2000 2001 2002 2003 Honda TRX350 Rancher 350* Factory Service / Repair/ Workshop Manual ! (00 01 02 03)

－－－ Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. HOW TO USE THIS MANUAL CONTENTS GENERAL INFORMATION MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ALTERNATOR/STARTER CLUTCH BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES FRAME/BODY PANELS/EXHAUST SYSTEM CLUTCH/GEARSHIFT LINKAGE REAR WHEEL/SUSPENSION TROUBLESHOOTING ENGINE REMOVAL/INSTALLATION TECHNICAL FEATURES FRONT WHEEL/SUSPENSION/ STEERING REAR DRIVING MECHANISM CHASSIS ELECTRICAL INDEX CYLINDER/PISTON CRANKCASE/TRANSMISSION/ CRANKSHAFT BRAKE SYSTEM WIRING DIAGRAM ENGINE CYLINDER HEAD/VALVE • • • FRONT DRIVING MECHANISM (FM/FE models) ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) Date of Issue: Honda Motor Co., Ltd. May, 2002 Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: Instructions how to service this vehicle correctly and safety. This service manual describes the service procedures for the TRX350 TM/TE and TRX350 FM/FE. Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the California Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Sections 4 through 21 describe parts of the vehicle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to Section 24, Troubleshooting. Safety Labels on the vehicle Safety Messages preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 23 24 25

－－－－ 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)

－－－－－－－－－－－－－－－－－－－－－－－－－－ ± ＃＃－－－－ STANDARD ITEM ITEM SPECIFICATIONS ITEM SERVICE LIMIT SERVICE LIMIT STANDARD FUEL SYSTEM GENERAL INFORMATION LUBRICATION CYLINDER HEAD/VALVE/CAMSHAFT 1-7 Recommended engine oil Engine oil capacity After draining After draining/filter change After disassembly 1.95 (2.06 US qt , 1.72 Imp qt) 2.0 (2.1 US qt , 1.8 Imp qt) 2.5 (2.6 US qt , 2.2 Imp qt) Cylinder head warpage Valve, valve guide Valve spring Rocker arm Camshaft and cam follower Valve clearance Cylinder compression at 450 rpm Valve stem O.D. Valve guide I.D. Stem-to-guide clearance Valve seat width Free length Arm I.D. Shaft O.D. Arm-to-shaft clearance Cam lobe height Cam follower O.D. Follower bore I.D. Follower-to-bore clearance IN/EX IN EX IN/EX IN EX IN/EX Inner Outer IN/EX IN/EX IN/EX IN/EX IN/EX IN/EX IN/EX 0.028 0.059 (0.0011 0.0023) 22.510 22.526 (0.8862 0.8868) 22.467 22.482 (0.8845 0.8851) 35.2995 35.4595 (1.38974 1.39604) 0.016 0.052 (0.0006 0.0020) 11.966 11.984 (0.4711 0.4718) 12.000 12.018 (0.4724 0.4731) 41.67 (1.641) 36.95 (1.455) 1.2 (0.05) 0.030 0.057 (0.0012 0.0022) 0.010 0.037 (0.0004 0.0015) 5.500 5.512 (0.2165 0.2170) 5.455 5.470 (0.2148 0.2154) 5.475 5.490 (0.2156 0.2161) 0.15 (0.006) 667 kPa (6.8 kgf/cm , 97 psi) 0.10 (0.004) 0.07 (0.003) 22.54 (0.887) 22.46 (0.884) 35.13 (1.383) 0.08 (0.003) 11.92 (0.469) 12.05 (0.474) 40.42 (1.591) 36.94 (1.454) 1.5 (0.06) 0.14 (0.006) 0.12 (0.005) 5.52 (0.217) 5.43 (0.214) 5.45 (0.215) Carburetor identification number Main jet Slow jet Jet needle clip position Pilot screw opening Float level Idle speed Throttle lever free play 3 8 mm (1/8 5/16 in) 1,400 100 rpm 18.5 mm (0.73 in) 3rd groove from top 42 130 VE94A Tip clearance Body clearance Side clearance Oil pump 0.02 0.09 (0.001 0.004) 0.15 0.22 (0.006 0.009) 0.15 (0.006) 0.12 (0.005) 0.25 (0.010) 0.20 (0.008) Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher JASO T 903 standard: MA Viscosity: SAE 10W-40 Unit: mm (in) Unit: mm (in) See page 5-15

