2004-2006 Honda FourTrax Rancher (TRX350TE/TM/FE/FM) Service & Repair Manual

HOW TO USE THIS MANUAL n. -w:. manual dMerlbe. !he teMcIo procedures lor !he TAX350. Follow 1M M.m-nc. ~ (s.euon "I recommendations to .-..ute hlN ~ i$ ~ ~ operating condidon and emission Iewb Ire wiIIlI'I IIlI' ,tandatds MI t¥ Ihe CaliIomIa AJ( Resources Board (CARS). F'e<foi".1g the ... .meduied mllntenante is -.y hIponant. n ~IH for !he lnitiaI_r IIW 00CUI'a dUfWIQ 1hII ~k~ period. s.etiont 1 and " ~ 10 IIle whoII /TIOIon:ycII. s.etion 3 Illu$Uates proeedu ... tor ~ of (:OI!1IOnem.lMT "lIlY t. req.ared 10 pe!form ____ o.~ In !he IoIcJMng aecOons.. SecDcnI 5 tnrough 23 cIMerI:It PllrU 01 1M moIID!C'fCIto. grouped according 10 Ir;QbOn. "'n:I tilt HC1Ion)")Y want on Itlll p~, !hen turn 10 !he table 01 contenTS on !he flrs' pao- 01 tI'It MC1iorI, Moll! MetIor\I Ita1t wI1tI an .SMmbIy Of .ystllfT1 iIluatratioo, IIIOrvice inIorlNllion and IIOUOInhooIIng for IIw MCtion. ThII svOMqueot P30&S give dfltai\..:I procedures. II you .re not I,mll"', w~M till ..... hIoIe. rtWId the TectmicaJ Features III _. II )'OU don1 know the sourao 01 IIle troubIII, go 10 Sectioo 24, Troubiolahooong. 'fbuf _\ely. and to. Wtety 01 other., II .... ry hlporUnt . TO help you make Wlbrm«l o:IeeWont .... tIIr.-. pt'DYIded ulety messages and 0Iher ifTtI:>nnI,lion throughoUt IhI& manual. 01 oou.... II Is no! ~ Of possible 10 wt.m you about .U 1M I'IaDordl assoeIaled with Io8fYk:VlQ IIIit '4h1de. 'ItJu IT'IJSI use vourOWl'l good judpement 'Ibu will /WI ionporuonl .. lett ntDnNIlion in • Vllriely or i)rmI: ~; • s.t.Iy L..abotIt - on IIle ........ • SIIt.ty "'-11M - preceded by • ""'Iy *",tt S)'TlboI th and orw oIlhrM ~~. D.\NGER, WARNING, or CAlITlON. n- ~ wo~ mean: You WIll t. KILLED or SERIOUSLY IIl'Wt l S3j' HURT M)IOU don't foIow k'l&tructionL You CAN be KILLED or SERIOUSLY HURT ID.,.'i'f! 'W, • you don' tallow inslruclions. You CAN be HURT M you don" IoIIaw me,]·" ! '1,' Inatr\.lCllo!'w. • InsTruction. - how to Mf'IIioe this veNc_ COITeCtty and sale/y. .... you I'Nd !hit: mlnLotlI, you will find information thaI Is p!'8Ceded by. CJIQlI!I) lymboI. The purpO" 01 thit mesaagl Is to help prlMtnl damagl to your IIIIIhlcle. OIhtf prope~. Of !he envtronrneot. z " ~ w 2: a: c c z " w z ~ ... " U ~ W GENERAL INFORMATION TECHNICAL FEATURES FRAMEIBODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVALJlNSTALLATION CYLINDER HEADNALVE CYLINDERIPISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKCASElTRANSMISSIONlCRANKSHAFT FRONT WHEEUSUSPENSIDNISTEERING REAR WHEEUSUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM (FMlFE model) REAR DRIVING MECHANISM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTSIMETERSISWITCHES ELECTRIC SHIFT PROGRAM (ESP: TEIFE model) WIRING DIAGRAMS INDEX

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. 111 Replace the part(s) with new one(s) before assembly. , Use recommended engine oil, unless otherwise specified. , Use molybdenum oil solution (mixture of the engine oil and molybdenum grease In a ratio of 1:1). _..s;;;w. Usa multi-purpose grease (lithium based multi-purpose grease NLGli2 or equivalent). Use molybdenum disulfide grease (cootalning more than 3% molybdenum disulfide, NlGI #2 or equivalent) . .... Example: Mo/ykote4' 8R-2 Plus manufactured by Dow Corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishl Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI 112 or equivalen t). Example: Motykot~ G-o Paste manufactured by Dow Corning, U.S.A. .-'iMPli Honda Moly 60 (U.S.A. only) Aocol ASP manufactured by Aocol Umited, UK Aocol Paste manufactured by Sumico lubricant, Japan .... - Use silicone grease. D Apply a locking agent. Use a medium slrengt)"llocklng agent unless otherwise specified. -gn', ",'1lW Use sealant. I Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified . ... Use fork or suspension fluid. • • • • • •

