1985-1986 HONDA ATC 350x 3-Wheeler Service Repair Manual ATC350 - IMPROVED -

BS-BS ATC ' 3!5DX

IMPORTANT SAFETY NOTICE ------, ' .... ' rrrdicarft II IITO"1 ponibillly of Uv~rt pHSOll aJ Injury Or /011 of 11ft If Instructions a" no / followtd,' CAUTION: Ind/call'S II possibility 0/ personal i!tiury or equipment damage if ins/ruelions art 110/ JoI/o-..w1. NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures. salety principles and service operations era not included. It is imponanllO no te thaI this manual contains soma warnings lind eliutions against some specific service methods Which could cause PERSONAL INJURY to se rvice personnel or could damage II vehicle or render it unsafe. Pl ea se understand Ihal those warnings could not cover ell conceivable way s in wh ich service, whether Or not recommended by Honda might be done Or of the possibly hazardous consequences of each conceivable way. nor could Honda investigate all such ways. Any one using service procedures or tools. whether or not recommended by Hornla must SlJlisfy himself thoroughly that neill;oer personal safety nor vehicle safety will be jeopardized by the service method Or tools selected.

HOW TO USE THIS MANUAL Sections 1 through 3 apply to th e whole ATC , while sections 4 through 16 describe parts of the ATC, grouped acco rding to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration and all the required sp ecifi - cations. torque values, general instructi ons, tools and troubleshooting for the section. The subsequent pages give detailed procedures. If you don 't k now what the source of a prob- lem , refer to section 1 7, TROUBLE- SHOOTING . CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES w ~======================= Z CYLINDER /PISTON 8 F===================== :; CLUTCH/ Oil PUMP/KICK STARTER ALTERNATOR/GEARSHIFT LINKAGE FRONT WHEEl/SUSPENSION/STEERING (Il I REAR WHEELS ~ I REAR SUSPENSION iS l . HYDRAULIC BRAKES F===== =============== === REAR FENDER/SEAT/ EXHAUST SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING INDEX RICE

1. GENERAL INFORMATION GENERAL SA FETY 1-1 TOOLS 1-7 SERVICE RULES 1-1 CABLE & HARNESS ROUTING l -S MODEL IDENTIFI CA TION 1-2 NOISE EMISSION CONTROL SYSTEM 1-13 SPECIFI CA TIONS 1-3 (U.S .A . o nl y) TORQUE VA LUES 1-5 GENERAL SAFETY IWl,llii@ Ulf"iiiiild If/hI tngint "III!! bl ,unning 10 do Jam" ... or k . mQ/ct SUre thar area is w"I/·'-mli/flftrJ. N, ,-e, run fhl engine in a closed Qua. Th t exhaust coma/ng poisonous carbon mo", ;Uidt gas. Gasoli"t Is txl,emlly flammable {llld Is tx plosi.", undu Url a;n conditions. Do not smakl o. 0110'" fl ames o r sptJrb in your wurk {I reD. SERVICE RULES 1, Use genuine HONDA or HONDA·recommended parts and lubricants or their equivalent. Parts lh,l1 dan', meet HONDA's oo~i9n I'>p8ci hcations m,,'1 <:ause dilmage \0 the ATe. 2. Use the spedal tools designed for th is product to avoid damage and incorrect assembly. 3. Use only metric too ls when servidng th iS A TC. Metr ic bolts. nuts . and screws are not interchangeab le w ith English fasten- ers . 4. Insta ll new gas kets. a -rings. cotter pins. lock plates, etc. when reassembling. 5. When t ightening bolts Or nut s, begin with the larger-diameter or inner bolt lirst. Then tighten to the specified torque diago - nally in Z or 3 steps, unless a parti cular sequence is specified. 6. Clean parts in non-flammable Or high fl ash point solvent upon disassembly. 7. Lubr icate any sliding surfaces befo re reassembly. a. Ahe r reassembly, chec k all parts f or proper installation and operat ion. 1-1

GENERAL INFORMATION MODEL IDENTIFICATION '8 5: The frame serial number is stamped on the righ t side of the steering head, The carburetor ident ification number is on the carburetor body l eft side, 1-2 After '85: The engine serial number is stamped on the lower right side of the crankcase.

