2001 Honda TRX350 Rancher 350 Service Repair Manual

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HOW TO USE THIS MANUAL

CONTENTS

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.

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.

ENGINE

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.

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: • 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.

CHASSIS

If you don’t know the source of the trouble, go to Section 24, Troubleshooting.

You CAN be HURT if you don’t follow instructions.

• Instructions − how to service this vehicle correctly and safety.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS 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.

Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE

Date of Issue: May, 2002 Honda Motor Co., Ltd.

ELECTRICAL

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.

GENERAL INFORMATION

1

FRAME/BODY PANELS/EXHAUST SYSTEM

2

MAINTENANCE

3

LUBRICATION SYSTEM

4

FUEL SYSTEM

5

ENGINE REMOVAL/INSTALLATION

6

CYLINDER HEAD/VALVE

7

CYLINDER/PISTON

8

CLUTCH/GEARSHIFT LINKAGE

9

ALTERNATOR/STARTER CLUTCH

10

CRANKCASE/TRANSMISSION/ CRANKSHAFT FRONT WHEEL/SUSPENSION/ STEERING

11

REAR WHEEL/SUSPENSION

13

BRAKE SYSTEM

14

FRONT DRIVING MECHANISM (FM/FE models)

15

REAR DRIVING MECHANISM

16

BATTERY/CHARGING SYSTEM

17

IGNITION SYSTEM

18

ELECTRIC STARTER

19

LIGHTS/METERS/SWITCHES

20

ELECTRIC SHIFT PROGRAM (ESP: TE/FE models)

21

WIRING DIAGRAM

22

TECHNICAL FEATURES

23

TROUBLESHOOTING

24

INDEX

25

12

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1. GENERAL INFORMATION SERVICE RULES

1-1

LUBRICATION & SEAL POINTS

1-18

MODEL IDENTIFICATION

1-1

CABLE & HARNESS ROUTING

1-22

SPECIFICATIONS

1-3

EMISSION CONTROL SYSTEMS

1-33

TORQUE VALUES

1-13

EMISSION CONTROL INFORMATION LABEL (U.S.A only)

1-34

TOOLS

1-16

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 servicing the motorcycle. 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 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 1-22 through 1-32, Cable & Harness routing.

MODEL IDENTIFICATION 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.

TRX350 TM/FM: (U.S.A. type shown)

TRX350 TE/FE:

1-1

1

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GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER

FRAME SERIAL NUMBER The Vehicle Identification Number (VIN) is located on the left side frame down tube.

The frame serial number is stamped on the front side of the frame.

ENGINE SERIAL NUMBER

CARBURETOR IDENTIFICATION NUMBER The engine serial number is stamped on the left side of the rear crankcase.

COLOR LABEL

The color label is attached on the frame crossmember under the seat. When ordering colorcoded parts, always specify the designated color code.

1-2

The carburetor identification number is stamped on the left side of the carburetor body.

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GENERAL INFORMATION

SPECIFICATIONS GENERAL: TRX350TM/TE ITEM DIMENSIONS

FRAME

ENGINE

Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight

2000−2001: After 2001: 2000−2001: Curb weight After 2001: 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

SPECIFICATIONS 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) TM: 323 mm (12.7 in) /TE: 318 mm (12.5 in) 186 mm (7.3 in) TM: 226 kg (498 lbs) /TE: 232 kg (511 lbs) TM: 226.5 kg (499.3 lbs) /TE: 232.5 kg (512.6 lbs) TM: 237 kg (522 lbs) /TE: 243 kg (536 lbs) TM: 237.5 kg (523.6 lbs) /TE: 243.5 kg (536.8 lbs) 210 kg (463 lbs) Double cradle Double wish-bone 150 mm (5.9 in) Double tube Swingarm 150 mm (5.9 in) Double tube AT24 × 8-12 ★★ AT25 × 11-10 ★★ 12 × 6.0 AT 10 × 8.5 AT TRACKER CL (Goodyear) TRACKER CL (Goodyear) Hydraulic drum brake (Dual leading) Mechanical drum brake (Leading-trailing) 7° 31 mm (1.2 in) 0° 13.0 (3.43 US gal , 2.86 Imp gal) 3.2 (0.85 US gal , 0.70 Imp gal) Single cylinder, longitudinally installed 78.5 × 68.0 mm (3.09 × 2.68 in) 329.1 cm (20.08 cu-in) 8.8 : 1 OHV 8°BTDC (at 1 mm lift) 38°ABDC (at 1 mm lift) 40°BBDC (at 1 mm lift) 7°ATDC (at 1 mm lift) Forced pressure (dry sump) Trochoid Air cooled (with cooling fan [TE only] and oil cooler) Oiled urethane foam TM: 43.4 kg (95.7 lbs) /TE: 44.9 kg (99.0 lbs)

