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Honda Manuals
Offroad Vehicle
TRX350TM Rancher
Service manual
Table Of Contents - Honda TRX350TM Rancher Service Manual
2000-2003 rancher/rancher 4x4
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Table Of Contents
377
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
How To Use This Manual
2
Table Of Contents
2
General Information
3
Service Rules
3
Model Identification
3
Specifications
5
Lubrication Specifications
9
Fuel System Specifications
9
Cylinder Head/Valve/Camshaft Specifications
9
Cylinder/Piston Specifications
10
Clutch/Gearshift Linkage Specifications
10
Alternator/Starter Clutch
10
Crankcase/Transmission/Crankshaft Specifications
11
Front Wheel/Suspension/Steering Specifications
12
Rear Wheel/Suspension Specifications
12
Brake System Specifications
13
Front Driving Mechanism (Fm/Fe Model) Specifications
13
Rear Driving Mechanism Specifications
13
Battery/Charging System Specifications
14
Ignition System Specifications
14
Electric Starter Specifications
14
Lights/Meter/Switches Specifications
14
Torque Values - Standard
15
Torque Values - Engine
15
Torque Values - Frame
16
Tools
18
Lubrication & Seal Points
20
Cable & Harness Routing
24
Cable & Harness Routing - Early Production Of The Te/Fe Model Only
28
Cable & Harness Routing - Except Early Te/Fe Model Production
30
Noise Emission Control System
35
Emission Control Information Label (Usa Only)
36
Frame/Body Panels/Exhaust System - Service Information
37
Frame/Body Panels/Exhaust System - Torque Values
37
Frame/Body Panels/Exhaust System Troubleshooting
37
Body Panel Locations
38
Body Panel Removal Chart
39
Seat Removal
40
Seat Installation
40
Side Cover
40
Fuel Tank Cover
41
Rear Mud Guard (Tm/Fm Models)
41
Center Mud Guard (Te/Fe Models)
42
Front Mud Guard
42
Front Carrier/Carry Pipe
43
Front Fender
43
Rear Carrier
44
Rear Fender
44
Tool Box
45
Inner Fender
45
Outer Fender
45
Headlight Grill
46
Exhaust System Removal
46
Muffler
46
Exhaust Pipe
46
Exhaust System Disassembly/Assembly
47
Maintenance - Specifications
49
Brake Fluid
49
Fuel Hose
49
Maintenance - Torque Values
50
Maintenance Schedule - Trx350 Tm/Te
51
Maintenance Schedule - Trx350 Fm/Fe
52
Throttle Operation
53
Carburetor Choke
54
Air Cleaner
54
Air Cleaner Housing Drain Tube
55
Spark Plug
56
Valve Clearance
56
Engine Oil Level Check
58
Recommended Engine Oil
58
Engine Oil Change & Filter
59
Oil Change
59
Engine Idle Speed
60
Drive Shaft Boots (Fm/Fe Models)
60
Rear Final Gear Case Oil And Differential Oil
60
Differentianl Oil (Fm/Fe Only)
61
Brake Shoe Wear
62
Front Brake
62
Rear Brake
62
Brake System
63
Reverse Lock System
64
Skid Plates
65
Clutch System
65
Suspension
65
Spark Arrester Maintenance
66
Nuts, Bolts, Fasteners
66
Wheels/Tires Maintenance
66
Steering Shaft Holder Bearing
67
Steering System Maintenance
67
Lubrication System Diagram
68
Lubrication System Service Information
69
Lubrication System Specifications
69
Lubrication System Torque Values
69
Lubrication System Troubleshooting
69
Oil Cooler Inspection
70
Oil Cooler Removal/Installation
70
Cooling Fan (Except Usa Tm Model)
70
Cooling Fan (Except Usa Tm Model) Disassembly
71
Cooling Fan (Except Usa Tm Model) Assembly
71
Oil Pump Removal
72
Relief Valve Check
72
Oil Pump Disassembly
73
Oil Pump Inspection
74
Oil Pump Assembly
75
Oil Pump Installation
76
Fuel System Diagram
78
Fuel System Service Information
79
Fuel System: Specifications
79
Fuel System Torque Values
79
Fuel System - Tools Needed
79
Air Cleaner Housing
79
Fuel System Troubleshooting
80
Air Cleaner Housing Removal/Installation
81
Carburetor Removal
82
Carburetor Disassembly/Inspection
83
Air Cut-Off Valve
83
Vacuum Chamber
84
Primer Knob
85
Float Chamber
85
Carburetor Cleaning
87
Carburetor Assembly
87
Float And Jets
88
Float Level Inspection
