Honda Rancher 400 service manual 2004-2007
Contents
1. Turn the crankshaft with the recoil starter and align the T mark on the flywheel with the index mark on INDEX MARK the rear crankcase cover T MARK Remove the bolts and cylinder head cover a em mm CYLINDER HEAD COVER 8 Remove the dowel pins and gasket DISASSEMBLY Remove the rocker arm shaft retaining bolts p eg BOLTS Push the rocker arm shaft with the small screw driver through the bolt hole until the O ring on the shaft is removed out of the head cover ROCKER ARM SHAFTS 8 7 CYLINDER HEAD VALVE CAMSHAFT Remove the rocker arm shafts lock washers and Fro a rocker arms ROCKER ARM ROCKER ARM SHAFT INSPECTION ROCKER ARM SHAFT Check the rocker arms and shafts for wear or dam age If the rocker arm follower is worn or damaged check the push rod and oil passages Measure each rocker arm shaft O D SERVICE LIMIT 11 92 mm 0 469 in Measure each rocker arm LD SERVICE LIMIT 12 05 mm 0 474 in Subtract each rocker arm shaft O D from the corre sponding rocker arm LD to obtain the rocker arm to shaft clearance SERVICE LIMIT 0 08 mm 0 003 in CYLINDER HEAD REMOVAL Remove the following carburetor page 6 7 exhaust pipe page 3 14 cylinder head cover page 8 6 Remove the bolts and carburetor insulator Remove the upper engine hanger bracket bolts engine side Remove the upper engine hanger bracket bolt f p frame side mo2. 5 0 8851 22 46 0 884 Follower bore I D INEN 22 510 22 526 0 8862 0 8868 22 54 0 887 Follower to bore clear IN EX 0 028 0 059 0 0011 0 0023 0 07 0 003 ance Cylinder head warpage me eme 0 10 0 004 TORQUE VALUES Cylinder head flange cap nut 39 N m 4 0 kgf m 29 Ibf ft Apply oil to the threads and seating surface Cam chain tensioner pivot bolt 12 N m 1 2 kgf m 9 Ibf ft Apply a locking agent to the threads Timing hole cap 10 N m 1 0 kgf m 7 Ibf ft Exhaust pipe stud bolt See page 1 15 Engine hanger bracket bolt frame 54 N m 5 5 kgf m A0 Ibf ft side Engine hanger bracket bolt engine 32 N m 3 3 kgf m 24 Ibf ft side 8 3 CYLINDER HEAD VALVE CAMSHAFT TOOLS Compression gauge attachment 07510 MB00101 or equivalent commercially avail able in U S A Valve guide reamer 5 510 mm 07984 2000001 or 07984 200000D U S A only Flat cutter 30 mm EX 32 07780 0012200 or equivalent commercially avail able in U S A Interior cutter 37 5 mm IN 60 07780 0014100 or equivalent commercially avail able in U S A Valve spring compressor 07757 0010000 Cutter holder 5 5 mm 07781 0010101 oe G r sp e or equivalent commercially avail able in U S A Seat cutter 35 mm IN 45 07780 0010400 or equivalent commercially avail able in U S A Interior cutter 30 mm EX 60 07780 0014000 ES or equivalent commercially avail abl
3. 8 CYLINDER HEAD VALVE CAMSHAFT SYSTEM COMPONENTS rvvsvevsvrvrsvsvsvnssnss 8 2 SERVICE INFORMATION NNN 8 3 TROUBLESHOOTING wiara 8 5 CYLINDER COMPRBESSION 8 6 CYLINDER HEAD COVER REMOVAL DISASSEMBLY diris o naren citcmens 8 6 CYLINDER HEAD REMOVAL ovress es eseereeeeeees 8 8 CYLINDER HEAD DISASSEMBLY 8 9 VALVE GUIDE REPLACEMENT 8 12 VALVE SEAT INSPECTION REFACING 8 13 ES CAMSHAFT REMOVAL ssisiisssscsssisssisse isssasss 8 15 CAMSHAFT INSTALLATION iiite 8 19 CYLINDER HEAD ASSEMBLY 8 21 CYLINDER HEAD INSTALLATION 8 22 CYLINDER HEAD COVER ASSEMBLY Ar EAR geesegamg gege smake 8 24 KS CYLINDER HEAD VALVE CAMSHAFT SYSTEM COMPONENTS Q Q 54 N m 5 5 kgf m 40 Ibf ft CYLINDER HEAD VALVE CAMSHAFT SERVICE INFORMATION GENERAL This