1-3

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GENERAL INFORMATION GENERAL: TRX350TM/TE (Cont’d) ITEM CARBURETOR DRIVE TRAIN

ELECTRICAL

1-4

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

SPECIFICATIONS Constant Vacuum (VE type) 32 mm (1.3 in) Centrifugal and Multi-plate, wet Automatic Constant mesh, 5-speeds with reverse 2.188 (70/32) 1.933 (29/15) 3.692 (48/13) 3.455 (38/11) 1.933 (29/15) 1.333 (28/21) 0.966 (28/29) 0.720 (18/25) 4.600 (39/13 × 23/15) R−N−1−2−3−4−5 Left foot operated return system (TM) Electric shift (left hand operated) return system (TE) DC-CDI Electric starter motor and emergency recoil starter Triple phase output alternator SCR shorted, triple phase full wave rectification Battery

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GENERAL INFORMATION GENERAL: TRX350FM/FE ITEM DIMENSIONS

FRAME

ENGINE

Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight

2000−2001: After 2001: Curb weight 2000−2001: After 2001: 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

SPECIFICATIONS 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) FM: 334 mm (13.1 in)/FE: 330 mm (13.0 in) 184 mm (7.2 in) FM: 237.5 kg (523.6 lbs)/FE: 242.5 kg (534.6 lbs) FM: 238 kg (525 lbs) /FE: 243 kg (536 lbs) FM: 248.5 kg (547.8 lbs)/FE: 253.5 kg (558.9 lbs) FM: 249 kg (549 lbs) /FE: 254 kg (560 lbs) 220 kg (485 lbs) Double cradle Double wish-bone 150 mm (5.9 in) Double tube Swingarm 150 mm (5.9 in) Double tube AT24 × 8-12 ★★ AT24 × 9-11 ★★ 12 × 6.0 AT 11 × 7.0 AT DIRT HOOKS 15 (Bridgestone) DIRT HOOKS 14 (Bridgestone) Hydraulic drum brake (Dual leading) Mechanical drum brake (Leading-trailing) 4° 17 mm (0.7 in) 0° 06’ 13.0 (3.43 US gal , 2.86 Imp gal) 3.2 (0.85 US gal , 0.70 Imp gal) Single cylinder, longitudinally installed 78.5 × 68.0 mm (3.09 × 2.68 in) 329.1 cm (20.08 cu-in) 8.8 : 1 OHV 8°BTDC (at 1 mm lift) 38°ABDC (at 1 mm lift) 40°BBDC (at 1 mm lift) 7°ATDC (at 1 mm lift) Forced pressure (dry sump) Trochoid Air cooled (with cooling fan and oil cooler) Oiled urethane foam FM: 43.8 kg (96.6 lbs) /FE: 45.3 kg (99.9 lbs)

1-5

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GENERAL INFORMATION GENERAL: TRX350FM/FE (Cont’d) ITEM CARBURETOR DRIVE TRAIN

ELECTRICAL

1-6

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

SPECIFICATIONS Constant Vacuum (VE type) 32 mm (1.3 in) Centrifugal and Multi-plate, wet Automatic Constant mesh, 5-speeds with reverse 2.188 (70/32) 1.933 (29/15) 3.769 (49/13) 3.692 (48/13) 3.455 (38/11) 1.933 (29/15) 1.333 (28/21) 0.966 (28/29) 0.720 (18/25) 4.600 (39/13 × 23/15) R−N−1−2−3−4−5 Left foot operated return system (FM) Electric shift (left hand operated) return system (FE) DC-CDI Electric starter motor and emergency recoil starter Triple phase output alternator SCR shorted, triple phase full wave rectification Battery

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GENERAL INFORMATION Unit: mm (in)

LUBRICATION ITEM Engine oil capacity

STANDARD

After draining After draining/filter change After disassembly

Recommended engine oil

Tip clearance Body clearance Side clearance

Oil pump

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) 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 0.15 (0.006) 0.15−0.22 (0.006−0.009) 0.02−0.09 (0.001−0.004)

SERVICE LIMIT

0.20 (0.008) 0.25 (0.010) 0.12 (0.005)