88
Primer Knob Installation
89
Vacuum Chamber Installation
89
Air Cut-Off Valve Installation
90
Carburetor Installation
92
Pilot Screw Adjustment
93
Idle Drop Procedure
93
High Altitude Adjustment
94
Fuel Tank Removal/Installation
95
Fuel Strainer Screen Cleaning
95
Engine Removal/Installation - Diagram
98
Engine Removal/Installation - Service Information
99
Engine Removal/Installation - Specifications
99
Engine Removal/Installation - Torque Values
99
Engine Removal
100
Engine Installation
103
Cylinder Head/Valve Diagram
104
Cylinder Head/Valve Service Information
105
Cylinder Head/Valve Specifications
105
Cylinder Head/Valve Torque Values
106
Cylinder Head/Valve - Tools Needed
106
Cylinder Head/Valve Troubleshooting
106
Cylinder Compression
107
Cylinder Head Removal
107
Head Cover Removal
107
Cylinder Head And Rocker Arm Holder
108
Cylinder Head Disassembly
109
Rocker Arm Holder
109
Rocker Arm/Shaft Inspection
110
Cylinder Head Inspection
110
Valve Spring Check
111
Valve/Vave Guide Check
111
Valve Guide Replacement
112
Valve Seat Inspection/Refacing
112
Valve Seat Refacing
113
Cylinder Head Assembly
115
Cylinder Head Installation
117
Cylinder Head And Rocker Arm Holder Installation
117
Camshaft Removal
119
Head Cover Cleaning
119
Camshaft Inspection
120
Camshaft Installation
121
Cam Chain Tensioner
121
Cam Follower
121
Cylinder/Piston Diagram
124
Cylinder/Piston Service Information
125
Cylinder/Piston - Specifications
125
Cylinder/Piston Torque Value
125
Cylinder/Piston Troubleshooting
125
Cylinder/Piston Removal
126
Cylinder Inspection
127
Piston/Piston Ring Inspection
128
Piston Ring Installation
129
Cylinder Stud Bolt Replacement
129
Cylinder/Pistion Installation
129
Piston Installation
130
Cylinder Installation
130
Clutch/Gearshift Linkage Diagram
132
Clutch/Gearshift Linkage Sercive Information
133
Clutch/Gearshift Linkage - Specifications
133
Clutch/Gearshift Linkage Torque Values
133
Clutch/Gearshift Linkage - Tools Needed
134
Clutch/Gearshift Linkage Troubleshooting
134
Front Crankcase Cover Removal
135
Centrifugal Clutch Removal
136
One-Way Clutch Inspection
137
Clutch Drum And Lining Inspection
137
Clutch Spring Inspection
138
Weight Spring Inspection
138
Clutch/Gearshift Linkage Assembly
139
Clutch/Gearshift Linkage Installation
140
Change Clutch Removal
141
Lifter Bearing Inspection
142
Lifter Cam Check
143
Clutch Spring Check
143
Clutch Disc Check
143
Clutch Plate Check
144
Clutch Center Check
144
Clutch Outer And Outer Guide Check
144
Primary Drive Gear Check
144
Mainshaft And Crankshaft Check
145
Gearshift Linkage Removal
147
Gearshift Linkage Inspection
147
Stopper Arm And Cam Inspection
147
Gearshift Linkage Installation
148
Gearshift Plate Check
148
Gearshift Spindle And Reverse Stopper Arm
149
Gearshift Spindle Removal
149
Reverse Stopper Arm Removal
149
Gearshift Spindle And Reverse Stopper Arm Inspection
149
Front Crankcase Cover Installation
150
Reverse Stopper Arm Inspection
150
Gearshift Spindle Inspection
150
Alternator/Starter Clutch Diagram
154
Alternator/Starter Clutch Service Information
155
Alternator/Starter Clutch Specification
155
Alternator/Starter Clutch Torque Values
155
Alternator/Starter Clutch Troubleshooting
155
Alternator Stator
155
Flywheel/Starter Clutch
155
Recoil Starter
155
Recoil Starter Removal
156
Recol Starter Disassembly
156
Recoil Starter Assembly
157
Recoil Starter Installation
158
Alternator Cover Removal
159
Stator Removal/Installation
159
Alternator Stator Installation
160
Rear Crankcase Cover Removal
161
Flywheel Removal
161
Starter Clutch Removal/Inspection
162
Starter Clutch Installation
163
Flywheel Installation
163
Rear Crankcase Cover Installation
164
Crankcase/Transmission/Crankshaft Diagram
166
Crankcase/Transmission/Crankshaft Service Information
167
Crankcase/Transmission/Crankshaft - Specifications
