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TRX350D FOREMAN 1988
Honda TRX350D FOREMAN 1988 Manuals
Manuals and User Guides for Honda TRX350D FOREMAN 1988. We have
1
Honda TRX350D FOREMAN 1988 manual available for free PDF download: Service Manual
Honda TRX350D FOREMAN 1988 Service Manual (304 pages)
4 X 4
Brand:
Honda
| Category:
Motorcycle
| Size: 46.76 MB
Table of Contents
How to Use this Manual
3
Contents
3
General Information: General Safety
4
General Information: Service Rules
4
General Information: Model Identification
5
Product View Fourtrax
5
Product View Model Foreman
5
General Information: Specifications
6
General Information: Torque Values
8
Torque Values: Engine
8
Torque Values: Frame
8
General Information: Tools
10
Tools: Special
10
Tools: Common
11
General Information: Cable & Harness Routing
12
General Information: Product View Foreman
17
Lubrication Diagram
19
Lubrication: Service Information
20
Lubrication: Troubleshooting
20
Lubrication: Engine Oil Level
21
Lubrication: Engine Oil & Filter Change
21
Lubrication: Differential/Final Drive Oil
22
Differential/Final Drive Oil: Check
22
Differential/Final Drive Oil: Change
22
Lubrication Points
23
Maintenance: Service Information
24
Maintenance Schedule
25
Maintenance: Fuel Line
26
Maintenance: Throttle Operation
26
Maintenance: Fuel Filter
26
Maintenance: Carburetor Choke
27
Maintenance: Air Cleaner Element
27
Maintenance: Spark Plug
28
Maintenance: Breather Tube
28
Maintenance: Valve Clearance
28
Valve Clearance: Startes Decompressor Free Play Adjustment ('86, '87 Only)
29
Maintenance: Carburetor Idle Speed
30
Maintenance: Cylinder Compression
30
Maintenance: Brake Fluid
30
Maintenance: Brake Shoes
31
Brake Shoes: Brake System & Front Brake
31
Maintenance: Brake System
31
Brake System: Front Brake
31
Brake System: Rear Brake
32
Brake System: Rear Brake Pedal Height
33
Maintenance: Reverse Lock System
33
Maintenance: Clutch System
33
Maintenance: Suspension
34
Maintenance: Spark Arrester Cleaning
34
Maintenance: Nuts/Bolts/Fasteners
34
Maintenance: Wheels/Tires
35
Maintenance: Steering Shaft Holder Bearing
35
Maintenance: Steering System
35
Steering System: Toe-In
35
Steering System: Caster
36
Maintenance: Skid Plate/Guard Plate (after '86)
36
Fuel System Product View
37
Fuel System: Service Information
38
Fuel System: Troubleshooting
39
Fuel Tank: Removal
40
Fuel Pump: Removal
41
Fuel Tank: Installation
41
Fuel Pump: Installation
41
Fuel System: Air Cleaner Case
42
Air Cleaner Case: Removal
42
Air Cleaner Case: Installation
44
Fuel System: Carburetor Removal
45
Fuel System: Carburetor Disassembly
46
Carburetor Disassembly: Choke Valve
46
Carburetor Disassembly: Piston Throttle Valve
46
Carburetor Disassembly: Float and Jets
47
Fuel System: Carburetor Assembly
49
Carburetor Assembly: Float Level Inspection
50
Carburetor Assembly: Throttle Valve Synchronization
50
Fuel System: Carburetor Installation
51
Fuel System: Pilot Screw Adjustment
53
Fuel System: High Altitude Adjustment
53
High Altitude Adjustment: Specifications
53
Engine Removal/Installation Product View
55
Engine Removal/Installation: Service Information
57
Engine Removal
58
Engine Installation
62
Cooling System Product View
65
Cooling System: Service Information
66
Cooling System: Oil Cooler/Oil Hoses
67
Oil Cooler/Oil Hoses: Inspection
67
Oil Cooler/Oil Hoses: Removal
67
Oil Cooler/Oil Hoses: Installation
67
Cooling Fan: Removal
68
Cooling Fan: Disassembly
68
Cooling Fan: Assembly
69
Cooling Fan: Installation
69
Cylinder Head/Valves Product View
71
Cylinder Head/Valves: Service Information
72
Cylinder Head/Valves: Troubleshooting
73
Cylinder Head Cover Removal/Disassembly
74
Cylinder Head Cover Removal/Disassembly: Inspection
75
Cylinder Head/Valves: Camshaft Removal
76
Camshaft Removal: Inspection
76
Cylinder Head Removal
77
Cylinder Head Removal: Disassembly
78
Cylinder Head Removal: Inspection
78
Valve Guide Replacement
79
Valve Seat Inspection/Refacing
80
Cylinder Head Assembly
82
Cylinder Head Installation
83
Cylinder Head/Valves: Camshaft Installation
84
Cylinder Head Cover Assembly/Installation
