1986-1989 Honda TRX350 Fourtrax 4x4 & Honda TRX350D Foreman 4x4 Service & Repair Manual

... BS-B7 TRX35D FOURTRAX s 4X4 B7-B9 TRX35DO FOREMAN TM 4X4

.--------- IMPORTANT SAFETY NOTICE --------, Indicates a strong possibility oj severe persona/Injury or death 1/ irutructloru an not fol/owed. CAUTION : Indicates a possibility of personal injury or equipment damage if instructions are not folfowed. NOTE: Gives helpful information . Detailed descriptions of standard workshop procedures, safety principles and service operations ere not included. It is i mportant to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAllNJURV to service personnel or could damage 8 vehicle or render it unsafe. Please understand that those warnings CQuid not cover all conceivable ways in which 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 . Anyone using service procedUres or tools, whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools se lected.

HOW TO USE THIS MANUAL Sections 1 through 3 apply to the complete FOURTRAX and FOREMAN, while sections 4 through 21 describe parts of the FOURTRAX and FOREMAN , grouped according to loca- tion . 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, service information and troubleshooting for the sectio n. Th e subse- quent pages 9ive detailed procedures. If you are not familiar with this vehicle, read the Technical Features in section 22. If you don't know the sou rce of the trouble. go to section 23 . Troubleshooting. CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION COOLING SYSTEM W CYLINDER HEADIVALVES ~ :============== z W CYLINDER/PISTON F================= CLUTCH/OIL PUMP/KICK STARTER FRONT WHEEL/SUSPENSION/STEERING BRAKES '" ~ ~============ "'« REAR WHEEL/SUSPENSION "' :============= u FRONT DIFFERENTIAL/FINAL DRIVE BUMPERS, FENDERS, CARRIERS IGNITION SYSTEM -' BATTERY/ CHARGING SYSTEM 5 :============== 0: ... STARTER SYSTEM ~ :========== ========= -' LIGHTS/SWITCHES w ~============ WIRING DIAGRAMS TECHNICAL FEATURES TROUBLESHOOTING INDEX

GEN ERAL SAFETY SERVICE RUL ES M OOEL IOENTIFICA nO N SPECI FICATIONS GENERAL SAFETY Ii 1-1 1-1 1-2 1-3 If the engine must In running to do some work, make sure the area Lr well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gru that may cause loss of consciousness and lead 10 death. r.',e battery generates hydrogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery, especially while charging it. Gasoline is extremely flammable and;s explosive under certain conditions. Do not smoke or allow flames or sparks in your work area. i The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. In case of contact, /lush thoroughly with water and call a doctor 1/ electro/yle gets in your eyes. SERVICE RULES 1. GENERAL INFORMATION TORQUE VALUES TOOLS CAB LE & HARNESS ROUTING ~Ii 1-5 1 -7 1-9 Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Ne~'er use an air hose or dry brush to clean brake or clutch assemblies. In the United Stales, use OSHA- approved vacuum cleaner or alternate method approved by OSHA designed 10 minimize the hazard caused by airborne asbestos fibers. CAUTION: Used engine oil may cause skin cancer if repealedly left in contact with the skin jor prolonged periods, Although this is Unlikely unless you handle used oil on a daily basis, it is still adviseable to thoroughly wash your hands with soop and water as soon as possible after handling used oil. 1. 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 vehicle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger-diameter or inner bolt first. Then tighten to the specified torque diagonally in ' ·5 steps, unless a particular sequence is specified. 6. Clean parts in non-flammable or high flash point solvent upon disassembly. 7. Lubricate any sliding surfaces before reassembly. 8. After reassembly, check all parts for proper installation and operation. 1-1

GENERAL INFORMATION MODEL IDENTIFICATION FOREMAN f' S7 Shown; After '87 similarl (3) The frame serial number is stamped on the front bum- per. (5) The carburetor identification number is on the left side of the carburetor body. 1-2 FOURTRAX raG Shown; '87 similar) ~(21 (4) The engine serial number is stamped on the upper side of the right crankcase.