－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－ ITEM ITEM SERVICE LIMIT STANDARD SERVICE LIMIT ITEM STANDARD SERVICE LIMIT STANDARD 1-8 GENERAL INFORMATION CYLINDER/PISTON ALTERNATOR/STARTER CLUTCH CLUTCH/GEARSHIFT LINKAGE Cylinder Piston, Piston pin, piston ring Cylinder-to-piston clearance Connecting rod small end I.D. Connecting rod-to-piston pin clearance Piston ring end gap Piston ring-to-ring groove clearance Top Second Oil (side rail) Top Second Change clutch Centrifugal clutch Primary drive gear Spring free length Disc thickness Plate warpage Outer I.D. Outer guide Mainshaft O.D. at clutch outer guide Drum I.D. Weight lining thickness Clutch spring height Clutch weight spring free length Gear I.D. Crankshaft O.D. at drive gear TM/FM TE/FE I.D. O.D. Starter driven gear boss O.D. 78.500 78.510 (3.0905 3.0909) 78.465 78.485 (3.0892 3.0900) 17.002 17.008 (0.6694 0.6696) 16.994 17.000 (0.6691 0.6693) 0.002 0.014 (0.0001 0.0006) 0.15 0.30 (0.006 0.012) 0.30 0.45 (0.012 0.018) 0.20 0.70 (0.008 0.028) 0.030 0.060 (0.0012 0.0024) 0.015 0.045 (0.0006 0.0018) 0.015 0.045 (0.0006 0.0018) 17.016 17.034 (0.6699 0.6706) 0.016 0.040 (0.0006 0.0016) 0.10 (0.004) 0.10 (0.004) 17.04 (0.671) 16.96 (0.668) 0.02 (0.001) 0.5 (0.02) 0.6 (0.02) 0.9 (0.04) 0.09 (0.004) 0.09 (0.004) 0.10 (0.004) 17.10 (0.673) 0.06 (0.002) 28.0 (1.10) 2.62 2.78 (0.103 0.109) 28.000 28.021 (1.1024 1.1032) 22.000 22.021 (0.8661 0.8670) 27.959 27.980 (1.1007 1.1016) 21.967 21.980 (0.8648 0.8654) 126.0 126.2 (4.96 4.97) 2.0 (0.08) 2.87 (0.113) 25.8 (1.02) 26.959 26.980 (1.0614 1.0622) 45.660 45.673 (1.7976 1.7981) 2.3 (0.09) 0.20 (0.008) 28.04 (1.104) 22.05 (0.868) 27.92 (1.099) 27.05 (1.065) 26.93 (1.060) 0.10 (0.004) 31.3 (1.23) 27.000 27.021 (1.0630 1.0638) 78.60 (3.094) 78.43 (3.088) 27.0 (1.06) 30.2 (1.19) 21.93 (0.863) 126.4 (4.98) 1.3 (0.05) 2.73 (0.107) 26.9 (1.06) 45.65 (1.797) I.D. Out-of-round Taper Warpage Piston O.D. at 15 (0.6) from bottom Piston pin hole I.D. Piston pin O.D. Piston-to-piston pin clearance Unit: mm (in) Unit: mm (in) Unit: mm (in)

2000 2001 2002 2003 Honda TRX350 Rancher 350* Factory Service / Repair/ Workshop Manual ! (00 01 02 03)

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