FUEL SYSTEM ITEM

SPECIFICATIONS

Carburetor identification number Main jet Slow jet Jet needle clip position Pilot screw opening Float level Idle speed Throttle lever free play

VE94A ＃ 130 ＃ 42 3rd groove from top See page 5-15

18.5 mm (0.73 in) 1,400 ± 100 rpm 3−8 mm (1/8−5/16 in) Unit: mm (in)

CYLINDER HEAD/VALVE/CAMSHAFT ITEM Cylinder compression at 450 rpm Valve clearance Valve stem O.D. Valve, valve guide Valve guide I.D. Stem-to-guide clearance

Valve spring

Valve seat width Free length

Arm I.D. Shaft O.D. Arm-to-shaft clearance Cam lobe height Camshaft and Cam follower O.D. cam follower Follower bore I.D. Follower-to-bore clearance Cylinder head warpage Rocker arm

STANDARD 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

667 kPa (6.8 kgf/cm , 97 psi) 0.15 (0.006) 5.475−5.490 (0.2156−0.2161) 5.455−5.470 (0.2148−0.2154) 5.500−5.512 (0.2165−0.2170) 0.010−0.037 (0.0004−0.0015) 0.030−0.057 (0.0012−0.0022) 1.2 (0.05) 36.95 (1.455) 41.67 (1.641) 12.000−12.018 (0.4724−0.4731) 11.966−11.984 (0.4711−0.4718) 0.016−0.052 (0.0006−0.0020) 35.2995−35.4595 (1.38974−1.39604) 22.467−22.482 (0.8845−0.8851) 22.510−22.526 (0.8862−0.8868) 0.028−0.059 (0.0011−0.0023)

SERVICE LIMIT

5.45 (0.215) 5.43 (0.214) 5.52 (0.217) 0.12 (0.005) 0.14 (0.006) 1.5 (0.06) 36.94 (1.454) 40.42 (1.591) 12.05 (0.474) 11.92 (0.469) 0.08 (0.003) 35.13 (1.383) 22.46 (0.884) 22.54 (0.887) 0.07 (0.003) 0.10 (0.004)

1-7

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03/01/08 09:08:11 61HN400A_011

GENERAL INFORMATION Unit: mm (in)

CYLINDER/PISTON ITEM

STANDARD

I.D. Out-of-round Taper Warpage Piston O.D. at 15 (0.6) from bottom Piston, Piston pin hole I.D. Piston pin, Piston pin O.D. piston ring Piston-to-piston pin clearance Piston ring end gap Top Second Oil (side rail) Top Piston ring-to-ring Second groove clearance Cylinder-to-piston clearance Connecting rod small end I.D. Connecting rod-to-piston pin clearance Cylinder

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)

Change clutch

Spring free length

STANDARD TM/FM TE/FE

Disc thickness Plate warpage Outer I.D. Outer guide

Centrifugal clutch

Primary drive gear

I.D. O.D. 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

28.0 (1.10) 31.3 (1.23) 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) 27.000−27.021 (1.0630−1.0638) 26.959−26.980 (1.0614−1.0622)

Starter driven gear boss O.D.

1-8

SERVICE LIMIT 27.0 (1.06) 30.2 (1.19) 2.3 (0.09) 0.20 (0.008) 28.04 (1.104) 22.05 (0.868) 27.92 (1.099) 21.93 (0.863) 126.4 (4.98) 1.3 (0.05) 2.73 (0.107) 26.9 (1.06) 27.05 (1.065) 26.93 (1.060) Unit: mm (in)

ALTERNATOR/STARTER CLUTCH ITEM

78.60 (3.094) 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) 78.43 (3.088) 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) Unit: mm (in)

CLUTCH/GEARSHIFT LINKAGE ITEM

SERVICE LIMIT

STANDARD 45.660−45.673 (1.7976−1.7981)

SERVICE LIMIT 45.65 (1.797)

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GENERAL INFORMATION Unit: mm (in)

CRANKCASE/TRANSMISSION/CRANKSHAFT STANDARD

ITEM Shift fork

Transmission

I.D. Claw thickness Shaft O.D. Gear I.D.

Gear bushing O.D.

Gear-to-bushing clearance Gear bushing I.D.

Mainshaft O.D.

