HONDA TRX350 AND TRX350D

HONDA
TRX350 AND TRX350D
NOTE: Metric fasteners are used throughout vehicle.

CONDENSED SERVICE DATA

MODELS TRX350, TRX350D

General
Engine Make Honda
Engine Type Four-Stroke;
Air-Cooled
Number of Cylinders 1
Bore 81.0 mm
(3.189 in.)
Stroke 68.0 mm
(2.677 in.)
Displacement 350.4 cc
(21.4CU. in.)
Compression Ratio 8.5:1
Engine Lubrication Wet Sump;Oil Pump
Transmission Lubrication Common With Engine
Engine/Transmission Oil SAE 10W-40
Forward Speeds 5
Reverse Speeds 1
Front Drive Shaft & Gears
Rear Drive Shaft & Gears
Tire Size:
Front & Rear 24 x 9-11
Tire Pressure:
Front & Rear 15 kPa
(2.2 psi)
Battery 12V-12AH
Dry Weight:
TRX350 259 kg
(570 lbs.)
TRX350D 268 kg
(590 lbs.)
Tune-Up
Engine Idle Speed 1300-1500 rpm
Compression Pressure 1250-1450 kPa
(181-210 psi)
Spark Plug:
NGK DR8ES-L
Nippon Denso X24ESR-U
Electrode Gap 0.6-0.7 mm
(0.024-0.028 in.)
Ignition:
Type Breakerless
Timing 10° BTDC
Carburetor:
Make Keihin •
Model QA03A

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 HONDA TRX350 AND TRX350D

Tune-Up (Cont.)
Float Height 18.5 mm
(0.73 in.)
Main Jet #142
Idle Jet #35
Clip Position 3rd Groove From Top
Idle Mixture Setting 1V2 Turns
Throttle Lever Free Play 3-8 mm
(0.12-0.31 in.)
Sizes-Clearances
Valve Clearance (cold):
Intake & Exhaust 0.08 mm
(0.003 in.)
Valve Face & Seat Angle:
Intake & Exhaust 45°
Valve Seat Width:
Intake & Exhaust 1.2 mm
(0.05 in.)
Wear Limit 1.5 mm
(0.06 in.)
Valve Stem Diameter:
Intake 5.480-5.490 mm
(0.2157-0.2161 in.)
Wear Limit 5.45 mm
(0.215 in.)
Exhaust 5.460-5.470 mm
(0.2150-0.2154 in.)
Wear Limit 5.43 mm
(0.214 in.)
Valve Guide Bore Diameter:
Intake & Exhaust 5.500-5.512 mm
(0.2165-0.2170 in.)
Wear Limit 5.525 mm
(0.2175 in.)
Valve Stem-to-Guide
Clearance:
Intake 0.010-0.032 mm
(0.0004-0.0013 in.)
Wear Limit 0.12 mm
(0.005 in.)
Exhaust 0.030-0.052 mm
(0.0012-0.0020 in.)
Wear Limit 0.14 mm
(0.006 in.)
Valve Spring Free Length:
Inner 35.15 mm
(1.384 in.)
Minimum Length 32.2 mm
(1.27 in.)
Outer 45.75 mm
(1.801 in.)
Minimum Length 42.7 mm
(1.68 in.)
Valve Spring Pressure:
Inner 5.7-6.9 kg @ 26.8 mm
(12.5-15.2 lbs. @ 1.05 in.)
Outer 14.4-17.6 kg @ 30.8 mm
(31.7-38.7 lbs. @ 1.21 in.)

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HONDA TRX350 AND TRX350D

Sizes-Clearances (Cont.)
Rocker Arm Bore Diameter:
Intake & Exhaust 11.988-12.006 mm
(0.4720-0.4727 in.)
Wear Limit 12.04 mm
(0.474 in.)
Rocker Shaft Diameter:
Intake & Exhaust 11.966-11.984 mm
(0.4711-0.4718 in.)
Wear Limit 11.92 mm
(0.469 in.)
Camshaft Lobe Height
1986 Models:
Intake 36.134-36.144 mm
(1.4226-1.4230 in.)
Wear Limit 35.964 mm
(1.4159 in.)
Exhaust 35.926-35.936 mm
(1.4144-1.4148 in.)
Wear Limit 35.756 mm
(1.4077 in.)
Models After 1986:
Intake & Exhaust 35.391-35.401 mm
(1.3933-1.3937 in.)
Wear Limit 35.201 mm
(1.3859 in.)
Cylinder Head Distortion (Max.) 0.10 mm
(0.004 in.)
Cylinder Bore Diameter 81.00-81.01 mm
(3.1890-3.1894 in.)
Wear Limit 81.10 mm
(3.193 in.)
Piston-to-Cylinder Clearance 0.015-0.045 mm
(0.0006-0.0018 in.)
Wear Limit 0.10 mm
(0.004 in.)
Piston Diameter—
Measured 10 mm (0.4 in.) From
Skirt Bottom & 90° to Pin Bore 80.965-80.985 mm
(3.1876-3.1884 in.)
Wear Limit 80.90 mm
(3.185 in.)
Piston Pin Bore 21.002-21.008 mm
(0.8268-0.8271 in.)
Wear Limit 21.04 mm
(0.828 in.)
Piston Pin Diameter 20.994-21.000 mm
(0.8265-0.8268 in.)
Wear Limit 20.96 mm
(0.826 in.)
Piston-to-Pin Clearance 0.002-0.014 mm
(0.0001-0.0006 in.)
Wear Limit 0.02 mm
(0.001 in.)
Piston Ring End Gap:
Top & Second Rings 0.20-0.35 mm
(0.008-0.014 in.)

