2000-2003 Honda TRX350 Rancher factory service manual

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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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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