section covers service of the rocker arms cylinder head valves and camshaft These services can be done with the engine installed in the frame e When disassembling mark and store the disassembled parts to ensure that they are reinstalled in their original loca tions e Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection Rocker arm valve and camshaft lubricating oil is fed through oil passages in the cylinder head and head cover Clean the oil passages before assembling cylinder head and head cover Be careful not to damage the mating surfaces when re
4. ICE LIMITS Inner 37 04 mm 1 458 in Outer 41 85 mm 1 648 in STEM SEAL RETAINER JP VALVE SPRINGS TA SPRING SEAT COMBUSTION CHAMBER 8 10 Inspect and reface the valve seats whenever the valve guides are replaced page 8 13 CYLINDER HEAD VALVE CAMSHAFT VALVE VALVE GUIDE Check that the valve moves smoothly in the guide Check the valve for bending burning or abnormal wear Measure each valve stem O D and record it SERVICE LIMITS IN 5 45 mm 0 215 in EX 5 43 mm 0 214 in Ream the valve guide to remove any carbon build up before measuring the guide REAMER Insert the reamer from the combustion chamber side of the cylinder head and always rotate the reamer clockwise TOOLS Valve guide reamer 5 510 mm 07984 2000001 or 07984 200000D U S A only Measure each valve guide LD and record it SERVICE LIMIT 5 53 mm 0 218 in Subtract each valve stem O D from the correspond ing guide LD to obtain the stem to guide clearance SERVICE LIMITS IN 0 12 mm 0 005 in EX 0 14 mm 0 006 in If the stem to guide clearance exceeds the service limit determine if a new guide with standard dimensions would bring the clearance within toler ance If so replace any guides as necessary and ream to fit If the stem to guide clearance exceeds the service limit with a new guide also replace the valve 8 11
5. cker arm and or shaft Worn rocker arm follower or valve stem end Worn or damaged push rod and or cam follower Worn cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth Cylinder piston problem page 9 3 Rough idle Low cylinder compression 8 5 CYLINDER HEAD VALVE CAMSHAFT CYLINDER COMPRESSION Warm up the engine to normal operating tempera ture Stop the engine disconnect the spark plug cap and remove the spark plug page 4 8 Install the compression gauge into the spark plug hole TOOL Compression gauge attachment 07510 MB00101 or equivalent com mercially available in U S A Shift the transmission in neutral Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising The maximum reading is usually reached within 4 7 seconds COMPRESSION PRESSURE 736 kPa 7 5 kgf cm 107 psi at 450 rpm Check that there is no leakage at the gauge connec tion Low compression can be caused by blown cylinder head gasket improper valve adjustment valve leakage worn piston ring or cylinder High compression can be caused by carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL DISASSEMBLY REMOVAL Remove the fuel tank and heat guard plate page 6 25 Remove the timing hole cap COMPRESSION GAUGE 1 TIMING HOLE CAP 1 CYLINDER HEAD VALVE CAMSHAFT