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 HONDA TRX350 AND TRX350D

Sizes-Clearances (Cont.)
Piston Ring End Gap: (Cont.)
Wear Limit 0.55 mm
(0.022 in.)
Oil Ring 0.2-0.7 mm
(0.008-0.028 in.)
Piston Ring Side Clearance:
Top & Second Rings 0.015-0.045 mm
(0.0006-0.0018 in.)
Wear Limit 0.09 mm
(0.004 in.)
Connecting Rod Small
End Bore Diameter 21.020-21.041 mm
(0.8275-0.8284 in.)
Wear Limit 21.10 mm
(0.831 in.)
Connecting Rod Big End
Side Clearance (Max.) 0.80 mm
(0.031 in.)
Connecting Rod Big End
Radial Clearance (Max.) 0.05 mm
(0.002 in.)
Crankshaft Runout (Max.) 0.05 mm
(0.002 in.)
Capacities
Fuel Tank 10.5 L
(2.8 gal.)
Engine/Transmission Sump See Text
Tightening Torques
Camshaft Sprocket 17-23 N.m
(12-17 ft.-lbs.)
Clutch Nut:
Centrifugal Clutch (L.H. Threads) 120 N.m
(88 ft.-lbs.)
Shift Clutch 110 N.m
(81 ft.-lbs.)
Crankcase 10 N.m
(88 in.-lbs.)
Crankcase Cover 10 N.m
(88 in.-lbs.)
Cylinder Base Screw 10 N.m
(88 in.-lbs.)
Cylinder Head Nut & Screw 40 N.m
(29 ft.-lbs.)
Flywheel Cap Screw 110 N.m
(81 ft.-lbs.)
Output Gear Housing to
Crankcase Screw 32 N.m
(24 ft.-lbs.)
Spark Plug 18 N.m
(159 in.-lbs.)
Wheel Retaining Nut 65 N.m
(48 ft.-lbs.)
Standard Screws:
5 mm 3.5-5.0 N.m
(31-44 in.-lbs.)
6 mm 7-11 N.m
(62-97 in.-lbs.)

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HONDA TRX350 AND TRX350D

Tightening Torques (Cont.)

standard Bolts & Nuts:
5 mm 4.5-6.0 N.m
(40-53 in.-lbs.)
6 mm 8-12 N.m
(71-106 in.-lbs.)
8 mm 18-25 N.m
(13-18 ft.-lbs.)
10 mm 30-40 N.m
(22-29 ft.-lbs.)
12 mm 50-60 N.m
(36-43 ft.-lbs.)
Flanged Bolts & Nuts:
6 mm 10-14 N.m
(89-124 in.-lbs.)
8 mm 24-30 N.m
(17-22 ft.-lbs.)
10 mm 35-45 N.m
(25-32 ft.-lbs.)

LUBRiCATiON mended oil is SAE 80 hypoid gear oil. If changing oil, fill
housing with 110 cc (3.7 oz.) on 1986 models or 210 cc
EMGINE AND TRANSMISSION. The engine and (7.1 02.) on models after 1986. Housing capacity totally
transmission are lubricated by a gear-driven, trochoid- dry is 135 cc (4.6 oz.) for 1986 models or 225 cc (7.6
type pump located on the right side of the crankcase and oz.) for models after 1986.
driven by the crankshaft. The engine and transmission
share a common sump. Recommended oil is SAE 10W- FRONT DRIVE HOUSING. The oil in the front drive
40 with an API classification of SF or SG. housing should be changed every two years. With vehi-
cle on level ground, oil in housing should be level with
Oil level should be maintained at upper mark on
threads of hole for check plug (G—Fig. H13-3. Remove
dipstick attached to fill plug. Do not screw plug in when
oil by unscrewing drain screw (D—Fig. H13-3). Fill
checking oil level. Fill sump through opening for fill plug
housing with oil through opening for fill plug (F—Fig.
(F—Fig. H13-1). Drain oil by removing drain plug on
H13-4). Recommended oil is SAE 80 hypoid gear oil.
underside of crankcase. Fill crankcase with 2.3 L (2.4
qt.) of oil if oil and oil filter are changed. Crankcase
capacity totally dry is 2.8 L (3.0 qt.).
The manufacturer recommends changing the oil and
oil filter after the first week of operation and then after
every 30 days of operation. Asump filter screen, located
in a compartment in the right crankcase half, should be
removed periodically and cleaned.
Remove oil filter cover (C—Fig. H13-1) for access to
oil filter. Before installing filter, be sure spring is against
engine (crankcase cover) and "O" rings are in place.
Install filter so rubber seal side and "OUTSIDE" are
toward filter cover.

REAR DRIVE HOUSING. The oil in the rear drive

housing should be changed every two years. With vehi-
cle on level ground, oil in housing should be level with
threads of hole for ifill plug. Remove oil by unscrewing
drain screw from underside of housing. Fill housing with Fig. HI3-1—The oii dipstick is attached to fiil plug (F).
oil through opening for fill plug (F—Fig. H13-2). Recom- Remove cover (C) for access to oil filter.

