Honda TRX350TE 2002 ATV Parts Manuals

Manuals and User Guides for Honda TRX350TE 2002 ATV Parts. We have 1 Honda TRX350TE 2002 ATV Parts manual available for free PDF download: Service Manual

Honda TRX350TE 2002 Service Manual

Honda TRX350TE 2002 Service Manual (377 pages)

2000-2003 Rancher/Rancher 4x4

Brand: Honda | Category: Offroad Vehicle | Size: 23 MB

Table of Contents

Table of Contents
2
How to Use this Manual
2
General Information
3
- Model Identification
  3
- Service Rules
  3
- Specifications
  5
- Cylinder Head/Valve/Camshaft Specifications
  9
- Fuel System Specifications
  9
- Lubrication Specifications
  9
- Alternator/Starter Clutch
  10
- Clutch/Gearshift Linkage Specifications
  10
- Cylinder/Piston Specifications
  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
- Electric Starter Specifications
  14
- Ignition System Specifications
  14
- Lights/Meter/Switches Specifications
  14
- Torque Values - Engine
  15
- Torque Values - Standard
  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 Installation
  40
- Seat Removal
  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
- Inner Fender
  45
- Outer Fender
  45
  - Tool Box
    45
  - Exhaust Pipe
    46
  - Exhaust System Removal
    46
  - Headlight Grill
    46
  - Muffler
    46
  - Exhaust System Disassembly/Assembly
    47
- Brake Fluid
  49
- Fuel Hose
  49
- Throttle Operation
  53
  - Air Cleaner
    54
  - Carburetor Choke
    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
  - Drive Shaft Boots (FM/FE Models)
    60
- Engine Idle Speed
  60
  - Rear Final Gear Case Oil and Differential Oil
    60
  - Differentianl Oil (FM/FE Only)
    61
  - Brake Fluid
    62
  - Brake Shoe Wear
    62
- Front Brake
  62
- Rear Brake
  62
  - Brake System
    63
  - Front Brake
    63
  - Rear Brake
    63
- Reverse Lock System
  64
- Clutch System
  65
- Skid Plates
  65
- Suspension
  65
- Nuts, Bolts, Fasteners
  66
  - Spark Arrester Maintenance
    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
  - Cooling Fan (Except USA TM Model)
    70
  - Oil Cooler Inspection
    70
  - Oil Cooler Removal/Installation
    70
  - Cooling Fan (Except USA TM Model) Assembly
    71
  - Cooling Fan (Except USA TM Model) Disassembly
    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
- Air Cleaner Housing
  79
  - Fuel System - Tools Needed
    79
  - Fuel System Service Information
    79
  - Fuel System Torque Values
    79
  - Fuel System: Specifications
    79
  - Fuel System Troubleshooting
    80
  - Air Cleaner Housing Removal/Installation
    81
  - Carburetor Removal
    82
  - Air Cut-Off Valve
    83
  - Carburetor Disassembly/Inspection
    83
  - Vacuum Chamber
    84
  - Float Chamber
    85
  - Primer Knob
    85
- Carburetor Assembly
  87
  - Carburetor Cleaning
    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
  - Idle Drop Procedure
    93
- Pilot Screw Adjustment
  93
- High Altitude Adjustment
  94
- Engine Installation
  103
  - Cylinder Head/Valve Diagram
    104
  - Cylinder Head/Valve Service Information
    105
  - Cylinder Head/Valve Specifications
    105
  - Cylinder Head/Valve - Tools Needed
    106
  - Cylinder Head/Valve Torque Values
    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
  - Cylinder Head Inspection
    110
  - Rocker Arm/Shaft 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 and Rocker Arm Holder Installation
    117
  - Cylinder Head Installation
    117
  - Camshaft Removal
    119
  - Head Cover Cleaning
    119
  - Camshaft Inspection
    120
  - Cam Chain Tensioner
    121
  - Cam Follower
    121
- Camshaft Installation
  121
  - Cylinder/Piston Diagram
    124
  - Cylinder/Piston - Specifications
    125
  - Cylinder/Piston Service Information
    125
  - Cylinder/Piston Torque Value
    125
  - Cylinder/Piston Troubleshooting
    125
  - Cylinder/Piston Removal
    126
  - Cylinder Inspection
    127
  - Piston/Piston Ring Inspection