6. e in U S A Valve guide remover 5 5 mm 07742 0010100 Flat cutter 35 mm IN 32 07780 0012300 or equivalent commercially avail able in U S A Seat cutter 29 mm EX 45 07780 0010300 2 or equivalent commercially avail able in U S A BF OSS CYLINDER HEAD VALVE CAMSHAFT TROUBLESHOOTING Engine top end problems usually affect engine performance These can be diagnosed by a compression test or by trac ing top end noise with a sounding rod or stethoscope Ifthe performance is poor at low speeds check for a white smoke in the crankcase breather hose If the hose is smoky check for seized piston ring page 9 2 Compression too low hard starting or poor performance at low speed Valves Incorrect valve adjustment Burned or bent valve Incorrect valve timing Broken valve spring Uneven valve seating Valve stuck open Cylinder head Leaking or damaged cylinder head gasket Loose spark plug Warped or cracked cylinder head Cylinder piston problem page 9 3 Compression too high overheating or knocking Excessive carbon build up on piston head or combustion chamber Worn or damaged decompressor system Excessive smoke Worn valve stem or valve guide Damaged stem seal e Cylinder piston problem page 9 3 Excessive noise Incorrect valve clearance Sticking valve or broken valve spring Excessively worn valve seat Worn or damaged camshaft Worn ro
7. moving the cylinder head cover and cylinder head SPECIFICATIONS g R Unit mm in ITEM STANDARD SERVICE LIMIT Cylinder compression at 450 rpm 736 kPa 7 5 kgf cm 107 psi ai Valve clearance i IN 0 15 0 006 E EX 0 15 0 006 S Valve Valve stem O D IN 5 475 5 490 0 2156 0 2161 5 45 0 215 valve guide EX 5 455 5 470 0 2148 0 2154 5 43 0 214 Valve guide LD IN X 5 500 5 512 0 2165 0 2170 5 53 0 218 Stem to guide clearance IN 0 010 0 037 0 0004 0 0015 0 12 0 005 EN 0 030 0 057 0 0012 0 0022 0 14 0 006 Valve guide projection IN 15 8 16 0 0 62 0 63 above cylinder head EX 15 8 16 0 0 62 0 63 d Valve seat width IN X 1 0 1 1 0 039 0 043 i 1 4 0 06 Valve spring Free length Inner 37 8 1 49 37 04 1 458 ar 7 Outer 42 7 1 68 41 85 1 648 Rocker arm Arm LD IN X 12 000 12 018 0 4724 0 4731 12 05 0 474 Shaft O D NES 11 964 11 984 0 4710 0 4718 11 92 0 469 __ Arm to shaft clearance IN X 0 016 0 054 0 0006 0 0021 0 08 0 003 Camshaft and Cam lobe height IN 35 9795 36 2195 1 41651 1 42600 35 84 1 411 cam follower EX 35 9245 36 1654 1 41435 1 42383 35 79 1 409 L Cam follower OD IN X 22 467 22 482 0 884
8. unting rubbers and the upper a N engine hanger bracket SS CYLINDER HEAD VALVE CAMSHAFT Remove the push rods y PUSH RODS Remove the two cylinder head mounting bolts and sealing washers d Remove the four cylinder head mounting cap nuts and sealing washers Do not strike the Remove the cylinder head cylinder head too hard and do not damage the mating surface with screworiver S x f d BOLTS SEALING WASHERS Remove the dowel pins and gasket Remove the orifice dowel and O rings ORIFICE O RINGS DOWEL er CYLINDER HEAD DISASSEMBLY To prevent loss of Remove the valve spring cotters using the valve tension do not spring compressor compress the valve springs more than TOOL necessary Valve spring compressor 07757 0010000 VALVE SPRING COMPRESSOR 8 9 CYLINDER HEAD VALVE CAMSHAFT Mark all the parts Remove the following so theycanbe spring retainer placed back in their inner and outer valve springs original locations valve stem seal spring seat INSPECTION CYLINDER HEAD Be carefulnotto Remove the carbon deposits from the combustion damage the gasket chamber being careful not to damage the gasket surface surface Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge SERVICE LIMIT 0 10 mm 0 004 in VALVE SPRING Measure the valve spring free length SERV
Download Pdf Manuals
Related Search