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 HONDA TRX350 AND TRX350D

Fig. HI3-2—Pour oii into rear drive housing through Fig. HI3-4—Pour oil into front gearcase through open-
opening for fiii piug (F). The drain screw is iocated on ing for fiii piug (F).
underside of housing.
Thoroughly clean the foam element in a nonflamma-
ble solvent. Compress element between hands to re-
Fill housing with 110 cc (3.7 oz.) of oil if oil is being move solvent. Saturate element in clean SAE 10W-40
changed. Housing capacity totally dry is 135 cc (4.6 oz.). engine oil. Compress element to remove excess oil.
Install element and reassemble air cleaner components.
CABLES AND LEVERS. All cables and levers should
be inspected and lubricated after the first week of op- FUEL SYSTEiWi
eration and after every 30 days of operation thereafter.
Fuel is contained in the fuel tank under the seat. Afuel
gauge sender unit is attached to the side of the fuel tank
on Model TRX350D to monitor fuel level. Fuel is routed
AiR CLEANER ELEiMENT from the tank through the control valve attached to the
side of the fuel tank, to the fuel filter, to the eiectric fuel
The air cleaner element should be removed and pump, then to the carburetor. A relay attached to the
cleaned after every 30 days of operation. To remove the panel on the right rear portion of the frame controls the
air cleaner element, remove the seat, unscrew center fuel pump. Refer to the following sections for service
panel wing bolt, release four cover clips and remove information on fuel system components.
cover. Loosen air cleaner frame to inlet tube clamp, then
withdraw element and frame from case. Remove nut
CARBURETOR. The engine is equipped with a Kei-
and rear frame bracket, then carefully separate foam
hin Model OA03A carburetor. Carburetor is similar to
element from frame.
carburetor shown in Fig. H13-5. Initial setting of idle
mixture screw (15—Fig. H13-6) is 1V2 turns out. Rotat-
ing idle mixture screw clockwise will lean idle mixture.
Final adjustment must be performed with engine at
normal operating temperature. Adjust idle speed screw
knob (14) so engine idles at 1300-1500 rpm. Slowly
rotate idle mixture screw (15) clockwise, leaning idle
mixture, until engine stalls, then turn idle mixture screw
two turns counterclockwise. Readjust idle speed.
When servicing carburetor, note the following: Jet
needle clip (21—Fig. H13-7) should be in third groove
from top. To gain access to jet needle (20) and throttle
slide (22), remove set screw in throttle slide arm (17)
and withdraw throttle slide shaft (3—Fig, H13-5). Extract
throttle slide assembly. Be careful not to lose washer
(18—Fig. H13-7). Remove two screws (19) and sepa-
rate components. Check synchronization of throttle
Fig. H13-3—Oii in front gearcase shouid just fiow from slide and throttle plate. With throttle slide and throttle
hoie for check piug (G). Unscrew drain piug (D) to drain plate completely closed, throttle slide lever (3—Fig.
oil from gearcase. H13-5) should just contact throttle link (2). To synchro-

117
HONDA TRX350 AND TRX350D

11

Fig, HI3-6—View of carburetor with fuei bowi removed.

Components are also shown in Fig. HI3-1.
8. Needle jet
9. Main jet 13. Primary jet
10. Baffle 14. Idle speed screw
11. Pilot jet 15. Idle mixture screw

18
Fig. H13-5—View of partially disassembled carburetor 19
used on all models. Also refer to Figs. HI3-6 artd H13-7.
1. Carburetor body 9. Main jet
2. Throttle link 10. Baffle
3. Throttle slide lever & shaft 11. Pilot jet
4. Cover 12. Primary nozzle
5. Fuel inlet valve 13. Primary jet
6. Float 14. Idle speed screw
7. Float pin 15. Idle mixture screw
8. Needle jet 16. Fuel bowl

nize the throttle slide and plate, open or close the slot in 22
throttle link (2). Float height should be 18.5 mm (0.73
in.) between bottom of float and carburetor body. Hold
carburetor so float is vertical and resting lightly against Fig. HI3-7—Refer to text to remove jet needle (20) and
fuel inlet valve. See Fig. H13-8. Float height is not throttie siide (22).
adjustable. Renew float and/or fuel inlet valve if float 17. Throttle slide arm 20. Jet needle
height is incorrect. 18. Washer 21. Clip
19. Screw 22. Throttle slide
Recommended main jet size for operation above
3000 feet is #132.
route fuel line into a container. Turn ignition switch to
FUEL PUMP. An electric fuel pump is attached to the "ON" for 5 seconds and measure output of fuel pump. If
frame near the carburetor. A relay attached to the panel fuel pump output is not 270-330 cc (9.1 -11.1 oz.), renew
on the right rear portion of the frame controls the fuel pump. Fuel pump must be serviced as a unit assembly.
pump. The pump is protected by a 5 amp fuse (10 amp To check fuel pump relay, disconnect three-wire con-
on Model TRX350D) located in the fuse box under the nector from relay and turn ignition switch "ON". Connect
seat. the positive lead of a voltmeter to connector black/green
To check fuel pump, disconnect three-wire connector wire terminal (black/brown wire on 1986 models) and
from fuel pump relay and connect a jumper wire be- negative lead to green wire terminal. Voltmeter should
tween connector black/green wire terminal (black/brown indicate battery voltage. If not, check fuse. Reconnect
wire on 1986 models) and black/blue wire terminal. positive voltmeter lead to black/blue wire terminal. Volt-
Disconnect fuel line from fuel pump to carburetor and meter should indicate zero voltage. Reinstall connector.