167
Crankcase/Transmission/Crankshaft - Tools Needed
168
Crankcase/Transmission/Crankshaft Troubleshooting
168
Crankcase Separation
169
Transmission Disassembly
170
Gear/Bushing/Shaft Inspection
171
Output Shaft/Joint Shaft/Gear Inspection
172
Shift Drum Check
172
Shift Fork Drum Check
172
Shift Fork Shaft Check
172
Countershaft Assembly
173
Sub-Gearshift Spindle Check
173
Crankshaft/Balancer Removal
176
Crankshaft Inspection
176
Crankshaft Bearing Installation
177
Balancer Check
177
Crankcase Bearing Replacement
178
Front Crankcase Removal
178
Rear Crankcase
180
Front Crankcase Cover
181
Crankcase Assembly
182
Front Wheel/Suspension/Steering Diagram
184
Front Wheel/Suspension/Steering Service Information
185
Front Wheel/Suspension/Steering - Specifications
185
Wheel Hub And Knuckle
185
Suspension Arm
185
Front Wheel/Suspension/Steering Torque Values
186
Front Wheel/Suspension/Steering - Tools Needed
186
Front Wheel/Suspension/Steering Troubleshooting
186
Handlebar Removal
187
Handlebar Installation
189
Throttle Housing Disassembly
191
Throttle Housing Assembly
191
Front Wheel Removal
191
Front Wheel Installation
192
Tires Removal
192
Tire Repair
193
Tire Assembly
194
Wheel Hub And Knuckle Removal
195
Wheel Hub And Knuckle Inspection
197
Bearing Replacement
197
Knuckle
198
Wheel Hub And Knuckle Installation
199
Suspension Arm Removal
200
Suspension Arm Inspection
200
Ball Joint Replacement
201
Upper Arm
201
Ball Joint Installation
202
Steering Shaft And Tie-Rod Removal
203
Steering Shaft And Tie-Rod Inspection
204
Bearing Replacement (Tie-Rod)
205
Tie-Rod Assembly
205
Tie-Rod Installation
206
Front Shock Absorber Removal
207
Front Shock Absorber Inspection
208
Front Shock Absorber Installation
208
Rear Wheel/Suspension Diagram
210
Rear Wheel/Suspension Service Information
211
Rear Wheel/Suspension - Specifications
211
Rear Wheel/Suspension Torque Values
211
Rear Wheel/Suspension - Tools Needed
212
Rear Wheel/Suspension Troubleshooting
212
Rear Wheel Removal
213
Rear Wheel Installation
213
Rear Shock Absorber Removal
213
Rear Shock Absorber Inspection
213
Swingarm Removal
214
Rear Shock Absorber Installation
214
Swingarm Inspection
216
Swingarm Bearing Replacement
216
Swingarm Installation
217
Brake System Diagram
220
Brake System Service Information
221
Brake System - Specifications
221
Brake System Torque Values
222
Brake System Troubleshooting
222
Brake Fluid Replacement/Air Bleeding
223
Brake Fluid Draining
223
Brake Fluid Filling/Bleeding
223
Front Master Cylinder Disassembly
224
Front Master Cylinder Inspection
225
Front Master Cylinder Assembly
225
Front Brake Shoes And Drum
226
Brake Drum Removal
226
Shoes And Drum Inspection
226
Brake Drum Check
227
Brake Shoe Replacement
227
Brake Panel And Waterproof Seal Inspection
228
Waterproof Seal Replacement
228
Brake Drum Installation
229
Front Wheel Cylinder And Panel Disassembly
230
Front Wheel Cylinder And Panel Inspection
232
Front Wheel Cylinder And Panel Assembly
232
Rear Brake Shoes And Drum
234
To Remove The Brake Drum
234
Brake Drum Inspection
235
Rear Brake Shoes And Drum Disassembly
235
Rear Brake Shoes And Drum Assembly
236
Rear Brake Pedal Removal
239
Rear Brake Pedal Installation
239
Front Driving Mechanism (Fm/Fe Model) Diagram
240
Front Driving Mechanism (Fm/Fe Model) Service Information
241
Front Driving Mechanism (Fm/Fe Model) - Specifications
241
Front Driving Mechanism (Fm/Fe Model) Torque Values
241
Front Driving Mechanism (Fm/Fe Model) - Tools Needed
242
Front Driving Mechanism (Fm/Fe Model) Troubleshooting
242
Front Drive Shaft Removal
243
Front Drive Shaft Disassembly/Inspection
244
Front Drive Shaft Assembly
245
Front Drive Shaft Installation
247
Differential Removal
248
Differential Disassembly/Inspection
249
Propeller Shaft Removal
249
Propeller Shaft Inspection
