Honda rancher service manual free download

Check the vacuum piston for smooth operation up and down in the carburetor body. Air will leak out of the vacuum chamber if the diaphragm is damaged in any way, even with just a pin hole. Check the float valve and valve seat for scoring, scratches, clogging or damage. Install the float chamber and tighten the four screws.

Lift the bottom of the piston with your finger to set the diaphragm rib into the groove in the carburetor body. Turn the throttle stop screw to align the butterfly throttle valve with the edge of the outside by-pass hole in the carburetor body, If the throttle stop screw was removed.

Connect the choke cable by screwing the SE valve nut, being careful not to damage the SE valve. Install the carburetor into the insulator by aligning the lug with the groove, and tighten the band screw. Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change.

Loosen the intake duct band screw. Remove the trim clip and the intake duct from the air cleaner housing. Clean the strainer screen with non-flammable or high flash point solvent. Install a new O-ring onto the fuel valve. Install the fuel valve into the fuel tank and tighten the bolts with the collars. Install the fuel tank. Page 97 MEMO The following components require engine removal for service: alternator and starter clutch section 10 transmission including shift fork and shift drum section 11 crankshaft and balancer section 11 Other components without above can be serviced with the engine installed in the frame.

Loosen the band screw and remove the boot band. Remove the joint boot from the engine. Remove the following: upper hanger bolts and nut hanger bracket and mounting rubbers left and right lower hanger nuts Support the bottom of the engine securely.

Apply molybdenum disulfide grease to the out- put shaft spline. Note the installation direction of the hanger bolts, mounting rubbers large I. To service the camshaft, the engine must be removed from the frame. Stop the engine, disconnect the spark plug cap and remove the spark plug. Install the compression gauge into the spark plug hole. Shift the transmission in neutral and close the choke knob OFF.

T o prevent loss of Remove the valve spring cotters using the valve tension, do not spring compressor. If the rocker arm follower is worn or damaged, check the push rod and oil passages. Measure each rocker arm shaft O. Check the valve for bending, burning or abnormal wear. If the The valve seat contact should be within the speci- valve f ace is fied width and even all around the circumference. Install the valve spring seats. Install new stem seals. Lubricate the valve stem sliding surface with molyb- denum oil solution.

Insert the valve into the guide while turning it slowly to avoid damage to the stem seal. Set the rocker arms into the rocker arm holder and install the rocker arm shaft through the holder and arms. Turn the rocker arm shaft and align the bolt holes in the shaft and holder, and install the retaining bolt. Install the rocker arm holder onto the cylinder head. Install the following and tighten them in a crisscross pattern in 2 or 3 steps: four cap nuts with new sealing washers apply engine oil rocker arm holder bolt apply engine oil two cylinder head bolts Blow through the oil passage in the head cover with compressed air.

Install the following: new gasket new O-ring coat with engine oil Install the cylinder head cover and tighten the four bolts. Check the sprocket teeth for wear or damage.

Turn the outer race of each bearing with your finger. Check the tensioner lifter operation: the tensioner shaft should not go into the body when it is pushed. When stopper block is pressed in, the tensioner shaft should be pushed into the body. Do not turn the Install the cam chain over the cam sprocket and crankshaf t while insert the camshaft into the crankcase. Page MEMO Take care not to damage the cylinder wall and piston. Be careful not to damage the mating surfaces when removing the cylinder.

Do not strike the cylinder too hard during removal. Do not strike the Remove the following: cylinder too hard cylinder and do not damage the mating surf ace with a screwdriver. Never use a wire brush; it will scratch the groove. Measure the cylinder I. The rings should be able to move in their grooves without catching.

Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring-to-ring groove clearance. Install new stud bolts in their proper positions and tighten them. Apply molybdenum oil solution to the piston pin outer surface.

Apply engine oil to the piston pin hole and connecting rod inner surface. Be caref ul not to Install the cylinder over the piston while damage the piston compressing the piston rings with your fingers. Make sure that the cylinder touches the crankcase evenly.

To service the reverse stopper shaft and gearshift spindle, the engine must be removed from the frame. Be caref ul not to Unstake the clutch lock nut. Set the special tool into the grooves in the drive plate and hold it, and loosen the lock nut. Check the drive plate boss and clutch drum inner contact surfaces for abnormal wear or damage. Remove the following: outer plate clutch spring inner plate Measure the height of the clutch spring.

Install the following: inner plate with flange side facing up clutch spring with concavity side facing down outer plate with locating pins facing up Install the front crankcase cover page Remove the following: washer and lifter lever lifter bearing and bearing holder Loosen in a Check the cam plate, ball retainer and adjusting plate for abnormal wear or damage.

Check the plate warpage on a surface plate using a feeler gauge. Assemble the following and install them onto the mainshaft: pressure plate Install the discs six discs large I. Install the following: bearing holder and lifter bearing lifter lever by aligning wide groove indicated by punch mark with wide tooth of spindle washer Check the return spring and reset spring for fatigue or damage.

Set the spring end onto the arm groove. Install the shaft of the stopper arm into the hole in the crankcase securely while pressing the spring against the crankcase bottom and set the arm to the shift drum. Coat new O-rings with engine oil and install them onto the joint pipe. Install the spring onto the ball retainer and install them onto the lifter cam. Install the twelve bolts with the engine side cover stay and tighten them in a crisscross pattern in several steps.

Install the oil level dipstick. Page Alternator Stator To service the alternator stator, flywheel and starter clutch, the engine must be removed from the frame these items can be serviced by removing the swingarm if no additional engine work is needed. Remove the wire clip from the recoil starter housing. Remove the three mounting bolts and the recoil starter assembly.

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I had to replace ALL of the fuel system because it sat for years without being started. Before and after getting it to run properly I have a problem with the turn signals and only the turn signals. The Honda Rancher Service Manual Pdf can offer insight to the care and attention and routine maintenance, including the best time to change the oils or the best time to conduct an.

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