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2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair

Introduction

Over time, a four wheeler is exposed to many types of weather as well as dust, dirt, and mud. Throughout many years, dirt and grit builds up inside a carburetor and causes the device to malfunction. When a carburetor stops working properly, the engine does not get the right amount of gas and air it needs to run properly. As a result, a four wheeler ceases to start when it is cranked.

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

  1. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Disconnect Battery: step 1, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Disconnect Battery: step 1, image 2 of 2

    • 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.

    Edit

  2. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Loosen Carburetor Intake Band Clamp: step 2, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Loosen Carburetor Intake Band Clamp: step 2, image 2 of 2

    • Use a ratchet with a 10 mm socket to loosen the clamp that connects the carburetor to the intake manifold.

    Edit

    You may not have a 10mm nut to remove. It may be only a Phillips screw on the hose clamp.

    Jamie S - Reply

  3. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Plastic Side Panels: step 3, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Plastic Side Panels: step 3, image 2 of 2

    • 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.

    Edit

  4. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Black Plastic Side Panel: step 4, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Black Plastic Side Panel: step 4, image 2 of 2

    • Use a T30 Torx screwdriver to remove the screw securing the black plastic panel on the left side of the four wheeler.

    Edit

    Mine did not have a Torx screw holding on the black plastic cover. It just popped off.

    Jamie S - Reply

  5. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Bolt That Secures Right Side Panel: step 5, image 1 of 1

    • 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.

    Edit

  6. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Disconnect Air Vent Line from Engine: step 6, image 1 of 1

    • Disconnect the air vent line from the engine.

    Edit

  7. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Disconnect Air-Intake Tube from Metal Frame: step 7, image 1 of 1

    • Remove the plastic rivet that connects the air-intake tube to the metal frame of the four wheeler.

    Edit

  8. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Pull Air-Intake Tube Back: step 8, image 1 of 1

    • Pull the air-intake tube backwards away from the air filter box.

    Edit

  9. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Screw from Bottom of Air Filter Box: step 9, image 1 of 3 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Screw from Bottom of Air Filter Box: step 9, image 2 of 3 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Screw from Bottom of Air Filter Box: step 9, image 3 of 3

    • Use a 10 mm socket wrench to remove the screw on the right hand side of the bottom of the black air filter box.

    Edit

  10. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Air Filter Box: step 10, image 1 of 1

    • At this point, the black air filter box should be loose. Lift the air filter box vertically out of the four wheeler.

    Edit

  11. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Disconnect Carburetor Gas Line: step 11, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Disconnect Carburetor Gas Line: step 11, image 2 of 2

    • Use your fingers to pull the gas line off of the carburetor.

    Edit

  13. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Vacuum Line from Carburetor: step 12, image 1 of 1

    • Use your fingers to disconnect the vacuum line from the carburetor.

    Edit

  14. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Disconnect Electrical Sensor: step 13, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Disconnect Electrical Sensor: step 13, image 2 of 2

    • 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.

    Edit

  15. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Carburetor Cover: step 14, image 1 of 1

    • Use a Phillips screwdriver to remove the screw that secures the black cover on the right side of the carburetor.

    Edit

  16. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Throttle Cable: step 15, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Throttle Cable: step 15, image 2 of 2

    • 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.

    Edit

  17. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Choke Cable: step 16, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Choke Cable: step 16, image 2 of 2

    • Remove the choke cable attached to the carburetor by twisting the carburetor around to unscrew it.

    Edit

  18. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove the Carburetor from the Four Wheeler: step 17, image 1 of 1

    • 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.

    Edit

  19. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Primer Assembly: step 18, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Primer Assembly: step 18, image 2 of 2

    • 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.

    Edit

  20. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Top Cover: step 19, image 1 of 3 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Top Cover: step 19, image 2 of 3 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Top Cover: step 19, image 3 of 3

    • 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.

