2000-2003 Honda TRX350 Rancher factory service manual
Complete, detailed, searchable and indexed factory service manual for Honda TRX350 Rancher 2000-2003
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)
TRX350TM/TE Rancher
TRX350FM/FE Rancher 4X4
Manual chapters:
CONTENTS
1. GENERAL INFORMATION
- SERVICE RULES
- MODEL IDENTIFICATION
- SPECIFICATIONS
- TORQUE VALUES
- TOOLS
- LUBRICATION & SEAL POINTS
- CABLE & HARNESS ROUTING
- EMISSION CONTROL SYSTEMS
- EMISSION CONTROL INFORMATION LABEL
2. FRAME/BODY PANELS/EXHAUST SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- BODY PANEL LOCATIONS
- SEAT
- SIDE COVER
- FUEL TANK COVER
- READ MUD GUARD (TM/FM models)
- CENTER MUD GUARD (TE/FE models)
- FRONT MUD GUARD
- FRONT CARRIER/CARRY PIPE
- FRONT FENDER
- REAR CARRIER
- REAR FENDER
- TOOL BOX
- INNER FENDER
- OUTER FENDER
- HEADLIGHT GRILL
- EXHAUST SYSTEM
3. MAINTENANCE
- SERVICE INFORMATION
- MAINTENANCE SCHEDULE
- FUEL HOSE
- THROTTLE OPERATION
- CARBURETOR CHOKE
- AIR CLEANER
- AIR CLEANER HOUSING DRAIN TUBE
- SPARK PLUG
- VALVE CLEARANCE
- ENGINE OIL
- ENGINE OIL FILTER
- ENGINE IDLE SPEED
- DRIVER SHAFT BOOTS (FM/FE models)
- REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL
- BRAKE FLUID
- BRAKE SHOE WEAR
- BRAKE SYSTEM
- REVERSE LOCKING SYSTEM
- SKID PLATES
- CLUTCH SYSTEM
- SUSPENSION
- SPARK ARRESTOR
- NUTS, BOLTS, FASTENERS
- WHEELS/TIRES
- STEERING SHAFT HOLDER BEARING
- STEERING SYSTEM
4. LUBRICATION SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- OIL COOLER
- COOLING FAN
- OIL PUMP
5. FUEL SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- AIR CLEANER HOUSING
- CARBURETOR REMOVAL
- CARBURETOR DISASSEMBLY/INSPECTION
- CARBURETOR ASSEMBLY
- CARBURETOR INSTALLATION
- PILOT SCREW ADJUSTMENT
- HIGH ALTITUDE ADJUSTMENT
- FUEL TANK
6. ENGINE REMOVAL/INSTALLATION
- SERVICE INFORMATION
- ENGINE REMOVAL
- ENGINE INSTALLATION
7. CYLINDER HEAD/VALVE
- SERVICE INFORMATION
- TROUBLESHOOTING
- CYLINDER COMPRESSION
- CYLINDER HEAD REMOVAL
- CYLINDER HEAD DISASSEMBLY
- VALVE GUIDE REPLACEMENT
- VALVE SEAT INSPECTION/REFACING
- CYLINDER HEAD ASSEMBLY
- CYLINDER HEAD INSTALLATION
- CAMSHAFT REMOVAL
- CAMSHAFT INSTALLATION
8. CYLINDER/PISTON
- SERVICE INFORMATION
- TROUBLESHOOTING
- CYLINDER/PISTON REMOVAL
- CYLINDER/PISTON INSTALLATION
9. CLUTCH/GEARSHIFT LINKAGE
- SERVICE INFORMATION
- TROUBLESHOOTING
- FRONT CRANKCASE COVER REMOVAL
- CENTRIFUGAL CLUTCH
- CHANGE CLUTCH
- GEARSHIFT LINKAGE
- GEARSHIFT SPINDLE AND REVERSE STOPPER ARM
- FRONT CRANKCASE COVER INSTALLATION