SPECIFICATIONS DIMENSIONS FRAME ENGINE CARBURETOR Overall length Overall width Overall height Wheelbase Seat height Foot peg height Ground clearance Dry weight Type Rim size Front Atter '88: Rear After '88: Suspension travel Front Front tire size, pressure Rear tire size, pressure Front brake Rear brake Fuel tank capacity Rear Fuel reserve capacity '86, '87: Toe-in Caster angle Camber angle Trail length After '87: Tread Front Type Cylinder arrangement Bore x stroke Displacement Compression ratio Valve train Max i mum horsepower Maximum torque Oil capacity Lubrication system Cylinder compression Intake valve Exhaust valve Valve clearance (Cold) Type Identification mark Venturi diameter Main jet Slow jet Starter jet Pilot screw opening Jet needle Float level Idle speed Rear Opens Closes Opens Closes Intake Exhaust GENERAL INFORMATION < >:FOREMAN 1,850 mm (12.8 in) <1,975 mm (77.B in» 1,040 mm (40 .9 in) 1,080 mm ( 42 .5 inr 1,210 mm (47 .6 in) 770 mm (30.3 in) <After '87:785 mm (30.9 in I> 305 mm (12.0 in) 160 mm (6.3 in) 259 kg (571 Ibl <268 kg (591 Ibl> Double cradle 7.5)( 11 DC 11 x7.SAT 7.5xl1DC 11x7.SAT Axle. travel 110 mm (4.33 in) Axle. travel 110 mm (4.33 in) 24 x 9.00-11,2.2 psi ( 15 kPa, 0.15 kg /c m 2) 24 x 9.00-1 1, 2.2 psi (15 kPa, 0.15 kg/cm2) Hydraulic operated two leading shoe Cable operated leading/ trailing shoe 10.5 liters (2.8 US gal, 2.3 Imp gal) 2.6 litars (0.7 US gal, 0.6 Imp gal) 2.0 liters (0.5 US gal, 0.4 Imp gall Omm (0 in) 3· O· 14.0 mm (0.55 inl 800 mm 131.50 in) 800 mm (31.50 in) Gasoline, air-cooled 4 ·stroke Single cylinder inclined 20 0 from vertical 81 x S8 mm (3.19 x 2.S8 in) 350.4 cc 121.4 cu·in) 8.5:1 Overhead camshaft, chain driven 24.5 HP/S,OOO rpm (SAE) 2.9 kg ·m (21.0 ft·lb)/5,500 rpm (SAE) 2.8 lit 13.0 US qt, 2.5 Imp qt) at disassembly 2.3 lit (2.4 US qt, 2.0 Imp qtl after draining Forced pressure and wet sump with oil cooler 125 -1 45 kPa (12.5 - 14.5 kg/cm 1 , 178-206 psi) 50 BTDC 35 0 ABDC 35 0 BBDC 50 ATOC at 1 mm lift 0.08 mm 10.003 in) 0.08 mm (0.003 in) Dual valve QA03A 31 mm (1.22 in) #142 #35 #100 1· 1/2 turns out 3rd grOov8 from the top 18 .5 mm (0.73 in) 1,400 ::t 100 rpm 1-3

GENERAL INFORMATION DRIVE TRAIN Clutch Wet multi-plate, semi-automatic Transmission 5-speed constant mesh with reverse Primary reduction 2.103 (29/6 1) Gear ratio Sil 4.083 (12/ 49 ) I 2.389 (18/43) II 1.609 (23/37) III 1.179 (28/33) IV 0.906 (32/29) Reverse 4.781 Final reduct ion Middle 1.172 x 1.461 (29/34 x , 3'1 9) Final 3.889 (9/35) Gearshift pattern Left foot operated return system, Forward: N-S/ l- l -2-3-4 Reverse: N-R Differential oil capacity '86: 135 cc (4.6 oz) at disassembly 100 -110 cc 13.4 - 3.7 oz) after draining After '86: 225 cc (7.6 oz) at disassembly 200- 210 cc (6.8- 7.1 ozl after draining Final drive oil cap acity 135 cc 14.6 oz) at disassembly 100-' 10 cc (3.4-3.7 oz) after draining ELECTRICAL Ignition CO l Ignition timing Initial 10 ° BTDC at idle Full advance 30° BTDC at 3,500 rpm Alternator Capacity 240 W/ 5,000 rpm <3 10 W/5,000 rpm> Battery 12V-12AH NGK DRBES-L (OABES, DR7ES) NO X24ESA-U (X27ESA-U, X22ESR-U) Spark plug gap 0.S-0.7 mm (0.024-0.028 in) Headl ight 12V SO/55W Taillight 12V 5W X2 Neutral indicator 12V 3W Reverse indicator 12V 3W Oil temperature indicator 12V 3W Accessory light 12V 5W X2<12 V 25 W x 2> 1-4