    Edit

  21. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Float-Bowl Assembly: step 20, image 1 of 3 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Float-Bowl Assembly: step 20, image 2 of 3 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Float-Bowl Assembly: step 20, image 3 of 3

    • Use a Phillips screwdriver to remove the four screws that secure the float-bowl assembly.

    Edit

    Where does the line connected to the bottom of the float bowl connect? What line is that?

    DWil - Reply

    I think this line is a vent/overflow line for the float bowl, so the other end doesn’t connect to anything and hangs down underneath the carburetor.

    MASConsultants - Reply

    I think this line is a vent/overflow line for the float bowl, so the other end doesn’t connect to anything and hangs down underneath the carburetor.

    MASConsultants - Reply

    Thanks for responding. That’s what I thought.

    DWil - Reply

    Ok, so I need to ask, what is the purpose of the cup that sits over the main jet, and underneath the float? I can see that it acts as a guide of some sort, maybe for the overflow vent? To keep it from coming in contact with the float itself? Maybe to help keep prime on the main jet if on uneven surfaces? This I do know, I rebuilt my carb, and it kept allowing gas to come out my overflow. So I pulled the carb again, removed the cup over the main jet that saddles in between the float, and I've no longer had the issue with my float hanging up on it. The quad runs fine now. Anyone know the purpose of the part number 24 in what it's actually suppose to do? Thanks in advance.

    Larry Walden - Reply

  22. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Float Assembly: step 21, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Remove Float Assembly: step 21, image 2 of 2

    • Use a punch or small flat blade screwdriver to drive out the pin holding the float and lift the float out.

    Edit

  23. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Clean Carburetor: step 22, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Clean Carburetor: step 22, image 2 of 2

    • Thoroughly spray the disassembled carburetor pieces with Super Clean and scrub everything with a toothbrush.

    • Rinse the parts with water from a garden hose.

    Edit

  24. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Dry with Compressed Air: step 23, image 1 of 1

    • Use an air compressor to blow air through all of the openings in the carburetor to dry it.

    Edit

  25. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Clean with Carburetor Cleaner: step 24, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Clean with Carburetor Cleaner: step 24, image 2 of 2

    • 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.

    Edit

  26. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace Idle Speed Adjustment Screw and Spring: step 25, image 1 of 1

    • Unscrew and replace the idle speed adjustment screw and spring provided in the carburetor kit.

    Edit

  27. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace the Idle Air Adjustment Needle: step 26, image 1 of 2 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace the Idle Air Adjustment Needle: step 26, image 2 of 2

    • 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.

    Edit

    How many turns does the air adjustment needle valve need on a Honda 350 rancher

    Billy - Reply

  28. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace Carburetor Jet: step 27, image 1 of 1

    • Use a flat blade screwdriver to unscrew and replace the carburetor jet provided in the carburetor kit.

    Edit

  29. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace Orifice #1: step 28, image 1 of 1

    • Use a flat blade screwdriver to unscrew and replace the orifice highlighted in the photo.

    Edit

  30. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace Orifice #2: step 29, image 1 of 1

    • Use a flat blade screwdriver to unscrew and replace the orifice shown in the photo.

    Edit

  31. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace Orifice #3: step 30, image 1 of 1

    • Use a flat blade screwdriver to unscrew and replace the orifice shown in the photo.

    Edit

  32. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace Float Inlet Needle and Spring: step 31, image 1 of 3 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace Float Inlet Needle and Spring: step 31, image 2 of 3 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace Float Inlet Needle and Spring: step 31, image 3 of 3

    • 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.

    Edit

  33. 2004-2006 Honda Rancher 350 Four Wheeler Carburetor Repair, Replace Float Bowl Gasket: step 32, image 1 of 1

    • Remove the old gasket from the float bowl assembly and replace it with the new gasket provided in the kit.

    Edit
Conclusion

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.

9 other people completed this guide.

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MASConsultants

Member since: 04/03/17

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2 Comments

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.

Norma Johnson - Reply

Thanks for your feedback - this was absolutely a mistake and I have updated the article to correct it.

MASConsultants -

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