86
Cylinder/Piston Product View
89
Cylinder/Piston: Specifications
90
Cylinder/Piston: Troubleshooting
90
Cylinder: Removal
91
Cylinder: Inspection
91
Piston: Removal
92
Piston Ring Inspection
92
Piston/Cylinder: Installation
93
Clutch/Oil Pump/Kick Starter Product View
97
Clutch/Oil Pump/Kick Starter: Service Information
98
Clutch/Oil Pump/Kick Starter: Troubleshooting
99
Clutch/Oil Pump/Kick Starter: Right Crankcase Cover Removal
100
Centrifugal Clutch: Removal
101
Centrifugal Clutch: Inspection
102
Centrifugal Clutch: Installation
104
Change Clutch: Removal
105
Change Clutch: Inspection
106
Change Clutch: Installation
107
Change Clutch Lifter Mechanism: Disassembly
109
Change Clutch Lifter Mechanism: Assembly
110
Clutch/Oil Pump/Kick Starter: Right Crackcare Cover Bearing/Oil Seal/Follower Cam
111
Right Crackcare Cover Bearing/Oil Seal/Follower Cam: Inspection
111
Right Crackcare Cover Bearing/Oil Seal/Follower Cam: Bearing Replacement
112
Right Crackcare Cover Bearing/Oil Seal/Follower Cam: Follower Cam ('86, '87 Only)
112
Clutch/Oil Pump/Kick Starter: Reverse Lock Mechanism
113
Oil Pump/Primary Drive Gear: Removal
113
Reverse Lock Mechanism: Removal
113
Reverse Lock Mechanism: Installation
113
Oil Pump/Primary Drive Gear: Primary Drive Gear Inspection
114
Oil Pump Disassembly
115
Oil Pump Inspection
115
Oil Pump Assembly/Installation
116
Kick Starter: Removal
117
Kick Starter: Disassembly
118
Kick Starter: Inspection
118
Kick Starter: Assembly
119
Kick Starter: Installation
120
Clutch/Oil Pump/Kick Starter: Oil Filter Screen
121
Clutch/Oil Pump/Kick Starter: Richt Crankcase Cover Installation
121
Alternator/Starter Clutch/Gearshift Linkage Product View
123
Alternator/Starter Clutch/Gearshift Linkage: Service Information
124
Alternator/Starter Clutch/Gearshift Linkage: Thoubleshooting
124
Alternator/Starter Clutch/Gearshift Linkage: Starter Reduction Gear
125
Starter Reduction Gear: Removal
125
Starter Reduction Gear: Inspection
125
Starter Reduction Gear: Bearing Replacement (after '86)
125
Starter Reduction Gear: Installation
126
Alternator/Starter Clutch/Gearshift Linkage: Left Crankcase Cover Removal
127
Alternator: Stator/Pulse Generator Removal
129
Alternator: Stator/Pulse Generator Installation
129
Alternator: Flywheel Removal
130
Alternator: Flywheel Installation
131
Starter Clutch: Removal
131
Starter Clutch: Inspection
132
Starter Clutch: Installation
132
Gearshift Linkage: Removal
133
Gearshift Linkage: Installation
134
Alternator/Starter Clutch/Gearshift Linkage: Left Crankcase Cover Installation
136
Crankcase/Crankshaft/Transmission Product View
139
Crankcase/Crankshaft/Transmission: Service Information
140
Crankcase/Crankshaft/Transmission: Thoubleshooting
142
Crankcase Separation
143
Crankshaft/Balancer: Removal
144
Crankshaft/Balancer: Inspection
144
Crankshaft/Balancer: Bearing Replacement
145
Crankshaft/Balancer: Installation
146
Transmission: Removal
147
Transmission: Disassembly
148
Transmission: Inspection
148
Transmission: Bearing Replacement
150
Transmission: Assembly/Installation
151
Crankcase Assembly
152
Crankcase/Crankshaft/Transmission: Output Gear
153
Output Gear: Backlash Inspection
153
Output Gear: Output Drive Gear Disassembly
154
Output Gear: Drive Gear Bearing Replacement
156
Output Gear: Output Driven Gear Disassembly
156
Output Gear: Driven Gear Bearing Replacement
157
Output Gear: Gear Case Bearing Replacement
158
Output Gear: Driver Gear Shaft Bearing Replacement
159
Output Gear Case Assembly
160
Output Gear: Gear Tooth Contract Pattern Check
162
Front Wheel/Suspension/Steering Product View
165
Front Wheel/Suspension/Steering: Service Information
167
Front Wheel/Suspension/Steering: Troubleshooting
168
Front Wheel/Suspension/Steering: Handlebar
169
Handlebar: Removal
169
Handlebar: Installation
169
Front Wheel/Suspension/Steering: Throttle Housing
171
Throttle Housing: Disassembly
171
Throttle Housing: Assembly
171
Front Wheel: Removal
172
Front Wheel: Installation
172
Front Wheel/Suspension/Steering: Tires
173
Tires: Removal (U.S.A. Only)
173
Tires: Removal (Except U.S.A.)
