Replacing Fuel Pump Relay In Honda Rancher 420: Step-By-Step Guide

The fuel pump relay is an electric component located under the fuse box of the Honda Rancher 420. It supplies a constant electric current to the ATV's fuel pump when the ignition is switched on, enabling the transfer of gas from the fuel tank to the engine. Issues with the fuel pump relay can be caused by a faulty ignition switch, corrosion, dust, and dirt build-up on the relay, or a blown fuse due to electrical surges. To fix these problems, you can clean the relay and connectors, replace the ignition switch and any blown fuses, or re-solder cracked solder joints. The best solution is usually to replace the fuel pump relay, as it is not expensive.

Diagnosing fuel pump relay issues

Other signs of fuel pump relay issues include your ATV cranking but failing to start, stalling while riding, or a loss of power after riding for a while. These issues can be caused by a faulty ignition switch, or dirt, dust, and corrosion build-up on the relay.

To diagnose fuel pump relay problems, you can start by visually inspecting the component for any signs of dirt and corrosion. You can also check for cracked solder joints and blown fuses. If you have a multimeter, you can set it to resistance mode and connect it to your fuel relay connector terminals along with a 12V battery. If the multimeter reading is not zero, the relay is faulty.

Additionally, you can try swapping the fuel pump relay with another one temporarily. If the pump runs with the alternate relay, then your original relay is faulty.

Locating the fuel pump relay

To locate the fuel pump relay, you can start by looking under the fuse box, which is located near the battery. You should see three relays there. The fuel pump relay is typically the one at the very bottom that is on an angle under the fuse box. It has three connectors, and it may be part of a solid piece with other connectors.

Another way to identify the fuel pump relay is by its function. If you use a screwdriver to touch the top connector of each relay while turning the key, the fuel injector relay will cause the fuel injector to make a whirring sound and the ATV to start.

Additionally, you may be able to identify the fuel pump relay by its part number. For some Honda Rancher 420 models, the part number for the fuel pump relay is 38580-HP5-601 or 38580-HP5-600.

If you are still unsure about locating the fuel pump relay, it is recommended to refer to the specific service manual for your Honda Rancher 420 model or seek assistance from a qualified mechanic.

Cleaning the fuel pump relay

To clean a fuel pump relay, you must first locate it. Depending on the manufacturer, it could be in the engine bay with the other fuses, or on the car's firewall near the brake and gas pedal, hidden under a plastic panel.

Once you've located the fuel pump relay, use a blower to dust off any particles. Do not use water to clean the relay, as it is an electrical component. Instead, use a small amount of ethanol to wipe away any remaining dust or dirt. Allow the relay to dry for a few seconds before putting it back into the fuse box.

If your Honda Rancher 420 is having issues with the fuel pump relay, it may be more cost-effective to simply replace the part. Fuel pump relays are not expensive, and you can purchase one for between $750 and $2,000 PHP, depending on the model of your car.

Replacing the fuel pump relay

The fuel pump relay is an essential component of your Honda Rancher 420's fuel system, supplying the fuel pump with a constant electric current to enable the transfer of gas from the fuel tank to the engine. Over time, you may experience issues with your fuel pump relay due to various factors, such as a faulty ignition switch, corrosion, dirt and dust build-up, or electrical surges.

Step 1: Purchasing a Replacement Relay

Before you begin, you will need to purchase a replacement fuel pump relay. The OEM replacement relay is a good option, and it typically costs around $30 to $40. You can find these relays at various automotive stores or online retailers.

Step 2: Locating the Fuel Pump Relay

The fuel pump relay is located under the fuse box of your Honda Rancher 420, alongside other relays. To access it, look behind the battery. There should be three relays in total. The fuel pump relay is usually the one at the very bottom, positioned at an angle under the fuse box.

Step 3: Cleaning and Inspection

Before replacing the relay, it is good practice to clean the fuel pump relay prongs with a wire brush to remove any dust, rust, or corrosion. You can also use an electrical cleaner and a blower to ensure a thorough cleaning. Additionally, inspect the relay for any visible damage, such as cracked solder joints or blown fuses.

Step 4: Replacing the Relay

Once you have cleaned and inspected the old relay, you can proceed to replace it with the new one. Simply remove the old relay by disconnecting it from the fuse box and install the new relay in its place, ensuring it is securely connected.

Step 5: Testing

After replacing the relay, turn on the ignition and listen for the familiar clicking sound from the fuel relay. If the relay is functioning correctly, you should hear this sound. Additionally, you can start the engine and pay attention to whether your ATV stalls or has any issues starting.

Step 6: Preventative Maintenance

To prevent future issues with your Honda Rancher 420's fuel pump relay, regular maintenance and inspection are key. Clean any dirt or corrosion build-up during your routine maintenance checks to ensure the relay remains in good working condition.

Preventing fuel pump relay problems

To prevent fuel pump relay problems in your Honda Rancher 420, it's important to maintain the fuel delivery system and regularly inspect its components. Here are some detailed instructions to help you avoid potential issues:

Fuel Filter Inspection:

Locate the fuel filter, which is usually found near the fuel pump. Check the fuel filter for any signs of clogging or debris buildup. A clogged fuel filter can restrict fuel flow and cause starting issues. Replace the fuel filter if necessary.

Fuel Line Inspection:

Visually inspect the fuel lines for any kinks, cracks, or damage. Ensure that the fuel lines are intact and free-flowing. Kinks or blockages in the fuel lines can disrupt fuel delivery to the engine.

Fuel Pump Maintenance:

Keep the fuel pump in good condition by regularly checking its operation. Listen for the fuel pump priming when you turn the key to the "on" position before starting the engine. If the fuel pump is not priming, it may indicate a problem with the pump or a related component.

Fuel Quality:

Always use clean, uncontaminated fuel. Dirty or contaminated fuel can cause issues with the fuel pump and injectors. Ensure that you are using the correct type of fuel recommended by the manufacturer.

Spark Plug Inspection:

Even if your Rancher 420 has spark, it's important to inspect the spark plug. A faulty or fouled spark plug can cause ignition problems. Clean or replace the spark plug if necessary, ensuring it is gapped correctly.

Air Intake System Inspection:

Inspect the air intake system, including the air filter, for any blockages or damage. A restricted air intake system can disrupt the air-fuel mixture and affect engine performance. Replace the air filter if it is dirty or damaged.

Vacuum Leaks:

Check for vacuum leaks by examining all vacuum lines and connections. Leaks can disrupt the engine's air-fuel mixture and lead to starting and running issues. Ensure all connections are secure and intact.

Sensor Functionality:

Ensure that sensors related to the fuel and ignition systems, such as the throttle position sensor (TPS) and idle air control valve (IACV), are functioning correctly. Faulty sensors can impact the engine's performance and starting ability.

Electrical Connections:

Verify the integrity of electrical connections related to the fuel and ignition systems. Ensure that all connectors are secure and free from corrosion. Loose or damaged connections can lead to starting and performance problems.

By regularly inspecting and maintaining the fuel delivery system, spark plugs, sensors, and electrical connections, you can help prevent fuel pump relay problems in your Honda Rancher 420.

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