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 HONDA TRX350 AND TRX350D

(B), loosen the knurled nut and rotate cable adjuster.

Retighten knurled nut.

IGNITION SYSTEM
SPARK PLUG. The recommended spark plug for
normal operating conditions is a NGK DR8ES-L or
Nippon Denso X24ESR-U. Spark plug electrode gap
should be 0.6-0.7 mm (0.024-0.028 in.). The spark plug
should be removed, inspected, cleaned or renewed, and
regapped after every 30 days of operation.

IGNITION. All models are equipped with a breaker-

less, capacitor discharge ignition system. On Model
TRX350, power for the ignition is obtained by an exciter
coil located in the alternator. On Model TRX350D, power
for the ignition is provided by the battery. The electronic
Fig. HI3-8—Position carburetor so fioat rests iightiy ignition circuit consists of the CDI module, pulse gener-
against fuel inlet valve and measure float height (H). ator, ignition coii, spark plug, engine stop switch, ignition
switch and neutral switch. On models after 1987, an
alternator sensor wire detects alternator charging cur-
rent and prevents ignition if the engine is stopped.

To check ignition timing, remove timing hole plug in

left engine side cover and attach a suitable timing light
to engine. Initial ignition (10° BTDC) should occur when
"F" mark on flywheel is aligned with mark (M—Fig.
H13-10) on case at 1300-1500 rpm. Advanced ignition
timing is 30° BTDC. Advanced ignition should occur
when "=" mark on flywheel is aligned with mark (M) on
case at 3400-3600 rpm on all modeis. Ignition timing is
not adjustable. If ignition timing is not as specified,
check condition of CDI module and pulse generator as
described in the following test procedures and renew
Fig. HI3-9—Throttie free piay (F) should be 3-8 mm faulty or questionable components.
(1/8-5/16 In.) measured at throttle iever end. Siide rub-
ber boot (B) down cabie to expose knuried iocknut and If ignition malfunction occurs, check condition of
cabie adjuster. spark plug, all wires and connections before trouble-
shooting the ignition circuit. Using Honda Digital Multi-
Tester KS-AHM-32-003 or a suitable ohmmeter, refer to
Run engine. There should be voltage between connec- the following test procedures and specifications to aid
tors for black/blue and green wires leading to fuel pump. troubleshooting.
Fuel pump relay control voltage is carried by the
black/yellow wire between the relay and ignition module.

FUEL FILTER, A fuel filter is located in the line be-

tween the fuel tank and fuel pump. The fuel filter is a
one-piece unit that should be renewed every six months.

FUEL LINES. Fuel hoses should be inspected peri-

odically with particular attention directed to fuel hose
between fuel pump and carburetor. Renew any hoses
that are cracked, split, chaffed or hard.

Fig. HI3-10—Ignition at idie speed should occur when

THROTTLE LEVER FREE PLAY. Free play (F—Fig.
"F" mark on flywheei aiigns with stationary mark (M).
H13-9) at the end of the throttle lever should be 3-8 mm Piston is at TDC when "7" mark is aiigned with mark
(V8-5/I6 in.). To adjust free play, slide back rubber boot (M).