249
Backlash Inspection
250
Differential Case Disassembly
251
Bearing Inspection
251
Gear Tooth Contact Pattern Check
252
Differential Inspection
253
Differential Disassembly
254
Differential Components Inspection
254
Differential Cap
254
Differential Housing/Face Cam/Cam Follower
255
Side Cone Spring Check
255
Pinion Gear Removal
256
Case Bearing Replacement
257
Ring Gear Bearing
257
Pinion Gear Bearing And Shim Replacement
257
Pinion Needle Bearing
258
Differential Assembly
259
Pinion Gear Installation
260
Differential - Assembly
261
Differential Case Assembly
262
Differential Installation
263
Propeller Shaft Assembly/Installation
263
Rear Driving Mechanism Diagram
266
Rear Driving Mechanism - Service Information
267
Rear Driving Mechanism - Specifications
267
Rear Driving Mechanism Torque Values
267
Rear Driving Mechanism - Tools Needed
268
Rear Driving Mechanism Troubleshooting
268
Rear Axle Removal
269
Rear Axle Inspection
270
Axbe Bearing Check
270
Axle Bearing Replacement
270
Final Drive Removal
271
Brake Panel
271
Final Drive Inspection
272
Drive Shaft Check
272
Final Drive Disassembly/Inspection
272
Backlash Check
272
Final Gear Case Disassembly
273
Gear Tooth Contact Pattern Inspection
274
To Remove The Pinion Gear
276
Pinion Gear Bearinga And Shim Replacement
276
To Replace The Case Bearing
277
Pinion Needle Bearing Removal
278
Final Drive Assembly
279
Pinion Gear - Installation
279
Ring Gear Clearance Inspection
280
Final Gear Case Assembly
281
Final Drive Installation
282
Rear Axle Installation
283
Battery/Charging System Diagram
286
Battery/Charging System Service Information
287
Battery/Charging System Service Specifications
288
Battery Charging
288
Battery Testing
288
Battery/Charging System Troubleshooting
289
Battery Removal/Installation
290
Voltage Inspection
290
Battery Charging Procedure
290
Charging System Inspection
291
Current Leakage Test
291
Charging Voltage Inspection
291
Alternator Charging Coil Inspection
292
Regulator/Rectifier
292
Wire Harness Inspection
292
Ignition System Diagram
294
Ignition System Service Information
295
Ignition System - Specifications
295
Ignition System Torque
295
Ignition System - Tools Needed
295
Ignition Coil
295
Ignition Timing
295
Ignition System Troubleshooting
296
Ignition System Inspection
297
Ignition Primary Peak Voltage
297
Ignition Coil Replacement
298
Ignition Pulse Generator Peak Voltage
298
Electric Starter Diagram
300
Electric Starter Service Information
301
Electric Starter - Specifications
301
Starter Motor
301
Electric Starter Troubleshooting
302
Starter Motor Removal
304
Starter Motor Disassembly/Inspection
304
Starter Motor Assembly
307
Starter Relay Switch Inspection
309
Starter Motor Installation
309
Diode Inspection
310
Ground Line Check
310
Starter Relay Voltage Check
310
Operation Check
310
Lights/Meters/Switches Diagram
312
Lights/Meters/Switches Service Information
313
Lights/Meters/Switches Specifications
313
Lights/Meters/Switches Torque Values
313
Handlebar Switch
313
Headlight Bulb Replacement
314
Taillight Replacement
314
Headlight Removal/Installation
315
Indicator (Usa Tm/Fm Model Only) Replacement
315
Accessory Socket Inspection
316
Accessory Socket Replacement
316
Headlight Aim
316
Ignition Switch Inspection
317
Ignition Switch Replacement
317
Handlebar Switch Inspection
317
Gear Position Switch Inspection
319
Gear Position Switch Replacement
319
Carburetor Heater Inspection
320
Combination Meter/Speed Sensor (Except Usa Tm/Fm Models)
321
Power/Ground Line Inspection
321
Speedometer/Speed Sensor System Inspection
322
Oil Cooling System/Temperature Indicator Inspection
323
Speed Sensor Replacement
323
Oil Thermosensor Inspection
326
Electric Shift Program (Esp: Te/Fe Model) Diagram
328
Electric Shift Program (Esp: Te/Fe Model) Service Information
329