1. GENERAL INFORMATION SERVICE RULES ................................ ............ '·2 MODEL IDENTIFiCATION······················ ········ '-2 GENERAL SPECiFiCATIONS························· '-5 LUBRICATION SYSTEM SPECIFICATIONS· '·8 FUEL SYSTEM SPECiFiCATIONS················· '·8 CYLINDER HEADIVALVE/CAMSHAFT SPECI- FICATIONS············································· ........ '-8 CYLINDER/PISTON SPECiFiCATIONS········· '-9 CLUTCH/GEARSHIFT LINKAGE SPECIFICA· TIONS ················································· ............ '·9 ALTERNATORS/STARTER CLUTCH SPECIFI- CATIONS ........................................................ '·9 CRANKCASE/AUTOMATIC TRANSMISSION SPECiFiCATIONS········································· '-'0 FRONT WHEEl/SUSPENSION/STEERING SPECIFICATIONS ITM/TE model) ·············· '·'0 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS IFM/FE model) .............. '- '0 REAR WHEEL/SUSPENSION SPECIFICATIONS ITMITE model) .............. .. ............................ ,-" REAR WHEEL/SUSPENSION SPECIFICATIONS IFM/FE model)· ·········································· ···,·" BRAKE SYSTEM SPECIFICATIONS··········· ··,-" FRONT DRIVING MECHANISM SPECIFICATIONS IFM/FE model) ·············· ·, -" REAR DRIVING MECHANISM SPECiFiCATIONS·········································· '·'2 BATTERY/CHARGING SYSTEM SPECiFiCATIONS·········································· '-'2 IGNITION SYSTEM SPECIFICATIONS ········ '-'2 ELECTRIC STARTER SPECIFICATIONS ······'-'2 LIGHTS/METER/SWITCHES SPECiFiCATIONS··········· .. ······························'-'2 STANDARD TORQUE VALUES··················· '-'3 ENGINE & FRAME TORQUE VALUES ········' -'3 LUBRICATION & SEAL POINTS ··················' ·'7 CABLE & HARNESS ROUTING ··················· '·2' EMISSION CONTROL SYSTEMS ················'·29 EMISSION CONTROL INFORMATION LABEL IU .S .A. only) ·················································'·30 .. 1-1

GENERAL INFORMATION SERVICE RULES 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 motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when serviC ing the motorcycle. Metric bolts, nuts and screws are not interchangeable with Engli sh fasteners. 4. Install new gaskets, O-rings, coner pins, and lock plates when reassembling. 5. When tightening bohs 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. 6. Clean parts in cleaning solvent upon disassembly. lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown on pages 1-21 through 1-29, Cable & Harness routing. MODEL IDENTIFICATION This manual covers 4 types ofTRX350 models: • TM - 2WDfLeft foot operated gearshift • TE - 2WDlElectric shift program (ESP) • FM - 4WD/Left foot operated gearshift • FE - 4WDlElectric shift program (ESP) Be sure to refer to the procedure that pertains to the appropriate version of the TRX350. mX350 TM/FM (U.S.A. type shown): 1-2 • • •

The Model Identification label is located on the left side frame down tube. GENERAL INFORMATION The engine serial number is stamped on the left side of the rear ;:::======= E = N =G='= N= E= S = E = R = '=A= L= N = U =M == B= E= R=~ crankcase. The color label is anached on the frame crossmember under the seat. When ordering color·coded parts, always specify the designated color code. The vehicle identifiacation number (VIN) is stamped on the front side of the frame. o 1-3

GENERAL INFORMATION The carburetor identification number is stamped on the left side of th e carburetor body. 1-4