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HONDA TRX350 AND TRX350D

To check condition of exciter coil on Model TRX350, If no faulty component is found and ignition malfunc-
remove right frame cover, locate connector cover near tion persists, renew CDI module and recheck ignition
the fuel valve, and disconnect the black/red wire con- operation. The CDI module is attached to the vehicle
nector. Using an ohmmeter measure resistance be- frame under the front fender assembly.
tween exciter coil wire and vehicle ground. Exciter coil
is considered satisfactory if resistance is 50-200 ohms. ELECTRICAL SYSTEM
To check condition of alternator sensor wire on mod-
els after 1987, disconnect four-wire connector at CDI The vehicle is equipped with a charging system,
module (CDI module is attached to front upper portion battery and electric starter. The system is protected by
of vehicle frame). Attach one ohmmeter lead to yellow a 20 amp fuse on TRX350 models or 30 amp fuse on
sensor wire at connector and remaining ohmmeter lead TRX350D models.
to vehicle ground. Ohmmeter should read infinity (no
continuity). Disconnect three-yellow-wire alternator BATTERY. Remove the seat for access to battery.
connector at regulator/rectifier. Connect ohmmeter The negative terminal is grounded. The battery is a
leads to yellow wire terminal of CDI connector and any sealed, maintenance-free, 12-volt unit with 12 amp-hour
yellow wire terminal of alternator connector. Ohmmeter capacity.
should show continuity. If meter readings are unsatis-
factory, wiring or alternator is faulty. CHARGING SYSTEM. The charging circuit consists
To check condition of the pulse generator, remove of an alternator and a regulator/rectifier. The alternator
right frame cover, locate connector cover near the fuel rotor is attached to the left end of the crankshaft while
valve, and disconnect the blue/yellow wire connector. the stator is mounted on the inside of the left crankcase
Connect an ohmmeter lead to blue/yellow wire going to cover. The regulator/rectifier module is mounted on the
engine and remaining ohmmeter lead to vehicle ground. right rear of the vehicle frame.
Pulse generator is satisfactory if ohmmeter reading is The charging circuit should produce 13.5-15.5 VDC
300-360 ohms. If reading is incorrect, remove left crank- at 5000 rpm.
case cover and repeat test at terminal of pulse gener-
ator. NOTE: Do not disconnect battery terminal wires
To check condition of ignition coil, detach black/yellow while tlie engine is running as excessive alternator
wire and green wire from ignition coil. Disconnect high output wili damage the reguiator/rectifier.
tension lead from spark plug. To check primary winding
resistance, attach one ohmmeter lead to black/yellow To check the alternator stator coils, remove right
wire terminal on ignition coil and remaining ohmmeter frame cover, locate and disconnect green three-wire
lead to green wire terminal. Ohmmeter should read connector near the fuel valve (all wires are yellow). On
0.1-0.2 ohms. Perform two secondary winding tests, connector leading to alternator, alternately check resis-
one with the spark plug cap attached to coil wire and tance between each terminal and the remaining two
one without spark plug cap attached. Attach one ohm- terminals. Resistance between any pair should be 0.2-
meter lead to spark plug cap and remaining ohmmeter 1.0 ohms. Resistance between any terminal and vehicle
lead to coil ground (green wire terminal). Secondary ground must be infinity.
winding resistance through spark plug cap should be If previous tests prove satisfactory and fuse, wiring
7.5k-10.8k ohms. Remove spark plug cap from high and connections are all good, replace regulator/rectifier
tension wire. Attach an ohmmeter lead to high tension with a good unit and recheck operation.
wire and remaining ohmmeter lead to coil ground. Sec-
ondary winding resistance reading with spark plug cap ELECTRIC STARTER. The starting circuit consists of
removed should be 3.7k-4.5k ohms. If secondary wind- the starter, starter relay, starter switch, diode, neutral
ing resistance is now within specification, renew spark light, neutral switch and ignition switch. A fuse protects
plug cap. the circuit.
The neutral switch is located in the right crankcase The starter relay is located adjacent to the battery. To
cover near the right footpeg and marked "N". Note that check relay, disconnect relay pigtail lead and wires from
wire lead to switch is marked "N". To check neutral terminals on relay. Connect ohmmeter leads to termi-
switch, disconnect the light green wire from the switch. nals on top of relay. Ohmmeter should read infinity.
Connect an ohmmeter lead to the wire terminal of the Connect a 12-volt battery to terminals of pigtail lead with
switch and connect the remaining ohmmeter lead to positive battery lead connected to yellow/red wire termi-
vehicle ground. With transmission in neutral the ohm- nal and negative battery lead connected to light
meter should show continuity. When transmission is in green/red wire terminal. Ohmmeter should show conti-
gear the ohmmeter should read infinity. Crankcase oil nuity, if not, renew relay.
must be drained before removing neutral switch. Tight- To check the neutral switch, refer to procedure in
ening torque for neutral switch is 13 N.m (115 in.-lbs.). IGNITION section.

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 HONDA TRX350 AND TRX350D

The diode is molded into the neutral light wire near indicated, check circuit. If voltmeter indicates battery
neutral light. The neutral light must be on for the starter voltage, renew fan motor control module.
to operate. If the neutral light does not come on when The oil temperature sensor is located on the right
the transmission is in neutral, renew neutral light. If new crankcase cover near the right footpeg. To check oil
neutral light does not come on, disconnect wire from temperature sensor, remove oil temperature sensor
light. Disconnect wire marked "N" from the neutral (crankcase oil must be drained). Suspend sensor in
switch located in the right crankcase cover near the right heated oil so sensor does not touch sides of container
footpeg. Check for continuity between the wire ends at and measure resistance at sensor leads. On later mod-
neutral light and neutral switch using an ohmmeter. After els with a single lead, touch remaining ohmmeier lead
connecting the ohmmeter leads to the wire ends, ob- to body of sensor. Resistance readings should be 9.5k-
serve ohmmeter reading, then reverse ohmmeter leads 10k ohms at 25° C (77° F); 950-1050 ohms at 100° C
and observe the second reading. There should be con- (212° F); 209-231 ohms at 170° C (338° F). Tighten oil
tinuity during one test and no continuity (infinity) during temperature sensor to 18 N.m (160 in.-lbs.).
the other test. If not, renew neutral light wire.
To service starter motor, disconnect battery negative REVERSE SWiTCH. A reverse switch triggers a light
lead and remove the fuel pump. Remove starter gear to indicate when reverse gear is engaged. The reverse
cover, slide gear off starter shaft, unscrew two screws switch is located in the right crankcase cover near the
securing starter motor and remove motor. Disconnect right footpeg and marked "R". Note that wire lead to
starter motor cable. Before disassembling motor, note switch is marked "R". To check reverse switch, discon-
alignment marks, or make alignment marks, on center nect the black wire from the switch. Connect an ohm-
housing and end caps so they can be reassembled in meter lead to the wire terminal of the switch and connect
original positions. When disassembling motor note lo- the remaining ohmmeter lead to vehicle ground. With
cation of all shims and washers. Minimum brush length transmission in reverse the ohmmeter should show
is 5.5 mm (0.22 in.). Note pin on brush holder plate that continuity. When any other transmission gear is se-
must align with notch in frame during assembly. Install lected the ohmmeter should read infinity. Crankcase oil
rear cap so slot engages pin on brush holder plate. Be must be drained before removing reverse switch. Tight-
sure "O" rings are correctly positioned during assembly. ening torque for reverse switch is 13 N.m (115 in.-lbs.).

