the TRX400FA (Standard AT) and TRX400FGA (AT with GPS) variants. As a robust All-Terrain Vehicle (ATV), the Rancher 400 AT is engineered for versatility and reliability in demanding off-road conditions. It features a powerful 397cc liquid-cooled engine paired with an automatic transmission (Hondamatic) and electronically selectable 2WD/4WD system, making it suitable for work, recreation, and exploration. The fourth-generation Rancher line is recognized for its durable construction, independent double-wishbone suspension on all wheels, and the advanced integration of GPS navigation on the FGA model, enhancing its utility for various tasks. This comprehensive workshop service and repair manual provides detailed information essential for the maintenance and repair of your FourTrax Rancher 400 AT. It covers a wide array of systems including the engine, automatic transmission, drivetrain, chassis, body, and electrical components. Within its 515 pages, you will find step-by-step procedures for scheduled maintenance, tune-ups, fluid changes, complete disassembly and reassembly of major components, and systematic troubleshooting guides for common issues. The manual also includes hundreds of original photographs and illustrations, technical specifications, and wiring diagrams, empowering owners and technicians to effectively diagnose, maintain, and repair their vehicle.
🏷️ Basic Information
Identification
Make:
Honda
Model:
FourTrax Rancher 400 AT
Model Codes:
TRX400FA, TRX400FGA
Vehicle Type:
ATV (All-Terrain Vehicle)
Production Years Covered:
2004, 2005, 2006, 2007
Generation
Generation Identifier:
Fourth Generation (TRX400FA/FGA)
Codes
Chassis Codes:
TRX400FA (Standard AT), TRX400FGA (AT with GPS)
👋 Introduction
Market Position
Target Audience:
Owners of 2004-2007 Honda FourTrax Rancher 400 AT (TRX400FA/TRX400FGA) seeking to perform maintenance, repairs, and diagnostics. Also useful for professional technicians.
Competitive Analysis
Advantage:
Provides dealer-level repair information at a fraction of the cost. Instant download eliminates shipping delays and costs associated with physical manuals. Comprehensive and highly detailed, covering all aspects of the vehicle.
Key Features
Manual Features:
Hundreds of original photographs and illustrations, step-by-step procedures, complete disassembly/reassembly guides, troubleshooting sections, and technical specifications.
📋 Manual Details
Coverage Areas
Supported Models:
2004-2007 Honda Rancher TRX400FA (4x4 Auto Transmission), 2004-2007 Honda Rancher TRX400FGA (4x4 Auto Transmission with GPS)
Page Count
Total Pages:
515
Manual Type
Type:
Official Full Workshop Service and Repair Manual (FSM)
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Removal/Installation, Cylinder Head/Valve/Camshaft, Cylinder/Piston, Centrifugal Clutch, Alternator/Starter Clutch, Sub-Transmission/Gearshift Linkage, Crankshaft/Automatic Transmission (Hondamatic), Front Driving Mechanism, Rear Driving Mechanism
Chassis And Body:
Frame, Body Panels, Exhaust System, Front Wheels/Suspension/Steering, Rear Wheels/Suspension, Brake System, Selectable 4WD System
Electrical And Fuel:
Fuel System, Lubrication System, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagram
Procedures Included
Maintenance:
Scheduled Maintenance, Tune-Ups, Lubrication Schedule, Fluid Checks and Changes (Engine Oil, Gear Oil, Coolant)
Repair:
Complete Overhaul procedures for engine, transmission, drivetrain, suspension, brakes, and electrical components. Detailed repair instructions for specific parts and systems.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, including error code interpretation (if applicable for the era), no-spark diagnosis, starting problems, and performance issues.
Technical Depth
Depth:
Highly Detailed, covering complete disassembly and reassembly. Suitable for novice DIY mechanics to experienced professionals. Includes hundreds of original photographs and illustrations.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable without restriction. All pages can be printed as needed.
Binding Type
Binding:
Digital Download (PDF)
Paper Type
Paper Quality:
N/A (Digital Format)
Compatibility
Operating Systems:
All Versions of Windows & Mac
Requirements
Software Requirements:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, OHC, 4-valve, Unicam
Displacement:
397cc
Bore X Stroke:
85 mm x 70 mm
Compression Ratio:
8.9:1
Performance
Horsepower:
Approximately 22-25 HP (Specific figures vary slightly by year and testing method, details within manual)
Torque:
Detailed torque specifications for all engine fasteners are provided in the manual.
