Difficulty
Difficult
Steps
32
Time Required
3 hours
Sections
1
- Carburetor
- 32 steps
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Back2004-2006 Honda Rancher 350 Four Wheeler
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Introduction
Fortunately, however, relatively inexpensive carburetor repair kits can be ordered online so that individuals can fix the carburetor themselves. Repairing a carburetor involves three main steps: loosening and taking the carburetor out of the four wheeler, taking the carburetor apart to clean it and replace the worn-out parts (which are included in the kit), and, finally, reassembling the carburetor before mounting it back on the four wheeler.
In this repair guide, we will first show you how to disconnect and remove the carburetor from the four wheeler, and then we will show you how to thoroughly clean and replace its worn-out parts.
What you need
Step 1
Disconnect Battery
- As a safety precaution, use a Phillips screwdriver to disconnect the negative battery terminal.
- Make sure you never disconnect the positive terminal of the battery before the negative terminal.
As a safety precaution, use a Phillips screwdriver to disconnect the negative battery terminal.
Make sure you never disconnect the positive terminal of the battery before the negative terminal.
1024
Step 2
Loosen Carburetor Intake Band Clamp
- Use a ratchet with a 10 mm socket to loosen the clamp that connects the carburetor to the intake manifold.
Use a ratchet with a 10 mm socket to loosen the clamp that connects the carburetor to the intake manifold.
Step 3
Remove Plastic Side Panels
- Use a flat blade screwdriver to pry and remove the rivets securing both of the side panels so that you will be able to easily access the carburetor.
- There are about 10 rivets to remove.
Use a flat blade screwdriver to pry and remove the rivets securing both of the side panels so that you will be able to easily access the carburetor.
There are about 10 rivets to remove.
Step 4
Remove Black Plastic Side Panel
- Use a T30 Torx screwdriver to remove the screw securing the black plastic panel on the left side of the four wheeler.
Use a T30 Torx screwdriver to remove the screw securing the black plastic panel on the left side of the four wheeler.
Step 5
Remove Bolt That Secures Right Side Panel
- Use a wrench with a 10 mm socket to remove the hex bolt that secures the green plastic panel on the right side of the four wheeler.
Use a wrench with a 10 mm socket to remove the hex bolt that secures the green plastic panel on the right side of the four wheeler.
Step 6
Disconnect Air Vent Line from Engine
- Disconnect the air vent line from the engine.
Disconnect the air vent line from the engine.
Step 7
Disconnect Air-Intake Tube from Metal Frame
- Remove the plastic rivet that connects the air-intake tube to the metal frame of the four wheeler.
Remove the plastic rivet that connects the air-intake tube to the metal frame of the four wheeler.
Step 8
Pull Air-Intake Tube Back
- Pull the air-intake tube backwards away from the air filter box.
Pull the air-intake tube backwards away from the air filter box.
Step 9
Remove Screw from Bottom of Air Filter Box
- Use a 10 mm socket wrench to remove the screw on the right hand side of the bottom of the black air filter box.
Use a 10 mm socket wrench to remove the screw on the right hand side of the bottom of the black air filter box.
Step 10
Remove Air Filter Box
- At this point, the black air filter box should be loose. Lift the air filter box vertically out of the four wheeler.
At this point, the black air filter box should be loose. Lift the air filter box vertically out of the four wheeler.
Step 11
Disconnect Carburetor Gas Line
- Use your fingers to pull the gas line off of the carburetor.
Use your fingers to pull the gas line off of the carburetor.
Step 12
Remove Vacuum Line from Carburetor
- Use your fingers to disconnect the vacuum line from the carburetor.
Use your fingers to disconnect the vacuum line from the carburetor.
Step 13
Disconnect Electrical Sensor
- Disconnect the electrical sensor connector located on the top frame of the right side of the four wheeler.
- Be gentle so you do not break the plastic connector.
- You will probably have to pry the clip on the connector with a small flat blade screwdriver to separate the two halves of the connector.
Disconnect the electrical sensor connector located on the top frame of the right side of the four wheeler.
Be gentle so you do not break the plastic connector.
You will probably have to pry the clip on the connector with a small flat blade screwdriver to separate the two halves of the connector.
Step 14
Remove Carburetor Cover
- Use a Phillips screwdriver to remove the screw that secures the black cover on the right side of the carburetor.
Use a Phillips screwdriver to remove the screw that secures the black cover on the right side of the carburetor.
Step 15
Remove Throttle Cable
- Twist the spring-loaded mechanism located underneath the black cover that was just removed in the previous step in order to loosen and slip the throttle cable out of the inside of the carburetor.
Twist the spring-loaded mechanism located underneath the black cover that was just removed in the previous step in order to loosen and slip the throttle cable out of the inside of the carburetor.
Step 16
Remove Choke Cable
- Remove the choke cable attached to the carburetor by twisting the carburetor around to unscrew it.
Remove the choke cable attached to the carburetor by twisting the carburetor around to unscrew it.
Step 17
Remove the Carburetor from the Four Wheeler
- At this point, the carburetor should be fully disconnected. Lift the carburetor up out of the four wheeler and gently place it on a table where it can be further disassembled.