GENERAL INFORMATION SPECIFICATIONS DIMENSIONS Overall length 1,890 mm (7 4.4 inl Overall width 1,115 mm (4 3.9 inl Overall height '85 : 1,082 mm (42.6 inl After '85 : 1.075 mm (42.3 inl Wheel base 1,270 mm 150.0 inl Rea r tread 870 mm 13 4.3 i nl Seat hei ght 750 mm 129.5 inl Foot peg height 290mm lll .4; n) Ground clearance 120mm ( 4.7 in) Dry we ight 145 kg 1320 Ibl - FRAME Type Semi-double c rad le Front suspension. travel Telescopic fork. 203 mm (8.0 inf Rear suspenSIon, travel Swing arm. 194 mm 17.6 inf Rim size Front I 1 in Rear 9 in Front tire Size, pressu re 23.5xB - II Rear ti re size, pressure 22 .0 xl 0- 9 Front brake Single disc Rear brake Single disc Fuel capacity 9.7 liter (2.56 US gal. 2.13 Imp gall Fuel reSerVe capacity 1.7 liter (0.45 US gal. 0.37 Imp gall Cas ter ,," Trail 34.5 mm 1 1.36 inl Front fork oil capacity 290 cc (9.8 US oZ. 10.2 Imp ozl ENGINE Type Gasoline. air-cooled 4-stroke Cylinder arrangement Single cylinder inclined 20" Bore x stroke 8 1 x 68 mm (3.2 x 2 .7 i nl Displacement 350.4 cc (21.38 cu in) Compressior> ratio 8.5: 1 Valve train Overhead camsh aft chain drive Maximum hotsepower 27PSI7.000 ,pm Max imum torque 3.0 kg-mI6.000 rpm 1 21.70 ft -lbI 6.000 rpm) Oil capacity 2 .3 liters 12.43 US qt. 2.03 Imp qt) at disassembly I.Bliters II.9 1 US qt , 1.59 Imp qtl after draining Lubrication system Forced pressure and wet sump Cylinder comp ression 1.250 kPa 112.5 kglem', 178 psi) Intake valve Opens 5" BTDC Closes 35" ABOC ,,' mm li ft Exhaust valve Opens 5° 8BDC Closes 35° ATOC Valve clearance I ntake 0.08 mm 10.003 inl ICold) Exhaust 0.08 mm (0.003 inl - CARBURETOR T,~ Dual valve Ventu, i dia. 31 mm 11. 22 inl Main jet If- 138 Pilot sc'ew opening 1-314 Jet needle 3rd groove Float level 18.5 rom 10.73 in/ Idle speed 1,400 % 100 ' pm 1-3

GENERAL INFORMATION DRIVE TRAIN Clutch Wet mult i- plate Transmi ssion 6-speed contl ant mesh Pr imary !eduction 2,833 (68/24) Gear rat io , 2.750 (44/ 1S) Gea •• atio " 2.050 (4 1120) Gear ratio '" I.S09137 /23) Gea. ratio 'V 1.308134 /2S) Gear ratio V 1.103132 /2 9) Gear ratio V, 0.935 (29/ 311 Final redllction 3.077 (40/131 Gearshift pattern Left foot operated retmn system , l- N- 2- 3- 4- 5- 6 Or ive chllin ,in/1inkt 520/90 li nk. ELECTRIC AL Ignition system CO, Init illl ignition timing 10° BTOC FlIl) advllnCIt 30 ° BTOC Attefnlltor 200 W/ S .OOO rpm Spark plllg NGK ORBES -L NO X24ESR - U Spark plllg gap 0.B - 0 .7 mm (0.02 4- 0.028 in) Helldl ight 12 V- 36.S/ 3S W x 2 Ta illight 12 V- S W 1-4