OIL COOLiNG SYSTEM. An oil temperature sensor LIGHTS. Headlight rating is 12V 60/50W. A dimmer
monitors oil temperature in the engine sump. Engine oil switch is located in the switch module on the handlebar.
is routed through a radiator to cool the oil. If oil tempera- Taillight rating is 12V 5W. Rating for neutral, reverse and
ture reaches 110°-130^ C (230°-266° F), the fan motor oil temperature lights is 12V 3W.
control module activates the electric fan. If oil tempera-
ture exceeds 170°-190° C (338°-374° F), the oil tem-
WIRING. If wiring requires repair, always install wire
perature warning light is energized.
that is the same gauge as original wire. Wires should be
The fan motor can be checked by disconnecting the routed away from areas of extreme heat or sharp edges.
blue wire lead and connecting a jumper wire from the Attach or hold wires in their original position using plastic
positive terminal of the battery to the motor's blue wire tie straps to prevent short circuits.
terminal.

CAUTION: Exercise caution during this proce- FASTENERS

dure. To prevent sparks at positive terminal, make
connection at positive terminai first. Do not aiiow After the first week of operation and after every 30
jumper wire to touch vehicie or engine after connec- days of operation thereafter, the vehicle should receive
tion is made at positive terminai. an overall inspection. All screws, nuts and other fasten-
ers should be checked and tightened to proper torque
If fan motor operates, chejck fan control module. If fan specification shown in CONDENSED SERVICE DATA
motor does not operate, check wiring and ground, and section or in the appropriate maintenance section.
if satisfactory, renew fan motor.
To check fan motor control module, disconnect mod- VALVE SYSTEM
ule connectors located on left side of frame near upper
end of front shock absorber. Connect a voltmeter to The engine is equipped with two exhaust valves and
connectors of wires leading toward engine. Connect two intake valves that are actuated via rocker arms by
negative voltmeter lead to green wire during testing and a single overhead camshaft. The camshaft is driven by
turn ignition switch to "ON". Voltmeter should read bat- a roller chain attached to the right end of the crankshaft.
tery voltage when positive lead is connected to white Valve clearance should be adjusted after the first week
wire (ignition switch), black/brown wire (ignition switch) of operation and then after every 30 days of operation.
and blue/red wire (oil warning light). If zero voltage is Adjust valve clearance with engine cold.

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HONDA TRX350 AND TRX350D

To adjust valve clearance, remove seat and air

cleaner cover. Remove frame brace above intake tube,
then remove intake tube and top fender cover. Detach
inlet tubes and breather hose from air cleaner box, then
remove air cleaner box. Unscrew timing hole plug in left
engine side cover and valve adjustment hole covers at
front and rear of cylinder head. The 'T' mark on the
flywheel indicates top dead center when aligned with
mark (M—Fig. H13-10) in plug hole. Remove plug in
center of cover and rotate the end of the crankshaft (Y)
clockwise. Align top dead center mark "T" with mark (M)
with piston on compression stroke. To ensure piston is
on compression stroke, rotate crankshaft past top dead
center and observe intake (rear) rocker arm. If intake
rocker arm movement is observed, continue to rotate Fig. HI3-12—To adjust dutch, ioosen iocknut (L) and
crankshaft until marks are again aligned. turn adjusting screw (S) counterciockwise untii inter-
Clearance between rocker arm adjusting screw and nai resistance is feit, then turn screw 1/4 turn clock-
valve stem should be 0.08 mm (0.003 in.) for both wise. Secure adjusting screw with locknut (L) and
install cover.
valves. Measure clearance with a suitable feeler gauge.
Adjust clearance by loosening the adjusting screw
locknut and turning the adjusting screw. Be sure to
recheck clearance after tightening locknut. CLUTCH
On models equipped with a decompression lever,
check adjustment as outlined in following section. The engine is equipped with two automatically actu-
ated clutches. A five-shoe centrifugal clutch is mounted
on the right end of the crankshaft. The centrifugal dutch
DECOMPRESSION LEVER is disengaged at idle speed and engages when crank-
shaft speed increases. A multiple-disc clutch is attached
Later models are equipped with a decompression to the transmission mainshaft and is actuated by the
lever that, when actuated, reduces starting effort. Actu- gear shift mechanism. When the gear shift lever is
ating the lever holds the exhaust valve open slightly operated, the multiple-disc clutch is disengaged to allow
thereby reducing compression pressure. smooth transmission gear movement.
To adjust the decompression lever, remove timing The clutch should be adjusted after the first week of
hole plug in left engine side cover. Rotate crankshaft so operation and after every 30 days of operation. To adjust
piston is on compression stroke and "T" mark on fly- clutch, remove cover on right side of crankcase. Loosen
wheel is aligned with mark (M) in plug hole. Free play at locknut (L—Fig. H13-12). Turn adjusting screw (S)
end of decompression lever (L—Fig. H13-11) should be counterclockwise until internal resistance is felt, then
1-3 mm (0.04-0.12 in.). Loosen locknut (N) and rotate turn screw V4 turn clockwise. Secure adjusting screw
adjuster (A) to obtain desired free play. Retighten with locknut (L) and install cover.
locknut and check adjustment. The dual-clutch system should automatically disen-
gage at engine idle speed. When selecting gears, clutch
should engage and disengage freely without excess
slippage. Difficult shifting, clutch grabbing or dutch slip-
ping may indicate overhaul is necessary.

