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I purchased a 2004 Honda Rancher 2X4 manual shift Sunday. The motor was locked up and the crank case was filled with "Mystery Oil". I pulled the head and freed the piston from the cylinder. I removed the jug but could not get the wrist pin out of the piston (yes, I removed the keepers). The piston will not pivot on the rod. So I am going to do a complete rebuild. I have zero experience on this motor (my other ATV has over head cam) so I am looking for a shop manual. Does anyone know where I can get a good shop manual? Also has anyone had the piston wrist pin seize to the rod and if so what was the root cause?
 

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Here’s what I did when I was given my rancher 350.

Take rags and stuff them in the hole so no debris gets in the motor!! Very important!

I took a cut off wheel or a dremel and cut the piston in half perpendicular to the wrist pin. The piston will/should fall off the pin.. then I took a long bolt with some sockets/ washers and I pushed the wrist pin out.

Then took my dremel and a sanding drum and VERY carefully cleaned the rod up and test fitted the new wrist pin.

Mine has been like that for over a year now and no problems or noises


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What dieseltech said will get the wrist pin out, but be sure and check the rod to wrist pin fit on the new wrist pin. I strongly suspect that you'll have to have a new rod put on the crank if that thing was run to the point that would seize it up to that degree.
 

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No, don't try to run that rod... the pin bore must be in perfect condition for them to survive. And the pin clearance must be precise. I'd split cases and sent the crank off to Vince at Mrcrankshaft.com for rebuilding and truing with a new rod kit.
 

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'' mistery oil '' ?, what..water ?..lol. oil filter put in backwards ?, sunk..then ran will lock them up all day long. time for a new rod, top end kit. may as well just rebuild the whole motor seeing how your already in this deep :).
 

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The dealer I have dealt with for years has rebuilt cranks for 350 rancher with heavy duty rod trued indexed etc 149.99 and complete rebuilt engines for 350 rancher 1yr war 1195.00 email if need more info etc. thanks
 
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Greg Smith
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