Electric Shift Program (Esp: Te/Fe Model) Torque Values
329
Electric Shift Program (Esp: Te/Fe Model) Troubleshooting ('00 '02)
330
Flowcharts
331
Electric Shift Does Not Operate
331
Electric Shift Malfunction During Vehicle Operation
334
Electric Shift Does Not Operate When Engaging The Reverse Gear
335
Control Motor Turns When The Shift Switch Is Pushed Down From The Neutral Position With The Reverse Selector Not Engaged
335
Electric Shift Program (Esp) Troubleshooting (After '02)
336
Diagnosis Table
337
Electric Shift Doesn't Operate
338
Gear Indicator Problem
338
Problem Code 1: Ecu (Writing And Recording Circuit)
340
Problem Code 2: Es Shift Switch System (Up And Down)
340
Problem Code 3, 8, 9: Angle Sensor System
341
Problem Codes 4 Or 12: Gear Position Switch System
343
Problem Code 5: Ecu Motor Driver Circuit
344
Problem Code 6: Ecu Fail-Safe Circuit Or Problem Code 7: Ecu Voltage Convert Circuit
345
Problem Code 10: Ignition Pulse Generator System
346
Problem Code 11: Vehicle Speed Sensor System
347
Angle Sensor Inspection
348
Angle Sensor Removal
349
Angle Sensor Installation
349
Control Motor And Reduction Gears Diagram
350
Motor Removal
350
Motor Installation
351
Reduction Gears Removal
351
Reduction Gears Installation
351
Gearshift Switch Inspection
352
Reverse Shift Switch Inspection
353
Reverse Shift Switch Removal/Installation
353
Wiring Diagrams
355
Usa Tm Model Wiring Diagram
356
Usa Fm Model Wiring Diagram
357
Canada Tm/Fm Models Wiring Diagram
358
Usa Te/Fe 00-02 Models Wiring Diagram
359
Usa Te/Fe After 02 Models Wiring Diagram
360
Canada Te/Fe 00-02 Models Wiring Diagram
361
Canada Te/Fe After 02 Models Wiring Diagram
362
Technical Features
363
Dry Sump Mechanism Of Integral Oil Tank In Crankcase
363
Electric Shift Program
363
(Esp: Te/Fe Models)
363
Oil Management System Drawing
364
Oil Supply And Drain Part Detail (Front Crankcase)
364
A.p Suretrac Torque Biasing Front Differential Construction
365
Conventional Type
366
New Type (Suretrac Differential)
366
Differential Operation
367
Electric Shift Program (Esp: Te/Fe Models)
368
Component Diagram
369
Description Of Major Components
370
Angle Sensor
370
Electronic Control Unit
370
Troubleshooting
371
Engine Lacks Power
372
Poor Performance At Low And Idle Speed
373
Poor Performance At High Speed
374
Poor Handling
374
Index
375
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376
377
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Table of Contents
Troubleshooting
Frame/body panels/exhaust system - service information
37
Lubrication system service information
69
Fuel system troubleshooting
80
Cylinder head/valve torque values
106
Cylinder/Piston Service Information
125
Clutch/Gearshift Linkage - Tools Needed
134
Alternator/starter clutch service information
155
Crankcase/transmission/crankshaft - tools needed
168
Front wheel/suspension/steering torque values
186
Rear wheel/suspension - tools needed
212
Brake system torque values
222
Front driving mechanism (FM/FE model) - tools needed
242
Rear driving mechanism - tools needed
268
Battery/charging system troubleshooting
289
Ignition system troubleshooting
296
Electric starter troubleshooting
302
Electric shift program (ESP: TE/FE model) troubleshooting ('00 '02)
330
Electric shift program (ESP) troubleshooting (after '02)
336
Troubleshooting
371
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This manual is also suitable for:
Trx350te
Trx350fm rancher 4x4
Trx350fe rancher 4x4
Trx350tm 2000
Trx350te 2000
Trx350te 2001
...
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Trx350fm 2001
Trx350tm 2002
Trx350fe 2001
Trx350te 2002
Trx350fm 2002
Trx350fe 2002
Trx350tm 2003
Trx350fm 2000
Trx350te 2003
Trx350fm 2003
Trx350fe 2003
Trx350fe 2000
Trx350tm 2001
Trx350te rancher
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