REVERSE LOCK
A reverse lock mechanism prevents accidental en-
gagement of reverse gear. There should be 2-4 mm
(5/64-^2 in.) free play at gap (G—Fig. H13-13). Adjust
free play at lower end of cable by loosening locknut and
turning adjusting nut. Retighten locknut.

FRONT BRAKE SYSTEM

Fig. H13-11—Free piay at end of decompression lever The front and rear brake systems are operated inde-
(L) shouid be 1-3 mm (0.04-0.12 In.). Loosen iocknut (N) pendently. The front brake system uses hydraulically
and rotate adjuster (A) to obtain desired free piay. actuated, drum-type brakes attached to each steering

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 HONDA TRX350 AND TRX350D

Fig. H13-13—Reverse lock free play should be 2-4 mm

(5/64-5/32 in.) at gap (G). Fig. H13-15—Free piay (F) at end of front brake iever
should be 25-30 mm (1 13/16 in.).

knuckle. Two brake shoes are contained behind each

brake drum. A handlebar-mounted master cylinder with
integral fluid reservoir supplies pressure to each wheel
cylinder when the right handlebar lever is operated.
Only DOT 3 or DOT 4 rated brake fluid is recom-
mended. Maintain brake fluid level between marks on
inner side of brake fluid reservoir. To avert spillage, be
sure reservoir is horizontal before removing cover.

INSPECTION. The brake system should be inspected

after every 30 days of operation. Correct any occur-
rences of brake fluid leakage. Renew worn, cracked or
damaged brake lines or hoses and determine and cor-
rect the cause. Brake shoes should be adjusted to
compensate for wear as needed.
To inspect the front brake drum components, support
the front of the vehicle so the wheels are off the ground.
Remove tire and wheel, unscrew axle nut and remove Fig. H13-16—Remove piug (P) from brake drum for
access to brake adjusters.
brake drum. Renew brake drum if inside diameter ex-
ceeds 161 mm (6.339 in.). Renew front brake shoes if
lining thickness is less than 1.0 mm (0.04 in.). Wheel
cylinders should be overhauled or renewed if brake fluid brake adjuster. Check brake lever free play. Repeat
is observed within boots. procedure if needed. Reinstall plug in brake drum. If
If either the brake shoes or wheel cylinders require brake lever free play cannot be adjusted by adjusting
servicing, then the complete drum brake assembly brake shoes, there may be air in brake fluid. F^erform
should be serviced as outlined in R&R AND OVERHAUL bleeding procedure as outlined in BLEEDING section.
section. If brake components are satisfactory, reassem-
ble brake and, if needed, perform adjustment. On later BLEEDiNG. The brake hydraulic system must be
models, apply multipurpose grease between lips of seal bled if any hydraulic brake components are discon-
attached to drum edge. Tighten axle nut to 80-100 N.m nected or if the reservoir is drained. With reservoir
(59-74 ft.-lbs.). Tighten wheel nuts to 65 N.m (48 ft.-lbs.). horizontal, fill reservoir with DOT 3 or 4 brake fluid to full
mark on inner side of reservoir. Do not allow reservoir
ADJUSTMENT Free play (F—Fig. H13-15) at end of to empty while performing bleeding operation. Fleinstall
front brake lever should be 25-30 mm (1 -13/i 6 in.). If free cover to prevent entrance of dirt or foreign material.
play is excessive, adjust brake shoes using following Attach a suitable hose, such as vacuum hose, to the
procedure. Support front of vehicle so wheels are off bleed screw on brake backing plate. Submerge end of
ground. Remove plug (P—Fig. H13-16) from brake hose in a container of brake fluid to prevent air from
drum™ Rotate wheel and locate notched adjuster wheel reentering system. Actuate brake lever several times,
(there are two adjuster wheels, one for each brake then hold brake lever toward handlebar. Open brake
shoe). Using a screwdriver or other tool, rotate adjuster bleed screw and allow fluid and air to flow into container.
wheel until brake shoe contacts brake drum, then back Continue holding brake lever and close bleed screw.
out adjuster three notches. Repeat procedure at other Recheck reservoir level and refill if needed. Repeat

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HONDA TRX350 AND TRX350D

procedure until air and/or old fluid is ejected from sys-

tem.

R&R AND OVERHAUL. Support front of vehide so

wheel is off ground and remove wheel.

WARNING: Iniialing asbestos brake dust is irtjuri-

ous to human health. Approved OSHA respiration
equipment must be worn when working on or
around brake drum and shoes. DO NOT use com-
pressed air to ciean brake drum, shoes or nearby
components as brake dust wiii be biown into air.
Oniy vacuum equipment designed to pick up brake
dust should be used.