    128
  - Cylinder Stud Bolt Replacement
    129
  - Cylinder/Pistion Installation
    129
  - Piston Ring Installation
    129
  - Cylinder Installation
    130
  - Piston Installation
    130
  - Clutch/Gearshift Linkage Diagram
    132
  - Clutch/Gearshift Linkage - Specifications
    133
  - Clutch/Gearshift Linkage Sercive Information
    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
  - Clutch Drum and Lining Inspection
    137
  - One-Way Clutch 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
  - Clutch Disc Check
    143
  - Clutch Spring Check
    143
  - Lifter Cam Check
    143
  - Clutch Center Check
    144
  - Clutch Outer and Outer Guide Check
    144
  - Clutch Plate Check
    144
  - Primary Drive Gear Check
    144
  - Mainshaft and Crankshaft Check
    145
  - Gearshift Linkage Inspection
    147
  - Gearshift Linkage Removal
    147
  - Stopper Arm and Cam Inspection
    147
  - Gearshift Linkage Installation
    148
  - Gearshift Plate Check
    148
  - Gearshift Spindle and Reverse Stopper Arm
    149
  - Gearshift Spindle and Reverse Stopper Arm Inspection
    149
  - Gearshift Spindle Removal
    149
  - Reverse Stopper Arm Removal
    149
  - Front Crankcase Cover Installation
    150
  - Gearshift Spindle Inspection
    150
  - Reverse Stopper Arm Inspection
    150
  - Alternator/Starter Clutch Diagram
    154
- 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
  - Alternator Stator
    159
  - Stator Removal/Installation
    159
  - Alternator Stator Installation
    160
  - Flywheel Removal
    161
  - Flywheel/Starter Clutch
    161
  - Rear Crankcase Cover Removal
    161
  - Starter Clutch Removal/Inspection
    162
  - Flywheel Installation
    163
  - Starter Clutch Installation
    163
  - Rear Crankcase Cover Installation
    164
  - Crankcase/Transmission/Crankshaft Diagram
    166
  - Crankcase/Transmission/Crankshaft - Specifications
    167
  - Crankcase/Transmission/Crankshaft Service Information
    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 Inspection
    176
  - Crankshaft/Balancer Removal
    176
  - Balancer Check
    177
  - Crankshaft Bearing Installation
    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 - Specifications
    185
  - Front Wheel/Suspension/Steering Service Information
    185
  - Suspension Arm
    185
  - Wheel Hub and Knuckle
    185
  - Front Wheel/Suspension/Steering - Tools Needed
    186
  - Front Wheel/Suspension/Steering Torque Values
    186
  - Front Wheel/Suspension/Steering Troubleshooting
    186
  - Handlebar Removal
    187
  - Handlebar Installation
    189
  - Front Wheel Removal
    191
  - Throttle Housing Assembly
    191
  - Throttle Housing Disassembly
    191
  - Front Wheel Installation
    192
  - Tires Removal
    192
  - Tire Repair
    193
  - Tire Assembly
    194
  - Wheel Hub and Knuckle Removal
    195
  - Bearing Replacement
    197
  - Wheel Hub and Knuckle Inspection
    197
  - Knuckle
    198
  - Wheel Hub and Knuckle Installation
    199
  - Suspension Arm Inspection
    200
  - Suspension Arm Removal
    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 - Specifications
    211
  - Rear Wheel/Suspension Service Information
    211
  - Rear Wheel/Suspension Torque Values
    211
  - Rear Wheel/Suspension - Tools Needed
    212
  - Rear Wheel/Suspension Troubleshooting
    212
  - Rear Shock Absorber Inspection
    213
  - Rear Shock Absorber Removal
    213
  - Rear Wheel Installation
    213
  - Rear Wheel Removal
    213
  - Rear Shock Absorber Installation
    214
  - Swingarm Removal
    214
  - Swingarm Bearing Replacement
    216
  - Swingarm Inspection
    216
  - Swingarm Installation
    217
  - Brake System Diagram
    220
  - Brake System - Specifications
    221
  - Brake System Service Information
    221
  - Brake System Torque Values
    222
  - Brake System Troubleshooting
    222
  - Brake Fluid Draining
    223