Fuel System
Carburetor:
34 mm Constant Velocity (CV) Carburetor (Specific model: Keihin, details on jetting and adjustments in manual)
Fuel Type:
Unleaded gasoline, 86 octane minimum
Lubrication System
Oil Type:
SAE 10W-40 API SG or higher. Specific Honda recommendations available in manual.
Oil Capacity:
Details on oil capacity for engine and transmission are provided.
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition) with electronic advance
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Honda Motorcycle Coolant or equivalent. Details on mixture ratio and capacity provided.
🔧 Transmission
Standard
Transmission Type:
Automatic transmission with torque converter and electronic shifting (Hondamatic)
Gear Selection:
Trax (Drive), Neutral, Reverse
Features
Drive System:
Shaft drive
Selectable 4Wd:
Yes, electronically selectable 2WD/4WD
Transmission Fluid:
Honda ATV Specific Transmission Fluid or equivalent. Manual specifies type and capacity.
📐 Dimensions
Exterior
Overall Length:
Approximately 77.7 inches (1973 mm)
Overall Width:
Approximately 45.1 inches (1145 mm)
Overall Height:
Approximately 45.5 inches (1156 mm)
Wheelbase:
Approximately 50.6 inches (1285 mm)
Weights
Dry Weight:
Approximately 560 lbs (254 kg)
Curb Weight:
Approximately 593 lbs (269 kg)
Capacities
Fuel Capacity:
3.1 US gallons (11.7 Liters), including 0.7-gallon reserve
Towing Capacity:
Not specified for towing by Honda, intended for off-road use and hauling.
Tires
Front Tire Size:
AT25 x 8-12
Rear Tire Size:
AT25 x 10-12
Suspension
Front Suspension Type:
Independent Double-Wishbone with adjustable spring pre-load
Rear Suspension Type:
Independent Double-Wishbone with adjustable spring pre-load
🛡️ Safety Features
Ratings
Safety Standards:
Complies with ANSI/SVIA standards for recreational ATVs.
Active Features
Braking System:
Front: Dual 180 mm hydraulic discs. Rear: Single 210 mm hydraulic disc with sealed mechanical drum parking brake. Details on pad replacement, fluid types (DOT 3 or 4), and bleeding procedures are in the manual.
Lighting:
Twin 30W headlights, 15W taillight/brake light. Specific bulb types and replacement procedures within the manual.
Passive Features
Frame Construction:
Steel frame with durable plastic body panels. Frame inspection and repair guidance within the manual.
💡 Technology Features
Infotainment
Gps System:
The TRX400FGA model includes an integrated GPS navigation system. The manual covers its operation and basic troubleshooting.
Driver Assistance
Selectable 4Wd:
Electronic engagement of 2WD or 4WD system via handlebar-mounted buttons.
Connectivity
Wiring Diagram:
Comprehensive wiring diagrams are included, essential for diagnosing electrical issues and understanding component relationships.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 600 miles (1000 km) or 6 months. Manual provides detailed procedure and oil filter part number (e.g., 15410-MFJ-001).
Air Filter Cleaning:
Every 100 miles (160 km) or 2 months. Replacement interval typically every 12 months or as needed.
Spark Plug Replacement:
Approximately every 4000 miles (6400 km) or 24 months. Manual specifies spark plug type (e.g., CR7EH-9, NGK) and gap.
Valve Clearance Adjustment:
Every 1200 miles (2000 km) or 12 months. Manual provides precise cold clearance specifications (e.g., Intake: 0.10 mm, Exhaust: 0.12 mm).
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-40
Brake Fluid Type:
DOT 3 or DOT 4
Coolant Type:
Honda Motorcycle Coolant or equivalent (50/50 mix with distilled water)
Known Issues
Common Problems:
Potential issues include wear on the automatic transmission clutches, starter motor issues, and charging system problems. The manual provides troubleshooting steps for these and other potential concerns.
📚 Vehicle History
Brand Heritage
Manufacturer:
Honda Motor Co., Ltd.
Model Evolution
Rancher Lineage:
The Rancher line has a long history in Honda's ATV lineup, known for its ruggedness, reliability, and versatility. The 400 AT model introduced advanced automatic transmission technology and a powerful engine.
Production
Manufacturing Location:
Primarily manufactured by Honda in Japan and/or the United States.
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