TORQUE VALUES ENGINE Item Engine oil drain bolt '86, '87 : After '87 : Oil filter cover Clutch adjusting screw lock nut Valve adjusting lock nut Spark plug Insulator band screw Oil hose set piece bolt Cylinder head cap nut Cylinder head flange bolt Cam sprocket bolt (NOTE 1) Cylinder head cover (7 mm flange bolt l (6 mm SH bolt) (6 mm flange bolt)) Oil path pipe bolt tOil cont rol bolt Bf Cylinder mounting bolt Oil pipe bolt ' 86, '87 : After '87: Mainshaft bearing stopper plate Change dutch lock nut Centrifugal clutch lock nut INOTE 1 and 2) Clutch spring bolt Relief vallie nut (Atter '87 only) (NOTE 1) Flvwheel bolt Starter clutch torx bolt Drille shaft holder bolt Crankcase bolt Output gear case mount ing bolt Output gear bearing l ock nut 10uter) (Inner) Output gear bearing holder socket bolt Cam chain tensioner lifter bolt Kick starter plate socket bolt Neutral switch Oil temperature sensor Gear shift return spring pin Decompressor cable nut ('86, '87 only) NOTE. 1, Apply locking agent to the threads. 2, left ·hand threads. FRAME Item Handlebar upper holder bolt Handlebar lower holder nut Front wheel nut Tie rod end nut '86, '87 : -.tr After '87: Tie rod lock nut Pillot arm nut Knuckle holder nut '86, '87: -.tr After ' 87 : lower kingpin bolt Upper kingpin bolt Kingpin lock nut Front brake panel bolt (NOTE 3) GENERAL INFORMATION a'ty Thread Oia. Torque After (mm) '87 N'm kg-m ft-lb 1 12 15 - 25 1.5 -2.5 11-18 1 12 20 - 30 2.0-3.0 14- 22 3 6 8- 12 0.8-1.2 6- 9 1 8 19 - 25 1.9-2.5 14 - 18 4 6 , 5-18 1.5-1.8 11 - 13 1 12 15 - 20 1 .5- 2.0 11 - 14 3 5 3- 5 0.3 - 0.5 2- 4 2 6 10 - 14 1.0- 1.4 7- 10 4 10 35-45 3.5- 4 .5 25-33 2 10 35 - 45 3.5- 4 .5 25 - 33 2 7 17- 23 1 .7 - 2.3 12 - 17 4 7 13 - 17 1.3-1.7 9- 12 7 (6) 6 8- 12 0.8 - 1.2 8- 9 3 (4) 6 10-14 1.0-1.4 7-10 2 8 12 - 16 1.2-1.6 9- 12 2 6 8- 12 0.8 - 1.2 6- 9 1 7 8- 12 0.8-1.2 6-9 1 7 10-14 1.0- 1.4 7- 10 2 6 10- 14 1.0- 1.4 7- 10 1 18 100 - 120 10.0 - 12 .0 72- 87 1 20 110 - 130 t 1 .0- 1 3.0 80-94 4 6 10 - 14 1.0-1.4 7- 10 1 8 13 - 18 1 .3 - 1.8 10 - 13 1 12 100 - 120 10.0- 1 2.0 72 - 87 6 8 20 - 25 2.0-2.5 14-18 2 8 20-25 2.0-2.5 14 - 18 12 6 8- 12 0.8-1.2 6- 9 4 8 30 - 34 3.0 - 3.4 22 - 25 2 64 90 - 110 9.0-11.0 65-80 2 30 70 - 80 7.0 - 8.0 51 - 58 4 8 20 - 25 2.0- 2.5 14 - 18 3 6 8- 12 0.8-1.2 6- 9 2 6 10 - 14 1.0 - 1.4 7- 10 1 10 11 - 15 1.1 - 1.5 8 - 1 1 1 12 15 - 20 1.5 - 2.0 11 - 15 1 8 18 - 25 1 .8- 2.5 13- 18 1 6 5- 7 0.5-0.7 4 -5 Thread Dia. Torque Q'ty (mm) kg·m ft -tb N'm 4 8 18 - 30 1 .8- 3.0 13- 22 2 10 40 - 48 4 .0- 4 .8 29 - 35 8 10 60 - 70 6 .0-7 .0 43 -51 6 10 65 - 75 6 .5-7. 5 50-54 6 10 35 - 45 3.5 - 4.5 25 - 33 6 10 35 - 45 3.5-4.5 25 - 33 1 14 60 - 70 6.0- 7.0 43-51 8 10 60 - 80 6.0 - 8.0 43 - 58 8 10 35-45 3.5 - 4.5 25 - 33 2 20 50 - 70 5.0-7.0 37 - 51 2 20 5- 10 0.5 - 1.0 4- 7 2 20 50 - 70 5.0-7.0 37 - 51 8 8 27- 33 2.7 - 3.3 20 - 24 1-5