10. ALTERNATOR/STARTER CLUTCH
- SERVICE INFORMATION
- TROUBLESHOOTING
- RECOIL STARTER
- ALTERNATOR STATOR
- FLYWHEEL/STARTER CLUTCH
11. CRANKCASE/TRANSMISSION/CRANKSHAFT
- SERVICE INFORMATION
- TROUBLESHOOTING
- CRANKCASE SEPARATION
- TRANSMISSION
- CRANSHAFT/BALANCER
- CRANKCASE BEARING REPLACEMENT
- CRANKCASE ASSEMBLY
12. FRONT WHEEL/SUSPENSION/STEERING
- SERVICE INFORMATION
- TROUBLESHOOTING
- HANDLEBAR
- THROTTLE HOUSING
- FRONT WHEEL
- TIRES
- WHEEL HUB AND KNUCKLE
- SUSPENSION ARM
- STEERING SHAFT AND TIE-ROD
- FRONT SHOCK ABSORBER
13. REAR WHEEL/SUSPENSION
- SERVICE INFORMATION
- TROUBLESHOOTING
- REAR WHEEL
- REAR SHOCK ABSORBER
- SWINGARM
14. BRAKE SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- BRAKE FLUID REPLACEMENT/AIR BLEEDING
- FRONT MASTER CYLINDER
- FRONT BRAKE SHOES AND DRUM
- FRONT WHEEL CYLINDER AND PANEL
- REAR BRAKE SHOES AND DRUM
- REAR BRAKE PEDAL
15. FRONT DRIVING MECHANISM (FM/FE models)
- SERVICE INFORMATION
- TROUBLESHOOTING
- FRONT DRIVE SHAFT
- DIFFERENTIAL REMOVAL
- DIFFERENTIAL DISASSEMBLY/INSPECTION
- CASE BEARING REPLACEMENT
- DIFFERENTIAL ASSEMBLY
- DIFFERENTIAL INSTALLATION
16. REAR DRIVING MECHANISM
- SERVICE INFORMATION
- TROUBLESHOOTING
- REAR AXLE REMOVAL
- FINAL DRIVE REMOVAL
- FINAL DRIVE DISASSEMBLY/INSPECTION
- CASE BEARING REPLACEMENT
- FINAL DRIVE ASSEMBLY
- FINAL DRIVE INSTALLATION
- REAR AXLE INSTALLATION
17. BATTERY/CHARGING SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- BATTERY
- CHARGING SYSTEM INSPECTION
- REGULATOR/RECTIFIER
- ALTERNATOR CHARGING COIL
18. IGNITION SYSTEM
- SERVICE INFORMATION
- TROUBLESHOOTING
- IGNITION SYSTEM INSPECTION
- IGNITION COIL
- IGNITION TIMING
19. ELECTRIC STARTER
- SERVICE INFORMATION
- TROUBLESHOOTING
- STARTER MOTOR
- STARTER RELAY SWITCH
- DIODE
20. LIGHTS/METERS/SWITCHES
- SERVICE INFORMATION
- BULB REPLACEMENT
- HEADLIGHT
- ACCESSORY SOCKET
- IGNITION SWITCH
- HANDLEBAR SWITCH
- GEAR POSITION SWITCH
- CARBURETOR HEATER
- COMBINATION METER/SPEED SENSOR
- OIL COOLING SYSTEM/TEMPERATURE INDICATOR
21. ELECTRIC SHIFT PROGRAM
- SERVICE INFORMATION
- TROUBLESHOOTING ('00-'02)
- TROUBLESHOOTING (After '02)
- ANGLE SENSOR
- CONTROL MOTOR AND REDUCTION GEARS
- GEARSHIFT SWITCH
- REVERSE SHIFT SWITCH
22. WIRING DIAGRAMS
- USA TM MODEL
- USA FM MODEL
- CANADA TM/FM MODELS
- USA TE/FE 00-02 MODELS
- USA TE/FE AFTER 02 MODELS
- CANADA TE/FE 00-02 MODELS
- CANADA TE/FE AFTER 02 MODELS
23. TECHNICAL FEATURES
- DRY SUMP MECHANISM OF INTEGRAL OIL TANK IN CRANKCASE
- A.P. SURETRAC TORQUE BIASING LIMITED SLIP DIFFERENTIAL