GENERAL INFORMATION TORQUE VALUES ENGINE Th read di a. Torque It em Imml '·m kg·m 1I · lb Oil drain plug '85: " 15 - 25 L5 2.5 11 -16 Alt er '65: " 20 - 30 2.0-3.0 15 - 22 Valve ad justing loc k nut 6 15-16 1.5 - 1.6 11 -13 Cyl inder head cover boh 6SH 6- 12 0.8-1.2 6- 9 6 8-12 0.8 - 1.2 6- 9 2 13 - 17 1.3-1.7 9- 12 Cylinder head cap nut W 35-45 3.5 -4 .5 25 - 32 Cylinder he ad bo lt W 35 - 45 3.5 -4 .5 25 - 32 Cam s proc ket bolt 2 17 - 23 1.7-2.3 12 - 17 Spark plug " 15 -20 1.5 - 2.0 11 - 1 5 Carb uretor insulator band sCrew 5 3- 5 0.3 - 0.5 2.2 - 3.6 Ca'.." chain len"ioner lilter 6SH 8- 12 0.8-1.2 6-9 Cam chain tens i oner liller sealing bolt 6 8-12 0.8 - 1.2 6- 9 Kick staner ratchet guide soc ket bolt 6 10 - 14 1 .0 - 1.4 7-10 Right cra nkcase cover bolt 6SH 8-12 0.8 - 1.2 6-9 Clutch loc k nut " 100 - 120 10.0-12.0 72 - 87 Clutch li lte r plate bolt 6 10 - 14 1.0 -1 .4 7- 10 Oil tilter cover boh 6SH 8-12 0.8 - 1.2 6-9 Oil bolt 8 12 -1 6 1.2 - 1.6 9- 12 Pr imary dr ive gear lock nut 20 60 - 80 6.0-8 .0 43 - 58 Left cra nk case cover 6SH 8- 12 0.8-1.2 6- 9 Gearshift return spri ng pi n 8 18 - 25 1.8 -2 .5 13 - 18 Shift drum ceme r boh 8 2 1 - 25 2. 1-2.5 15 - 18 Flywheel bolt " 100-120 10.0 - 12 .0 72-87 Pul se generator SCrew 5 5- 2 0.5-0.7 3 .6 - 5.1 Alternator stator bolt 6SH 8-12 0.8 - 1.2 8-9 Cyl i nder base bolt 6SH 8-12 0.8 - 1.2 6-9 Crankcase bolts 65H 8-12 0.8-1.2 8- 9 O il pipe mounting bolt 69H 8- r2 0.8-1.2 6- ' Oil p i pe bolt 2 10 - 14 1.0 - 1.4 7- 10 Breather plale soc ket bolt 6 10 - 14 1.0-1.4 7- 10 Orive sprOcket 6 8-12 0.8 - 1.2 6-9 FRAME Thread dia. Torq ue Item Imml '·m kg·m ft·lb Drive chain adjuster lock bolt ·85: 8 " " , .3 La 9 " Af t er ·85: 8 18 - 25 , .8 - 2.5 13-18 Fuel slraine r cu p " 3- 5 0.3 - 0.5 2.2 - 3.6 Fuel va lve lock nut " 20 - 25 2.0-2.5 15 - 18 Pa rking brake adjuster lock nut 8 15 - 20 1.5 - 2.0 11 -15 Engine mount ing bolt 8 24-35 2.4 - 3.5 17-25 '0 55 - 65 55-6 .5 40 - 48 Front wheel nut W 60-70 6.0 - 7.0 43-51 Front axle " 70-110 7 .0 - 11.0 51-80 Front axle holder nut 6 10-14 1 .0 - 1.4 7- 10 Gear shift pedal bolt 6 14 -18 1.4 _ 1.8 10 _ 13 1-5

GEN ERAL INFORMATION Thread dia. Torq ue Item (mm) N'm kg-m It-Ib From l ork socket bolt 8 15 25 1.5 2.5 " 18 Fronl fork lube cap 28 15-30 1. 5-3 .0 11 - 22 Front fork pinch bo ll 8 18-25 1.8-2.5 13 - 18 Front fork boot band 3 0.6- 1.2 0.06-0 . 12 0.4-0.9 Steer i ng bearing adjustment nut Ill itial 26 25 - 35 2.5 - 3.5 18 - 25 Final '85: 26 '-8 0 .7 - 0.8 5-8 Final After '85: 26 10 - 11 1.0 - 1. 1 '-8 Steer in g stem nut " 90 -1 20 9.0-12 .0 65 - 87 Rear wheel nut " 60-70 6.0 - 7.0 43 - 51 Rear axle outer lock nut 32 80 - 100 8.0 - 10.0 58 - 72 Reat axle inner lock nut 32 120 - 140 12 .0 - 14.0 87-101 Dri ve n sprocket nut " 55 - 65 5.5- 6.5 40 - 48 Rear axle nut 18 120 - 170 12 .0 - 17.0 87 -1 23 Shoc k absorber oil hose bolt " 27.5 - 32 .5 2.75-3 . 25 20 - 23 Shock absorber spr ing lock nut 50 80-100 8.0 - 10 .0 58-72 Shock absorber upper moun t bo ll " 40 - 50 4.0-5.0 29 - 36 Shoc k absorber lower mount bo lt " 40-50 4.0 - 5.0 29 - 36 Shock absorber bracket bolt " 40 - 50 4.0 - 5.0 29-36 Swing arm pi vot bolt " 70 -1 10 7.0-11.0 51 - 80 Rear brake torque link · to·swing arm bolt 1"851 8 8- 11 0.8 - 1.1 6- 8 Rear brake torque link·to·caliper bracket boll 1"851 8 24 - 30 2.4- 3.0 17 - 22 8ra ke air bleeder valve 8 ,-, 0.4 - 0.7 3- 5 Caliper mounting bolt 8 20 - 30 2.0 - 3.0 15-22 Brake pad pin bo lt 8 15 - 20 1.5 - 2.0 11 - 15 Front brake di sc moum i ng nut '85 : 8 20-30 2.0-3 .0 15 - 22 From brake disc mo unt i ng bolt After '85: 8 35 - 40 3.5 - 4.0 25-29 Rear brake disc moun ting bolt 8 37-43 3.7 - 4.3 27 - 31 Brake hose oil bolt 10 25 - 35 2.5 - 3.5 18 - 25 Rear cali per socket bolt 8 20-25 2.0- 2.5 15 - 18 Parking brake base bolt 8 20 - 25 2.0- 2.5 15-18 Parking brake adjus ting lock nut 8 15-20 1.5 _ 2.0 11 - 15 Front brake lever pivot bo lU nut 6 8- 12 0.8 - 1.2 6- 9 Rear brake rese rvoir joint screw , 1- 2 0.1- 0.2 0.7- 1.5 Foot peg mouming bolt 10 40- 50 4 .0 - 5 .0 29-36 Torque spec rfr cat lons hsted above are for spec./ ,c tIghtening pomts. If a torque SpeCI/ICaI I On IS no t li sted , fol l ow the standards gi ven below. STANDARD TORGUE VALUES TYPE TOROUE TYPE TORQUE Nom (kg-m. ft -Ib ) N·m (kg·m. ft-Ib) 5 mm boh, 00> " 6.0 (0. 45 0.6.3 .3 4.3) 5 mm screw 3.5 5.0 1 0.35 0.5. 2.5 3.61 6 mm bolt. nut 8 - 12 (0 .8-1 . 2.6-9 ) 6 mm screw. SH bolt 7- 11 1 0.7 - 1.1.5-81 8 mm bolt. nut 18-25 1 1.8-2 . 5.13 - 181 6 mm fl ange bolt. nut 10 - 14 (1.0 - 1.4.7 - 10 1 10 mm bolt, om 30 - 40 (3.0- 4.0.22 - 291 8 mm flange bolt, nut 24-30 12.4 - 3.0, 17 - 22 ) 12 mm bolt. nul 50 - 60 15.0- 6.0,36 - 431 10 mm flange boll, nut 35 - 45 13 .5- 4.5 , 25 - 32) 1-6