GENERAL INFORMATION Thread Dia. Item a'ty (mm) N·m Front shock absorber lower mount bolt (Ieftl 1 14 60-80 upperllower (rig ht ) mount nut '86, '87: 3 10 60-80 -.'r After '87: 3 10 35-45 Swingarm left pivot bolt 2 30 100 - 130 Swingarm right pillot bolt 2 30 16 - 20 lock nut 2 30 100 - 130 Differential gear case nut '86, '87: 12 10 60 - 80 * After '87: 12 10 35-45 Front axle nut 2 16 80-100 Swingarm joint nut '86, '87: 6 10 80 - 90 "fl After '87: 6 10 35 - 45 Steering stem nut 1 14 100- 120 Steering lower stay lock nut 1 46 50-70 Front skid plate bolt 3 8 18 - 25 Front guard plate/pipe bolt 5 8 18 - 25 Rear wheel nut 8 10 60 - 70 Rear axle nut 2 18 120- 160 Master cylinder hose bolt 2 10 25 - 35 Wheel cylinder hose bolt 2 10 25 - 35 Rear brake panel nut 'S6, '87: 4 10 50 - 60 -(( After '87: 4 10 35 - 45 Reservoir cover screw 2 4 1-2 Foot peg bolt 4 10 40-50 Brake pipe joint 5 10 12-15 Rear shock absorber upper mount nut '86, '87: 2 10 40 - 50 -(( After '87: 2 10 35 - 45 lower mount bolt/ nut '86, '87: 2 10 60 - 80 * After '87: 2 10 35-45 Trailer hitch 4 10 70 - 80 Final gear case (cover) joint nut '86, '87: 12 10 60 - 80 * After '87: 12 10 35 - 45 Differential assembly case rear cap torx bolt 6 8 30 - 35 case cap torx bolt 6 8 30 - 35 Ring gear bolt 6 8 45 - 55 Pinion bearing lock nut 1 60 90-110 Differential gear cover 10 mm bolt 2 10 45 - 50 8 mm bolt 6 8 23 - 28 Differential gear pinion joint nut 1 16 100 - 120 Final drive gear lock nut 1 60 90 - 110 Final drive gear cover 10 mm bolt 2 10 45 - 50 8 mm bolt 6 8 23 - 28 Final drive gear pinion joi nt nut 1 16 100 - 120 Differential /linal drive oil filler cap 2 30 10 - 14 Top engine hanger nut 1 10 70 - 80 Top engine hanger plate bolt 4 8 34-40 Front engine mounting bolt (upper/ lower) 2 10 70-80 Engine hanger bracket nut 4 10 70 - 80 Rear engine mounting nut lupper!lower) 2 10 70 - 80 Muffler band bolt 2 8 18 - 28 Exhaust pipe joint nut 4 8 24 - 30 Muffler mounting bolt 3 10 50 - 60 . NOTE 3: (After 87 Only) USing again strictly prohibited. CAUTION -tl : Nut fo r A/ter '87 is a self·locking nut with the nUI·head peened; nUl for '86 and '87 is a self·locking nul (U·lot:king nul). Tighten each nut to each specified torque, or the nut is broken or loosened. 1-6 Torque kg-m ft-Ib 6.0-8.0 43 - 58 6.0-8.0 43-58 3.5-4.5 25-33 10.0 - 13.0 72-94 1.6 - 2.0 12 - 14 10 .0-13.0 72 - 94 6.0 - 8.0 43 - 58 3.5 -4 .5 25 - 33 8.0-10.0 58 - 72 8.0 - 9.0 58 - 65 3.5 - 4.5 25 - 33 10,0-12.0 72 - 87 5.0-7.0 37 - 51 1.8-2.5 13- 18 1.8 - 2.5 13 - 18 6.0 - 7.0 43 - 51 12.0 - 16.0 87 - 116 2.5-3.5 18 - 25 2.5 - 3.5 18- 25 5.0 - 6.0 36 - 43 3.5 - 4.5 25 - 33 0.1-0.2 0.7-1.4 4.0 - 5.0 29-36 1.2 - 1.5 9- 11 4.0 - 5.0 29-36 3.5 -4 .5 25 - 33 6.0 - 8,0 43 - 58 3.5 -4 .5 25-33 7.0 - 8.0 51 - 58 6.0 - 8.0 43 - 58 3,5 -4 .5 25 - 33 3.0 - 3.5 22 - 25 3.0 - 3.5 22 - 25 4,5 - 5,5 33 - 40 9 ,0- 11. 0 65 - 80 4.5 - 5.0 33 - 36 2.3 - 2.8 17- 20 10,0 - 12,0 72 - 87 9.0 - 1 1 ,0 65 - 80 4.5-5.0 33-36 2.3 - 2.8 17-20 10.0 - 12.0 72 - 87 1.0 - 1.4 7- 10 7.0 - 8.0 51 - 58 304 - 4.0 25 - 29 7.0-8 .0 51- 58 7.0 - 8.0 51 - 58 7.0- 8.0 51 - 58 1.8 - 2.8 13 - 20 ZA-3.0 1 7-22 5.0 - 6.0 36 - 43 ~@ ('86, '87) (After '871