- ELECTRIC SHIFT PROGRAM
24. TROUBLESHOOTING
- ENGINE DOES NOT START OR IS HARD TO START
- ENGINE LACKS POWER
- POOR PERFORMANCE AT LOW AND IDLE SPEED
- POOR PERFORMANCE AT HIGH SPEED
- POOR HANDLING
INDEX
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Reference and Info files
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Full list of manual chapters:
CONTENTS
1. GENERAL INFORMATION
SERVICE RULES
MODEL IDENTIFICATION
SPECIFICATIONS
TORQUE VALUES
TOOLS
LUBRICATION and SEAL POINTS
CABLE and HARNESS ROUTING
EMISSION CONTROL SYSTEMS
EMISSION CONTROL INFORMATION LABEL
2. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
TROUBLESHOOTING
BODY PANEL LOCATIONS
SEAT
SIDE COVER
FUEL TANK COVER
READ MUD GUARD (TM/FM models)
CENTER MUD GUARD (TE/FE models)
FRONT MUD GUARD
FRONT CARRIER/CARRY PIPE
FRONT FENDER
REAR CARRIER
REAR FENDER
TOOL BOX
INNER FENDER
OUTER FENDER
HEADLIGHT GRILL
EXHAUST SYSTEM
3. MAINTENANCE
SERVICE INFORMATION
MAINTENANCE SCHEDULE
FUEL HOSE
THROTTLE OPERATION
CARBURETOR CHOKE
AIR CLEANER
AIR CLEANER HOUSING DRAIN TUBE
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL
ENGINE OIL FILTER
ENGINE IDLE SPEED
DRIVER SHAFT BOOTS (FM/FE models)
REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL
BRAKE FLUID
BRAKE SHOE WEAR
BRAKE SYSTEM
REVERSE LOCKING SYSTEM
SKID PLATES
CLUTCH SYSTEM
SUSPENSION
SPARK ARRESTOR
NUTS, BOLTS, FASTENERS
WHEELS/TIRES
STEERING SHAFT HOLDER BEARING
STEERING SYSTEM
4. LUBRICATION SYSTEM
SERVICE INFORMATION
TROUBLESHOOTING
OIL COOLER
COOLING FAN
OIL PUMP
5. FUEL SYSTEM
SERVICE INFORMATION
TROUBLESHOOTING
AIR CLEANER HOUSING
CARBURETOR REMOVAL
CARBURETOR DISASSEMBLY/INSPECTION
CARBURETOR ASSEMBLY
CARBURETOR INSTALLATION
PILOT SCREW ADJUSTMENT
HIGH ALTITUDE ADJUSTMENT
FUEL TANK
6. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
ENGINE REMOVAL
ENGINE INSTALLATION
7. CYLINDER HEAD/VALVE
SERVICE INFORMATION
TROUBLESHOOTING
CYLINDER COMPRESSION
CYLINDER HEAD REMOVAL
CYLINDER HEAD DISASSEMBLY
VALVE GUIDE REPLACEMENT
VALVE SEAT INSPECTION/REFACING
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD INSTALLATION
CAMSHAFT REMOVAL
CAMSHAFT INSTALLATION
8. CYLINDER/PISTON
SERVICE INFORMATION
TROUBLESHOOTING
CYLINDER/PISTON REMOVAL
CYLINDER/PISTON INSTALLATION
9. CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION
TROUBLESHOOTING
FRONT CRANKCASE COVER REMOVAL
CENTRIFUGAL CLUTCH
CHANGE CLUTCH
GEARSHIFT LINKAGE
GEARSHIFT SPINDLE AND REVERSE STOPPER ARM
FRONT CRANKCASE COVER INSTALLATION
10. ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION
TROUBLESHOOTING
RECOIL STARTER
ALTERNATOR STATOR
FLYWHEEL/STARTER CLUTCH
11. CRANKCASE/TRANSMISSION/CRANKSHAFT
SERVICE INFORMATION
TROUBLESHOOTING
CRANKCASE SEPARATION
TRANSMISSION
CRANKSHAFT/BALANCER
CRANKCASE BEARING REPLACEMENT
CRANKCASE ASSEMBLY
12. FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION
TROUBLESHOOTING
HANDLEBAR
THROTTLE HOUSING
FRONT WHEEL
TIRES
WHEEL HUB AND KNUCKLE
SUSPENSION ARM
STEERING SHAFT AND TIE-ROD
FRONT SHOCK ABSORBER
13. REAR WHEEL/SUSPENSION
SERVICE INFORMATION
TROUBLESHOOTING
REAR WHEEL
REAR SHOCK ABSORBER
SWINGARM
14. BRAKE SYSTEM
SERVICE INFORMATION
TROUBLESHOOTING
BRAKE FLUID REPLACEMENT/AIR BLEEDING
FRONT MASTER CYLINDER
FRONT BRAKE SHOES AND DRUM
FRONT WHEEL CYLINDER AND PANEL
REAR BRAKE SHOES AND DRUM
REAR BRAKE PEDAL
15. FRONT DRIVING MECHANISM (FM/FE models)
SERVICE INFORMATION
TROUBLESHOOTING
FRONT DRIVE SHAFT
DIFFERENTIAL REMOVAL
DIFFERENTIAL DISASSEMBLY/INSPECTION
CASE BEARING REPLACEMENT
DIFFERENTIAL ASSEMBLY
DIFFERENTIAL INSTALLATION
16. REAR DRIVING MECHANISM
SERVICE INFORMATION
TROUBLESHOOTING
REAR AXLE REMOVAL
FINAL DRIVE REMOVAL
FINAL DRIVE DISASSEMBLY/INSPECTION
CASE BEARING REPLACEMENT
FINAL DRIVE ASSEMBLY
FINAL DRIVE INSTALLATION
REAR AXLE INSTALLATION
17. BATTERY/CHARGING SYSTEM
SERVICE INFORMATION
TROUBLESHOOTING
BATTERY
CHARGING SYSTEM INSPECTION
REGULATOR/RECTIFIER
ALTERNATOR CHARGING COIL
18. IGNITION SYSTEM
SERVICE INFORMATION
TROUBLESHOOTING
IGNITION SYSTEM INSPECTION
IGNITION COIL
IGNITION TIMING
19. ELECTRIC STARTER
SERVICE INFORMATION
TROUBLESHOOTING
STARTER MOTOR
STARTER RELAY SWITCH
DIODE
20. LIGHTS/METERS/SWITCHES
SERVICE INFORMATION
BULB REPLACEMENT
HEADLIGHT
ACCESSORY SOCKET
IGNITION SWITCH
HANDLEBAR SWITCH
GEAR POSITION SWITCH
CARBURETOR HEATER
COMBINATION METER/SPEED SENSOR
OIL COOLING SYSTEM/TEMPERATURE INDICATOR
21. ELECTRIC SHIFT PROGRAM
SERVICE INFORMATION
TROUBLESHOOTING ('00-'02)
TROUBLESHOOTING (After '02)
ANGLE SENSOR
CONTROL MOTOR AND REDUCTION GEARS
GEARSHIFT SWITCH
REVERSE SHIFT SWITCH
22. WIRING DIAGRAMS
USA TM MODEL
USA FM MODEL
CANADA TM/FM MODELS
USA TE/FE 00-02 MODELS
USA TE/FE AFTER 02 MODELS
CANADA TE/FE 00-02 MODELS
CANADA TE/FE AFTER 02 MODELS
23. TECHNICAL FEATURES
DRY SUMP MECHANISM OF INTEGRAL OIL TANK IN CRANKCASE
A.P. SURETRAC TORQUE BIASING LIMITED SLIP DIFFERENTIAL
ELECTRIC SHIFT PROGRAM
24. TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
ENGINE LACKS POWER
POOR PERFORMANCE AT LOW AND IDLE SPEED
POOR PERFORMANCE AT HIGH SPEED
POOR HANDLING
INDEX