174
Tire Repair
175
Tires: Assembly
177
Front Wheel/Suspension/Steering: Tie-Rod
177
Tie-Rod: Removal
177
Tie-Rod: Inspection
177
Tie-Rod: Assembly
178
Tie-Rod: Installation
178
Tie-Rod: Toe-In Adjustment
179
Tie-Rod: Front Wheel Turning Angle Adjustment
179
Front Wheel/Suspension/Steering: Knuckle/Knuckle Holder/Drive Shaft
179
Knuckle Removal
179
Knuckle Bearing Inspection
180
Knuckle Bearing and Dust Seal Replacement
180
Knuckle Holder/Drive Shaft Removal
181
Knuckle/Knuckle Holder/Drive Shaft: Drive Shaft Boot Replacement
181
Knuckle Holder Dust Seal Replacement
182
Knuckle Holder Installation
183
Knuckle Installation
183
Front Wheel/Suspension/Steering: Front Shock Absorber
184
Front Shock Absorber: Removal
184
Front Shock Absorber: Disassembly
184
Front Shock Absorber: Assembly
185
Front Shock Absorber: Inspection
185
Front Shock Absorber: Installation
185
Front Wheel/Suspension/Steering: Swingarm
186
Swingarm: Removal
186
Swingarm: Pilot Bearing Replacement
187
Swingarm: Drive Shaft Inspection
188
Swingarm: Swingarm Installation
188
Steering Stem: Removal
190
Steering Stem: Bearing Inspection
191
Steering Stem: Bearing Replacement
191
Steering Stem: Installation
192
Brakes Product View
193
Brakes: Service Information
194
Brakes: Troubleshooting
195
Front Brake: Brake Fluid Draining
196
Front Brake: Brake Fluid Filling
196
Front Brake: Brake Bleeding
197
Front Brake: Brake Hose/Pipe Inspection
197
Front Brake: Front Brake Drum Removal/Inspection
198
Front Brake: Front Brake Panel Inspection (after '87)
198
Front Brake Waterproof Seal Inspection (after '87)
199
Front Brake Waterproof Seal Replacement (after '87)
199
Front Brake: Front Wheel Hub Removal
200
Front Brake: Front Wheel Hub Installation
200
Front Brake: Brake Drum Installation
200
Brake Shoes/Wheel Cylinder/Adjuster Assembly: Removal/Inspection
201
Brake Shoes/Wheel Cylinder/Adjuster Assembly: Assembly/Installation
202
Brake Adjustment
204
Brakes: Master Cylinder
204
Master Cylinder: Disassembly
204
Master Cylinder: Inspection
205
Master Cylinder: Assembly
205
Rear Brake: Removal
206
Rear Brake: Inspection
206
Rear Brake: Disassembly
207
Rear Brake: Brake Panel Assembly
208
Rear Brake Pedal: Removal
211
Rear Brake Pedal: Installation
211
Rear Wheel/Suspension Product View
213
Rear Wheel/Suspension: Service Information
214
Rear Wheel/Suspension: Troubleshooting
215
Rear Wheel: Removal
216
Rear Wheel: Installation
216
Rear Wheel/Suspension: Rear Axle/Wheel Bearing
217
Rear Axle/Wheel Bearing: Removal
217
Rear Axle Inspection
218
Rear Axle/Wheel Bearing: Rear Wheel Bearing Inspection
218
Rear Axle/Wheel Bearing: Rear Wheel Bearing Replacement
218
Rear Axle/Wheel Bearing: Installation
219
Rear Shock Absorber: Removal
220
Rear Shock Absorber: Spring Free Length Inspection
221
Rear Shock Absorber: Assembly
221
Rear Shock Absorber: Installation
221
Rear Wheel/Suspension: Swingarm
222
Swingarm: Pivot Bearing Replacement ('86)
223
Swingarm: Installation
224
Front Differential/Final Drive Product View
227
Front Differential/Final Drive: Service Information
228
Front Differential/Final Drive: Troubleshooting
229
Front Differential Removal: Differential Assembly Inspection
230
Front Differential Removal: Disassembly
231
Front Differential Removal: Inspection
232
Front Differential Removal: Assembly
232
Front Differential/Final Drive: Pinion Gear Removal
234
Pinion Bearing Removal
235
Front Differential/Final Drive: Care Bearing and Oil Seal Replacement
235
Front Differential/Final Drive: Pinion Gear Installation
236
Pinion Gear Assembly
236
Pinion Gear Installation: Gear Tooth Contact Pattern Check
237
Pinion Gear Installation: Backlash Inspection
239
Front Differential Installation
240
Final Drive Removal
240
Final Drive Disassembly
240