GENERAL INFORMATION Torque specifications listed on the previous pages are for the most important tightening points. If a torque specification is not listed, follow the standards given below. STANDARD TORQUE VALUES It em Torque N·m (kg-rn, h-Ib) Item Torque N·m (kg-m. ft -Ib) 5 mm bolt, nut 4.5 -6 (0.45-0.6, 3-4) 5 mm screw 3. 5-5 (0.35 - 0.5, 2- 41 6 mm bolt, nut 8- 1210.8-1.2,6-9) 6 mm screw, 6 mm 7- 1110.7 - 1.1,5 - 8) flange bolt with 8 mm head 8 mm bolt, nut 18- 2511.8-2.5,13-18) 6 mm flange bolt, nut 10-14 (1.0 -1.4 ,7 - 10) 10 mm bolt, nut 30 - 40 (3.0- 4.0 , 22-291 8 mm flange bolt, nut 24-30 {2. 4-3 .0 , 17 - 221 12 mm bolt, nut 50 - 60 (5.0-6.0. 36-43) 10 mm flange bolt, nut 35-45 (3.5- 4 .5, 25 - 33) TOOLS SPEC IAL DESCRIPTION TOOL NUMBER ALTERNATE TOOL REF. SEC. Camber/caster gauge attachment 07910-MJ30100 (Not available in U.S.A.) 3 Valve guide reamer, 5.5 mm 07984-2000000 or 07984 - 200000A (U .S. A. on ly ) 7 Remover handle 07936 - 3710100 9, 11 , 14, 15 Remover weight 07741 - 0010201 or 07936 - 3710200 9, 10, 11 , 14, '5 8earing remover, 1 7 mm 07936-3710300 9, 11 Clutch center holder 07923-KE10000 or Plate holder 07HG8 - oo1010A 9 and clutch center coltar " A" 07HGB - ool020A (U.S.A . only) Clutch holder 07G MB - HA 70100 9 8earing remover set, 10 mm 07936 - GEOOOOO 10 Shaft holder 07923 - 6890101 11 Lock nut wrench, 30 x 64 mm 07916-M800001 11 Lock nut wrench attachment 07GMA-HA70110 or 07916 - HA0020A 11 Attachment, 61.5 mm 07946-3600000 11 8earing remover, 20 mm 07936 - 3710600 11 Lock nut wrench, 34 x 44 mm 07916 - ME50001 1" 15 Lock nut wrench attachment 07916-9690100 11 Universal bearing puller 07931 - 4630000 or 07631 - 0010000 or equivalent 11, 15 commercially available in U.S.A. Crank assembly tool set 07931-KFOOOOO (Not available in U.S.A.) 11 - Crankshaft assembly collar 07931 - KF00100 11 - Shaft puller 07931-ME40000 or 07931 - ME4oo0A (U.S.A. only) 1" 1 5 - Threaded adapter 07931 - KFOO200 11 Attachment, 28 x 30 mm 07946 - 1870100 11 Attachment 07946 - HAOOOOO 11 Spring compressor adaptor 07967 - KC10000 (Not available in U.S.A .) 12 Lock nut wrench 07908 - 4690001 or KS - H8A - 08 - 469 (U . S.A. 12 only) Bearing remover set 07936-8890101 (Not available in U.S.A.) 12, 14 - Remover head 07936-8890200 (Not available in U.S.A.! 12, 14 - Bearing remover, 30 mm 07936 - 8890300 12, 14 - Remover weight 07741 - 0010201 or 07936 - 3710200 12 - Remover handle 07936 - 3710100 12 Wrench adaptor 07GMA-HA702oo 12 Attechment 07965-SA00600 13 Shock absorber compressor base 07959-MB10000 12, 14 Spring compressor adaptor 07967-KC10000 (Not available in U.S.A.) 12, 14 Pivot lock nut wrench 07908-4690001 or KS - HBA- OB - 469 (U.S.A. 14 only) Ball race driver 07945-3330300 14 Driver 07949 - 3710001 14 Differencial inspection attachement 07GMK - HA70100 15 1-7

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1986-1989 Honda TRX350 Fourtrax 4x4 & Honda TRX350D Foreman 4x4 Service & Repair Manual

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