Crankshaft

M4 M5 C1, C2, C3, CR Reverse idle M4 M5 C1, C2, C3, CR M4 M5, C1, C2, C3, CR M4 M5 C3 at M4 at M5 at C3

Countershaft O.D. Reverse idle shaft O.D. M4, C3 Bushing-to-shaft M5 clearance Reverse idle gear-to-shaft clearance Runout Big end side clearance Big end radial clearance

13.000−13.018 (0.5118−0.5125) 4.93−5.00 (0.194−0.197) 12.966−12.984 (0.5105−0.5112) 23.000−23.021 (0.9055−0.9063) 18.000−18.021 (0.7087−0.7095) 25.000−25.021 (0.9843−0.9851) 13.000−13.018 (0.5118−0.5125) 22.959−22.979 (0.9039−0.9047) 17.959−17.980 (0.7070−0.7079) 24.959−24.980 (0.9826−0.9835) 0.021−0.062 (0.0008−0.0024) 0.020−0.062 (0.0008−0.0024) 20.000−20.021 (0.7874−0.7882) 15.000−15.018 (0.5906−0.5913) 22.000−22.021 (0.8661−0.8670) 19.959−19.980 (0.7858−0.7866) 14.966−14.984 (0.5892−0.5899) 21.959−21.980 (0.8645−0.8654) 12.966−12.984 (0.5105−0.5112) 0.020−0.062 (0.0008−0.0024) 0.016−0.052 (0.0006−0.0020) 0.016−0.052 (0.0006−0.0020) 0.05−0.65 (0.002−0.026) 0.006−0.018 (0.0002−0.0007)

SERVICE LIMIT 13.04 (0.513) 4.5 (0.18) 12.96 (0.510) 23.04 (0.907) 18.05 (0.711) 25.05 (0.986) 13.04 (0.513) 22.94 (0.903) 17.94 (0.706) 24.93 (0.981) 0.10 (0.004) 0.10 (0.004) 20.04 (0.789) 15.04 (0.592) 22.04 (0.868) 19.93 (0.785) 14.94 (0.588) 21.93 (0.863) 12.94 (0.509) 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) 0.05 (0.002) 0.8 (0.03) 0.05 (0.002)

1-9

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GENERAL INFORMATION Unit: mm (in)

FRONT WHEEL/SUSPENSION/STEERING (TM/TE model) ITEM Minimum tire tread depth Cold tire pressure Standard Minimum Maximum With cargo Tie-rod distance between the ball joints Toe

STANDARD

4.0 (0.16) 20 kPa (0.20 kgf/cm , 2.9 psi) 17 kPa (0.17 kgf/cm , 2.5 psi) 23 kPa (0.23 kgf/cm , 3.3 psi) 20 kPa (0.20 kgf/cm , 2.9 psi) 355 ± 1 (14.0 ± 0.04) Toe-in: 3 ± 15 (1/8 ± 9/16) Unit: mm (in)

FRONT WHEEL/SUSPENSION/STEERING (FM/FE model) ITEM Minimum tire tread depth Cold tire pressure Standard Minimum Maximum With cargo Tie-rod distance between the ball joints Toe

SERVICE LIMIT

STANDARD

SERVICE LIMIT 4.0 (0.16)

25 kPa (0.25 kgf/cm , 3.6 psi) 22 kPa (0.22 kgf/cm , 3.2 psi) 28 kPa (0.28 kgf/cm , 4.0 psi) 25 kPa (0.25 kgf/cm , 3.6 psi) 346 ± 1 (13.6 ± 0.04) Toe-out: 18 ± 15 (3/4 ± 9/16)

REAR WHEEL/SUSPENSION (TM/TE model) ITEM Minimum tire tread depth Cold tire pressure Standard Minimum Maximum With cargo

STANDARD

SERVICE LIMIT 4.0 mm (0.16 in)

20 kPa (0.20 kgf/cm 17 kPa (0.17 kgf/cm 23 kPa (0.23 kgf/cm 20 kPa (0.20 kgf/cm

, 2.9 psi) , 2.5 psi) , 3.3 psi) , 2.9 psi)

REAR WHEEL/SUSPENSION (FM/FE model) ITEM Minimum tire tread depth Cold tire pressure Standard Minimum Maximum With cargo

1-10

STANDARD

SERVICE LIMIT 4.0 mm (0.16 in)

25 kPa (0.25 kgf/cm 22 kPa (0.22 kgf/cm 28 kPa (0.28 kgf/cm 25 kPa (0.25 kgf/cm

, 3.6 psi) , 3.2 psi) , 4.0 psi) , 3.6 psi)