GENERAL INFORMATION TOOLS SPECIAL DESCRIPTION TOOL NUMBER ALTERNATIVE TOOL TOOL NUMBER REF. PAGE Lock nut wrench. 56 mm 07916 HA20000 Lad nut wrench. 56 mm 07916 HA2010A 12-4. 12·7 I U.S.A. onlyl Lock nut wrench. 45 mm 07916 - 1870101 Commercially available 12-4. 12.7 in U.S.A. Universal bearing puller 07631 - 0010000 Commercially available 10- 11 in U.S.A . Steering stem socket 07916 - 3710100 . 11 - 22.11 · 24 He~ wrench. 6 mm 07917 - 3230000 Commercially available 11 - 15.11 · 18 in U.S.A, Clutch center holder 07923 - KEloooo Not available in U.S.A. 8-7. ,., Snap ring pliers 07914-3230001 Commercially available 11_16,11_19. in U.S.A. 14-19, 14- 21 Assembly collar 07931 - VMOOI 00 h-Assembly collar 07931 - KF00100 10- 13 Thread adaptor 07 9 31 - KF00200 I L...Assembly collar 07931 - HAS0100 10- 13 Shah puller 07931 - ME40000 10- 13 Bearing remove., 17 mm 07936 - 3710300 10- 7, 10 · 12 Remover handle 07936-3710100 10_7, 10·12 Remover weight 07741 - 0010201 Remover weight 07936 - 3710200 10·7. 10· 12 Ball race driver 07946-3290000 Steering stem driver 079 46- MBOOOOO 11-23 Steering stem driver 07946 - 4300101 Attachment GN-HT-54 11 · 23 Bal l race remOve. 07953 - 3330000 IU.S.A. only) 11 · 22 Valve guide reamer 07984-200000 ,., Needle bearing remOver 07946 - KA5oooo Dr iver 07749 - 0010000 13· 11 Attachment. 32 x 35 mm 07746 - 0010100 Pilot. 20 mm 07746-0040500 IU.S.A. only) Needle bearing remove, 07931 - MA7oooo Bushing remover M967X - 038 - 13- 11 and common drift XXXXX (U.S.A. only) Fork seal drive, 07947 - KA50100 Fork seal driver 07947-3710101 11 - 19 Fork seal driver al1achment 07947 - KL40100 11 -1 9 Gear holder 07724 - 0010100 8·13. 8· 14 Universal bead breaker GN--AH-958-BBI U.S.A. only 11·10 1-7

1985-1986 HONDA ATC 350x 3-Wheeler Service Repair Manual ATC350 - IMPROVED -

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