HONDA TRX350FM TRX350FE RANCHER 4X4 Service Repair Manual 2000-2003

－ A Few Words About Safety Service Information For Your Customer’s Safety For Your Safety Important Safety Precautions The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline of batteries. Use only a nonflammable solvent, not gasoline, to clean parts. Never drain or store gasoline in an open container. Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. • • • • • • • • • •

＃＃＃ SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Replace the part(s) with new one(s) before assembly. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1). Use multi-purpose grease (Lithium based multi-purpose grease NLGI 2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI 2 or equivalent). Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI 2 or equivalent). Example: Molykote G-n paste, manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use Fork or Suspension Fluid.

－－－－ SERVICE RULES 1-1 MODEL IDENTIFICATION 1-1 SPECIFICATIONS 1-3 TORQUE VALUES 1-13 TOOLS 1-16 LUBRICATION & SEAL POINTS 1-18 CABLE & HARNESS ROUTING 1-22 EMISSION CONTROL SYSTEMS 1-33 EMISSION CONTROL INFORMATION LABEL (U.S.A only) 1-34 SERVICE RULES MODEL IDENTIFICATION 1 1-1 1. GENERAL INFORMATION This manual covers 4 types of TRX350 models: TM 2WD/Left foot operated gearshift TE 2WD/Electric shift program (ESP) FM 4WD/Left foot operated gearshift FE 4WD/Electric shift program (ESP) Be sure to refer to the procedure that pertains to the appropriate version of the TRX350. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don’t meet HONDA’s design specifications may cause damage to the motorcycle. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. Route all electrical wires as shown on pages 1-22 through 1-32, Cable & Harness routing. 1. 2. 3. 4. 5. 6. 7. 8. TRX350 TM/FM: (U.S.A. type shown) TRX350 TE/FE:

GENERAL INFORMATION 1-2 The frame serial number is stamped on the front side of the frame. The engine serial number is stamped on the left side of the rear crankcase. The carburetor identification number is stamped on the left side of the carburetor body. The Vehicle Identification Number (VIN) is located on the left side frame down tube. The color label is attached on the frame crossmember under the seat. When ordering color- coded parts, always specify the designated color code. E EN NG GI IN NE E S SE ER RI IA AL L N NU UM MB BE ER R C CO OL LO OR R L LA AB BE EL L F FR RA AM ME E S SE ER RI IA AL L N NU UM MB BE ER R V VE EH HI IC CL LE E I ID DE EN NT TI IF FI IC CA AT TI IO ON N N NU UM MB BE ER R C CA AR RB BU UR RE ET TO OR R I ID DE EN NT TI IF FI IC CA AT TI IO ON N N NU UM MB BE ER R

× × ° × × × ★★ × ★★ －－ SPECIFICATIONS ITEM SPECIFICATIONS GENERAL INFORMATION GENERAL: TRX350TM/TE 1-3 1,983 mm (78.1 in) 1,143 mm (45.0 in) 1,119 mm (44.1 in) 1,253 mm (49.3 in) 851 mm (33.5 in) 840 mm (33.1 in) 812 mm (32.0 in) 186 mm (7.3 in) 318 mm (12.5 in) 226 kg (498 lbs) 323 mm (12.7 in) 43.4 kg (95.7 lbs) 44.9 kg (99.0 lbs) Oiled urethane foam Air cooled (with cooling fan [TE only] and oil cooler) Trochoid Forced pressure (dry sump) 7°ATDC (at 1 mm lift) 40°BBDC (at 1 mm lift) 38°ABDC (at 1 mm lift) 8°BTDC (at 1 mm lift) OHV 8.8 : 1 329.1 cm (20.08 cu-in) 78.5 68.0 mm (3.09 2.68 in) Single cylinder, longitudinally installed 3.2 (0.85 US gal , 0.70 Imp gal) 13.0 (3.43 US gal , 2.86 Imp gal) 0° 31 mm (1.2 in) 7 Mechanical drum brake (Leading-trailing) Hydraulic drum brake (Dual leading) TRACKER CL (Goodyear) TRACKER CL (Goodyear) 10 8.5 AT 12 6.0 AT AT25 11-10 AT24 8-12 Double tube 150 mm (5.9 in) Swingarm Double tube 150 mm (5.9 in) Double wish-bone Double cradle DIMENSIONS FRAME ENGINE 210 kg (463 lbs) 237 kg (522 lbs) Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight Curb weight Maximum weight capacity Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes Lubrication system Oil pump type Cooling system Air filtration Engine dry weight 226.5 kg (499.3 lbs) 232 kg (511 lbs) 243 kg (536 lbs) 232.5 kg (512.6 lbs) 243.5 kg (536.8 lbs) 237.5 kg (523.6 lbs) TM: /TE: TM: /TE: TM: /TE: TM: /TE: TM: /TE: TM: /TE: 2000 2001: After 2001: 2000 2001: After 2001:

－－－－－－ × ITEM SPECIFICATIONS GENERAL INFORMATION GENERAL: TRX350TM/TE (Cont’d) 1-4 CARBURETOR DRIVE TRAIN ELECTRICAL Constant Vacuum (VE type) 32 mm (1.3 in) Centrifugal and Multi-plate, wet Automatic Constant mesh, 5-speeds with reverse 2.188 1.933 3.692 3.455 1.933 1.333 0.966 0.720 4.600 R N 1 2 3 4 5 DC-CDI Electric starter motor and emergency recoil starter Triple phase output alternator SCR shorted, triple phase full wave rectification Battery Carburetor type Throttle bore Clutch system Clutch operation system Transmission Primary reduction Secondary reduction Final reduction Gear ratio 1st 2nd 3rd 4th 5th Reverse Gearshift pattern Ignition system Starting system Charging system Regulator/rectifier Lighting system (70/32) (29/15) (48/13) (38/11) (29/15) (28/21) (28/29) (18/25) (39/13 23/15) Left foot operated return system (TM) Electric shift (left hand operated) return system (TE)

× × ° × × × ★★ × ★★ －－ ITEM SPECIFICATIONS GENERAL INFORMATION GENERAL: TRX350FM/FE 1-5 1,983 mm (78.1 in) 1,143 mm (45.0 in) 1,130 mm (44.5 in) 1,246 mm (49.1 in) 844 mm (33.2 in) 860 mm (33.9 in) 824 mm (32.4 in) 334 mm (13.1 in) 330 mm (13.0 in) 184 mm (7.2 in) 242.5 kg (534.6 lbs) Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight Curb weight Maximum weight capacity Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve Exhaust valve Lubrication system Oil pump type Cooling system Air filtration Engine dry weight DIMENSIONS FRAME ENGINE 43.8 kg (96.6 lbs) 45.3 kg (99.9 lbs) Oiled urethane foam Air cooled (with cooling fan and oil cooler) Trochoid Forced pressure (dry sump) 7°ATDC (at 1 mm lift) 40°BBDC (at 1 mm lift) 38°ABDC (at 1 mm lift) 8°BTDC (at 1 mm lift) OHV 8.8 : 1 329.1 cm (20.08 cu-in) 78.5 68.0 mm (3.09 2.68 in) Single cylinder, longitudinally installed 3.2 (0.85 US gal , 0.70 Imp gal) 13.0 (3.43 US gal , 2.86 Imp gal) 0° 06’ 17 mm (0.7 in) 4 Mechanical drum brake (Leading-trailing) Hydraulic drum brake (Dual leading) DIRT HOOKS 14 (Bridgestone) DIRT HOOKS 15 (Bridgestone) 11 7.0 AT 12 6.0 AT AT24 9-11 AT24 8-12 Double tube 150 mm (5.9 in) Swingarm Double tube 150 mm (5.9 in) Double wish-bone Double cradle 220 kg (485 lbs) 248.5 kg (547.8 lbs) 253.5 kg (558.9 lbs) 237.5 kg (523.6 lbs) 238 kg (525 lbs) 243 kg (536 lbs) 249 kg (549 lbs) 254 kg (560 lbs) opens closes opens closes FM: /FE: FM: /FE: FM: /FE: FM: /FE: FM: /FE: FM: /FE: 2000 2001: After 2001: 2000 2001: After 2001:

－－－－－－ × ITEM SPECIFICATIONS GENERAL INFORMATION GENERAL: TRX350FM/FE (Cont’d) 1-6 CARBURETOR DRIVE TRAIN ELECTRICAL Constant Vacuum (VE type) 32 mm (1.3 in) Centrifugal and Multi-plate, wet Automatic Constant mesh, 5-speeds with reverse 2.188 1.933 3.692 3.455 1.933 1.333 0.966 0.720 4.600 R N 1 2 3 4 5 DC-CDI Electric starter motor and emergency recoil starter Triple phase output alternator SCR shorted, triple phase full wave rectification Battery 3.769 Carburetor type Throttle bore Clutch system Clutch operation system Transmission Primary reduction Secondary reduction Final reduction Front Rear Gear ratio 1st 2nd 3rd 4th 5th Reverse Gearshift pattern Ignition system Starting system Charging system Regulator/rectifier Lighting system Left foot operated return system (FM) Electric shift (left hand operated) return system (FE) (70/32) (29/15) (49/13) (48/13) (38/11) (29/15) (28/21) (28/29) (18/25) (39/13 23/15)

HONDA TRX350FM TRX350FE RANCHER 4X4 Service Repair Manual 2000-2003

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