  - Brake Fluid Filling/Bleeding
    223
  - Brake Fluid Replacement/Air Bleeding
    223
  - Front Master Cylinder Disassembly
    224
  - Front Master Cylinder Assembly
    225
  - Front Master Cylinder Inspection
    225
  - Brake Drum Removal
    226
  - Front Brake Shoes and Drum
    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 Assembly
    232
  - Front Wheel Cylinder and Panel Inspection
    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 Installation
    239
  - Rear Brake Pedal Removal
    239
  - Front Driving Mechanism (FM/FE Model) Diagram
    240
  - Front Driving Mechanism (FM/FE Model) - Specifications
    241
  - Front Driving Mechanism (FM/FE Model) Service Information
    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 Inspection
    249
  - Propeller Shaft Removal
    249
  - Backlash Inspection
    250
  - Bearing Inspection
    251
  - Differential Case Disassembly
    251
  - Gear Tooth Contact Pattern Check
    252
  - Differential Inspection
    253
  - Differential Cap
    254
  - Differential Components Inspection
    254
  - Differential Disassembly
    254
  - Differential Housing/Face Cam/Cam Follower
    255
  - Side Cone Spring Check
    255
  - Pinion Gear Removal
    256
  - Case Bearing Replacement
    257
  - Pinion Gear Bearing and Shim Replacement
    257
  - Ring Gear Bearing
    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
  - Axbe Bearing Check
    270
  - Axle Bearing Replacement
    270
  - Rear Axle Inspection
    270
  - Brake Panel
    271
  - Final Drive Removal
    271
  - Backlash Check
    272
  - Drive Shaft Check
    272
  - Final Drive Disassembly/Inspection
    272
  - Final Drive Inspection
    272
  - Final Gear Case Disassembly
    273
  - Gear Tooth Contact Pattern Inspection
    274
  - Pinion Gear Bearinga and Shim Replacement
    276
  - To Remove the Pinion Gear
    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
    288
  - Battery Testing
    288
  - Battery/Charging System Service Specifications
    288
  - Battery/Charging System Troubleshooting
    289
  - Battery Charging Procedure
    290
  - Battery Removal/Installation
    290
  - Voltage Inspection
    290
- Charging System Inspection
  291
  - Charging Voltage Inspection
    291
  - Current Leakage Test
    291
  - Alternator Charging Coil Inspection
    292
  - Regulator/Rectifier
    292
  - Wire Harness Inspection
    292
  - Ignition System Diagram
    294
- Ignition Coil
  295
  - Ignition System - Specifications
    295
  - Ignition System - Tools Needed
    295
  - Ignition System Service Information
    295
  - Ignition System Torque
    295
- Ignition Timing
  295
  - Ignition System Troubleshooting
    296
  - Ignition Primary Peak Voltage
    297
  - Ignition System Inspection
    297
  - Ignition Coil Replacement
    298
  - Ignition Pulse Generator Peak Voltage
    298
  - Ignition Timing
    299
  - Electric Starter Diagram
    300
  - Electric Starter - Specifications
    301
  - Electric Starter Service Information
    301
  - Starter Motor
    301
  - Electric Starter Troubleshooting
    302
  - Starter Motor Disassembly/Inspection
    304
  - Starter Motor Removal
    304
  - Starter Motor Assembly
    307
  - Starter Motor Installation
    309
  - Starter Relay Switch Inspection
    309
  - Diode Inspection
    310
  - Ground Line Check
    310
  - Operation Check
    310
  - Starter Relay Voltage Check
    310
  - Lights/Meters/Switches Diagram
    312
- Handlebar Switch
  313
- Headlight Bulb Replacement
  314
- Taillight Replacement
  314
- Indicator (USA TM/FM Model Only) Replacement
  315
- Headlight Removal/Installation
  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
- Dry Sump Mechanism of Integral Oil Tank in Crankcase
  363
Electric Shift Program
363
(ESP: TE/FE Models)
363
Technical Features
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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