At this point, the carburetor should be fully disconnected. Lift the carburetor up out of the four wheeler and gently place it on a table where it can be further disassembled.
Step 18
Remove Primer Assembly
- Use the Phillips screwdriver to remove the two screws holding the primer assembly on the carburetor.
- When you take this screw out, be careful that you do not lose the spring underneath it.
Use the Phillips screwdriver to remove the two screws holding the primer assembly on the carburetor.
When you take this screw out, be careful that you do not lose the spring underneath it.
Step 19
Remove Top Cover
- Use a Phillips screwdriver to unscrew the four screws that secure the top metal cover of the carburetor, and remove the cover.
- After you remove the metal cover, pull out the spring and rubber bellows that was underneath it.
- Be sure to remember the position of the vacuum holder highlighted in the picture so that you can put it back in the same position later.
Use a Phillips screwdriver to unscrew the four screws that secure the top metal cover of the carburetor, and remove the cover.
After you remove the metal cover, pull out the spring and rubber bellows that was underneath it.
Be sure to remember the position of the vacuum holder highlighted in the picture so that you can put it back in the same position later.
Step 20
Remove Float-Bowl Assembly
- Use a Phillips screwdriver to remove the four screws that secure the float-bowl assembly.
Use a Phillips screwdriver to remove the four screws that secure the float-bowl assembly.
Step 21
Remove Float Assembly
- Use a punch or small flat blade screwdriver to drive out the pin holding the float and lift the float out.
Use a punch or small flat blade screwdriver to drive out the pin holding the float and lift the float out.
Step 22
Clean Carburetor
- Thoroughly spray the disassembled carburetor pieces with Super Clean and scrub everything with a toothbrush.
- Rinse the parts with water from a garden hose.
Thoroughly spray the disassembled carburetor pieces with Super Clean and scrub everything with a toothbrush.
Rinse the parts with water from a garden hose.
Step 23
Dry with Compressed Air
- Use an air compressor to blow air through all of the openings in the carburetor to dry it.
Use an air compressor to blow air through all of the openings in the carburetor to dry it.
Step 24
Clean with Carburetor Cleaner
- Thoroughly spray carburetor cleaner all over the outside, inside, and openings of the carburetor.
- Be careful not to get carburetor cleaner on your skin or eyes or breathe it in.
Thoroughly spray carburetor cleaner all over the outside, inside, and openings of the carburetor.
Be careful not to get carburetor cleaner on your skin or eyes or breathe it in.
Step 25
Replace Idle Speed Adjustment Screw and Spring
- Unscrew and replace the idle speed adjustment screw and spring provided in the carburetor kit.
Unscrew and replace the idle speed adjustment screw and spring provided in the carburetor kit.
Step 26
Replace the Idle Air Adjustment Needle
- Use a flat blade screwdriver to unscrew and replace the idle air adjustment needle along with its rubber o-rings provided in the carburetor kit.
- Be sure to take note of the number of turns that the screw is initially screwed in, as this is the factory adjusted idle air for the four wheeler; you will want to put this screw in the exact same position when you screw the new needle in.
Use a flat blade screwdriver to unscrew and replace the idle air adjustment needle along with its rubber o-rings provided in the carburetor kit.
Be sure to take note of the number of turns that the screw is initially screwed in, as this is the factory adjusted idle air for the four wheeler; you will want to put this screw in the exact same position when you screw the new needle in.
Step 27
Replace Carburetor Jet
- Use a flat blade screwdriver to unscrew and replace the carburetor jet provided in the carburetor kit.
Use a flat blade screwdriver to unscrew and replace the carburetor jet provided in the carburetor kit.
Step 28
Replace Orifice #1
- Use a flat blade screwdriver to unscrew and replace the orifice highlighted in the photo.
Use a flat blade screwdriver to unscrew and replace the orifice highlighted in the photo.
Step 29
Replace Orifice #2
- Use a flat blade screwdriver to unscrew and replace the orifice shown in the photo.
Use a flat blade screwdriver to unscrew and replace the orifice shown in the photo.
Step 30
Replace Orifice #3
Step 31
Replace Float Inlet Needle and Spring
- Replace the float inlet needle and spring provided in the carburetor kit.
- Use pliers to re-attach the float to the carburetor by pressing in the float pin.
Replace the float inlet needle and spring provided in the carburetor kit.
Use pliers to re-attach the float to the carburetor by pressing in the float pin.
Step 32
Replace Float Bowl Gasket
- Remove the old gasket from the float bowl assembly and replace it with the new gasket provided in the kit.
Remove the old gasket from the float bowl assembly and replace it with the new gasket provided in the kit.
There are other optional parts included in the kit that you can replace if they are worn-out on your specific carburetor. Once you have finished replacing all of the old parts, reassemble your device by following these instructions in reverse order.
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MASConsultants
Member since: 04/03/2017
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Norma Johnson - Nov 27, 2018
Reply
It was a good article until step # 7. This is not a gas line. It is an engine vent line that goes from the engine to the air cleaner box. It has nothing to do with gasoline.
MASConsultants - Jun 4, 2019
Thanks for your feedback - this was absolutely a mistake and I have updated the article to correct it.