Final Drive Assembly: Pinion Gear Assembly
244
Sase Oil Seal Replacement
244
Final Drive Assembly: Ring Gear Assembly
245
Final Drive Assembly: Gear Tooth Contact Pattern Check
246
Final Drive Assembly: Backlash Inspection
248
Final Drive Installation
249
Bumpers/Fenders/Carriers: Front/Rear Bumpers
250
Bumpers/Fenders/Carriers: Front Fender
250
Front Fender: Removal
250
Front Fender: Installation
252
Rear Fender: Removal
253
Rear Fender: Installation '86-'88
254
Rear Fender: Installation after '88
255
Bumpers/Fenders/Carriers: Front/Rear Carriers (Foreman)
256
Front/Rear Carriers (Foreman): Removal
256
Front/Rear Carriers (Foreman): Installation
256
Ignition System: System Diagram
257
System Diagram: CDI System (Fourtrax)
257
System Diagram: DC-CDI System (Foreman)
258
Ignition System: Service Information
259
Ignition System: Troubleshooting
260
Ignition System: CDI Unit System Inspection
261
CDI Unit System Inspection: Fourtrax/Foreman
261
Ignition Coil: Removal & Inspection
261
Ignition Coil: Installation
262
Ignition System: Pulse Generator
262
Ignition System: Alternator
262
Alternator: Exciter Coil Inspection (Fourtrax)
262
Alternator: Revolution Research Line Inspection (after '87: Foremen)
263
Ignition Timing
263
Battery/Charging System: System Diagram
265
Battery/Charging System: Service Information
266
Battery/Charging System: Troubleshooting
267
Battery: Removal/Inspection
268
Battery: Charging
268
Battery: Installation
268
Charging System: Regulated Voltage Inspection
269
Battery/Charging System: Alternator Charging Coil
269
Battery/Charging System: Regulator/Rectifier
269
Regulator/Rectifier: Voltage Inspection
269
Starter System: System Diagram
271
Starter System: Service Information
272
Starter System: Troubleshooting
273
Starter Motor: Removal
274
Starter Motor: Inspection
274
Starter Motor: Assembly/Installation
276
Starter Relay Switch: Operation Inspection
277
Starter Relay Switch: Voltage Inspection
277
Starter Relay Switch: Continuity Inspection
277
Lights/Switches: Oil Cooling System Diagram
279
Lights/Switches: Service Information
280
Lights/Switches: Troubleshooting
281
Lights/Switches: Headlight
282
Headlight: Bulb Replacement
282
Headlight: Case Removal/Installation (Fourtrax)
282
Front Accessory Light/Taillight: Bulb Replacement
283
Front Accessory Light/Taillight: Case Removal/Installation
283
Indicator Lamp: Bulb Replacement
283
Lights/Switches: Indicator Lamp
283
Neutral Switch/Reverse Switch
284
Neutral Switch/Reverse Switch: Removal
284
Neutral Switch/Reverse Switch: Inspection
284
Neutral Switch/Reverse Switch: Installation
284
Ignition Switch
285
Handlebar Switch: Engine Stop Switch (Fourtrax/Foreman)
285
Handlebar Switch: Lighting Switch (Fourtrax)
285
Handlebar Switch: Lighting/Dimmer Switches (Foreman)
285
Lights/Switches: Oil Temperature Sensor
286
Lights/Switches: Fan Motor Control Unit
286
Fan Motor Control Unit: Voltage Inspection
286
Lights/Switches: Fuel Pump/Fuel Cut Relay
287
Fuel Cut Relay Inspection
287
Fuel Pump Inspection
287
Lights/Switches: Fuel Unit/Meter (Foreman)
288
Fuel Unit Inspection
288
Fuel Meter Inspection
289
Fuel Unit/Meter (Foreman): Removal
289
Wiring Diagrams: '86 Fourtrax
290
Wiring Diagrams: '87 Fourtrax
291
Wiring Diagrams: '87 Foreman
292
Wiring Diagrams: after '87 Foreman
293
Technical Features: Differential
294
Technical Features: Cooling System
296
Technical Features: DC-CDI System (Foreman)
297
DC-CDI System (Foreman): Description
297
Troubleshooting: Poor Performance at Low and Idle Speeds
298
Troubleshooting: Poor Performance at High Speeds
299
Troubleshooting: Poor Handling
299
Troubleshooting: Engine Does Not Start or Is Hard to Start
300
Troubleshooting: Engine Lacks Power
301
Index
302
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