GENERAL SPECIFICATIONS TRX350TMITE Overall Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weigh t Curb weight tyP' Front suspension Front wheel travel Front dampe r Rear suspension Rear wheel travel Rear damper Front tire sile Rear tire size Front rim size Rear rim size Front tire brand Rear ti re brand Front brake Rear b rake Caster angle Trail lengt h Camber angle Fuel tank capacity Fuel tank Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens Lubrication system Oil pump type Cooling syst em Air filtration closes GENERAL I NFORMATI ON , mm 1, '14 mm (43.9 in) 1,129 mm (44.4 in) 1,253 mm (49.3 in) 851 mm (33.5 in) 840 mm (33,1 in) 812 mm (32.0 in) TM: 337 mm (13.3 inlfTE: 327 mm (12.9 in) 186 mm (7.3 in) TM: 227 kg (500 lbs) TE: 232 kg (511 Ibs) TM: 238 kg (525 Ibs) TE: 242 kg (534 Ibs) I Double wish-bone 150 mm (5.9 in) Double tube Swingarm 150 mm (5.9 in) Dou ble tu be AT24 x 8- 12 ** AT25 x 11-10 ** 12 x 6.0 AT 10x8.5AT TRACKER Cl (Goodyear) TRACKER Cl (Goodyear) Hydraulic drum brake (Dual leadi ng) Mechanical dr um brake (Leading-trailing) '" 31 mm (1.2 in) 0" 13.9 liters (3 .67 US gal, 3.0Slmp gal) Ii I I I li i 78.5 x 68.0 mm (3.09 x 2.S8 329.1 cm 3 (20.08 cu -in) 8.8: 1 OHV 8 0 BTDC (at 1 mm li ft ) 38° AB DC (at 1 mm lift) 40° BBDC (at 1 mm lift) r ATDC (at 1 mm li ft ) Forced pressure (dry sump) Tr ochoid Air cooled (with cooling fan [TE only[ and oil cooler) Oiled urethane foam .~I~~~~~_~ . ; 1-5

GENERAL INFORMATION TRX350FM/FE DIMENSIONS 1-6 Cluten operation system Transmission Primary reduction Secondary reduction Final reduction Gear ratio Gearshift panern ; Starting system Charging system ; , ITEM Overall length Overall width Overall height Wheelbase Fro nt tread Rear tr ead Seat height Foctpeg height Ground clearance Dry weight Curb weight ,,, 2nd 3,d 4th 51h Reverse Maximum weiQht capacity Automatic Constant mesh, 5-speeds with reverse 2. 188 (70132) 1.933 (29/15) 3.692 (48113) 3.455 (3811 1) 1.933 (29115) 1.333 (28121) 0. 966 (28129) 0. 720 (18125) 4.600 (39/13 23115) A-N-1-2-3-4-5 left foot operated return system (TMj I Electric starter moto r and eme rgency recoil starte r Triple phase output alternator SeA shorted, triple phase fun wave rectification SPECIACATIONS 2,031 mm (80 in) 1,114 mm (43.9 in) 1,1 41 mm (44.9 in) 1,246 mm (49.1 in) 844 mm (33.2 in) 860 mm (33.9 in) 819 mm (32.3 in) FM : 344 mm (13. 5 in)/ FE : 334 mm (13.1 in) FM : 238 kg (525 Ibs) FE: 241 kg (531Ibs) FM : 249 kg (549 Ibs) FE : 252 kg (556 Ibs) 220 kg (485 Ibs) • • •

Front suspension Front wheel travel Front damper Rear suspension Rear wheel trave l Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Fr ont brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Double wish-bone 150 mm (5.9 in) Double tube Swingarm 150 mm (5.9 in) Double tube AT24 x 8-12 ** AT24 x 9- 11 ** 12x6.0AT '1 x 7.0 AT GENERAL INFORMATION DIRT HOOKS 15 (B ridgestone) DIRT HOOKS 14 (Bridgestone) Hydraulic dru m brake (Dual leading) Mechanical drum brake (Leading-trailing ) 4" 17 mm (0.7 in) 0° 06' 13.9 li ters (3.67 US gat. 3.06 Imp gal) L,NGmE-----+~~~~~~~~----_1~~' '~--------~ I i arrangement Jj"; Bore and stroke 78.5 x 68.0 mm (3.09 x 2.68 in) Displacement 329.1 em 3 (20.08 cu-in) Compression ratio 8. 8: 1 Valve train QHV Intake valve opens 8°BTDC (at ' mm lift) closes 38°ABDC (at 1 mm lift) Exhaust valve Lubrication system Oil pu mp type Cooling system Air filtration opens closes Clut ch operation system Transmission Primary reduction Secondary reduction Final reduction Front Gear ratio Gearshift pattern i i system i system Regu lator/r ecti fier Rear ,,, 20d ',d 4th 5th Reverse 40 0 BBDC (at 1 mm lift) 7°ATDC (at I mm lift) Forced pressure (dry sump) Trochoid Air cooled (with cooling fan and oi l cooler) Oi led uretha ne foam I Automatic Constant mesh, 5-speeds with reverse 2.188 170132) 1.933 (29/15) 3.769 (49/ 13 ) 3.692 (48113) 3.455 (38111) 1.933 (29/15) 1.333 (2812 1) 0.966 (28129) 0.720 (18/25) 4.600 (391 13 x 23/15) R-N -1-2-3- 4-5 Left foot operated return system (FM) Electric shift I hand Electric starter motor and emergency recoil starter Tr iple phase output alternator SCR shorted, triple phase full wave rectification 1-7

2004-2006 Honda FourTrax Rancher (TRX350TE/TM/FE/FM) Service & Repair Manual

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