Unscrew axle nut and remove brake drum and wheel

hub. While noting location of components, disassemble
brake assembly. Detach brake line from wheel cylinder
and plug line to reduce fluid loss. The wheel cylinders
are marked "L" or "R" to indicate position. Inspect com- Fig. H13-18—Exploded view of front brake master cyl-
ponents as outlined in INSPECTION section. inder.
Disassemble and inspect wheel cylinder. Renew 1. Boot 11. Diaphragm
complete wheel cylinder if bore is scored, pitted or 2. Snap ring 12. Bolt
3. Washer 13. Clamp
excessively worn. Maximum allowable bore diameter is 14. Body
4. Piston & cup
19.12 mm (0.753 in.). Minimum allowable piston diame- 5. Spring 15. Rubber boot
ter is 18.81 mm (0.741 in.). Superficial damage in wheel 6. Bolt 16. Brake lever
cylinder bore may be removed using a suitable cylinder 7. Seal 17. Nut
8. Screw 18. Union bolt
hone. After honing, rinse bore with dean brake fluid. 9. Cover 19. Seal washer
Shake out excess fluid but do not wipe dry. Using a shop 10. Diaphragm plate 20. Brake hose
towel or rag to dry cylinder will leave lint particles in bore.
Renew boots and piston cups. During reassembly, lubri-
cate components with dean brake fluid. lever, reservoir cover (9) and diaphragm (11). Remove
Backing plate retaining screws on models after 1987 dust boot (1) and snap ring (2). Disassemble piston
must be discarded. Tighten backing plate retaining assembly while noting location and direction of compo-
screws to 27-33 N.m (20-24 ft.-lbs.). Apply a suitable nents. Renew complete master cylinder if bore is
sealer to wheel cylinder contact area on backing plate scored, pitted or excessively worn. Maximum allowable
and install wheel cylinder. Note "L" or "R" on wheel bore diameter is 12.75 mm (0.502 in.). Minimum allow-
cylinder and install on indicated side of backing plate. able piston diameter is 12.64 mm (0.498 in.). Superficial
Attach brake line. damage in master cylinder bore may be removed using
The brake shoe adjuster fits in one end of the wheel a suitable cylinder hone. After honing, rinse bore with
cylinder. Clean adjuster and lubricate with silicon grease clean brake fluid. Shake out excess fluid but do not wipe
before installing in housing or wheel cylinder. Screw dry. Using a shop towel or rag to dry cylinder will leave
adjusters completely in to allow installation of new brake lint particles in bore. Renew boots and piston cups.
shoes. Apply a light coat of silicone grease to three During reassembly, lubricate components with clean
points on backing plate that will contact edge of brake brake fluid. Reassembly is reverse of disassembly. In-
shoe. Install brake springs behind brake shoes with stall spring (5) so small end contacts piston (4). Bleed
coiled end at same end as wheel cylinder piston. Secure brakes as previously outlined.
brake shoes with pins and clips. On later models, apply
multipurpose grease between lips of seal attached to FRONT AXLE
drum edge. Tighten axle nut to 80-100 N.m (59-74
ft.-lbs.). Tighten wheel nuts to 65 N.m (48 ft.-lbs.). The steering knuckles are supported by kingpins that
Adjust and bleed brakes as previously outlined. ride in bearings located in the axle housing flanges. A
ball bearing in each steering knuckle supports the axle
MASTER CYLINDER. To remove front brake master shaft. The front drive and axle assembly is located in a
cylinder (14—Fig. H13-18), detach brake line from mas- swing arm similar to the rear swing arm. The shock
ter cylinder. Brake fluid will remove paint; be careful absorbers attached to the swing arm limit and cushion
when removing master cylinder. Unscrew two retaining vertical movement of the front drive unit. A spring on
screws and remove master cylinder. Remove brake each shock absorber supports the vehide.

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 HONDA TRX350 AND TRX350D

To remove steering knuckle, support vehicle so wheel excessive effort is noted. Renew any damaged compo-
is off ground. Remove wheel and wheel hub. Detach tie nents.
rod from steering knuckle. Unscrew upper kingpin
locknut, then unscrew upper kingpin. Unscrew lower TOE-IN SETTING- Before checking toe-in setting,
kingpin bolt. Move steering knuckle and brake assembly inspect front steering assembly and renew or repair any
away from axie shaft. Support knuckle/brake assembly loose or damaged components.
so brake line is not pulled or twisted; do not allow To check toe-in, inflate tires to recommended pres-
assembly to hang from brake line. Inspect, and if nec- sure listed in CONDENSED SERVICE DATA. Position
essary, renew kingpin bearings. vehicle on a fiat, smooth surface and set handlebar
Steering knuckles are not identical. Knuckle is straight forward. Use a suitable measuring tool and
marked with an "L" or "R" to indicate side. Inspect, and measure distance (B—Fig. H13-19) at spindle height
if necessary, renew axle bearing in steering knuckle. between the center of the tires on the rear sides. Locate
Remove snap ring and drive out bearing. Pack bearing the same tire centerline points on front side of tires and
with grease before installation. Inspect, and if neces- measure front distance (F). The measured distance on
sary, renew bearing seals. the front side (F) should be equal to the measured
Reassemble by reversing disassembly procedure distance on the rear side (B). Toe-in should be 0 mm
while noting the following. Tighten the lower kingpin bolt (0.00 in.). Note that the distance from a projected vehide
first. Tighten lower kingpin bolt to 50-70 N.m (37-51 centerline to left (L) and right (R) tire centerlines should
ft.-lbs.), then lock head of bolt in place with tab washer. also be equal. Loosen locknuts at both ends of tie rods
Tighten upper kingpin bolt to 5-10 N.m (45-88 in.-lbs.), (T) and rotate tie rod shaft to adjust toe-in. Retighten
then while holding kingpin bolt, tighten locknut to 50-70 locknuts to 35-45 N.m (26-33 ft.-lbs.).
N.m (37-51 ft.-lbs.). There should be at least 2.0 mm
(0.08 in.) clearance between axle boot and knuckle. FRONT AXLE SHAFTS
Discard tie rod retaining nut on models after 1987.
Tighten tie rod nut to 65-75 N.m (48-55 ft.-lbs.) on The front-wheel-drive system is equipped with an axle
models prior to 1988 or to 35-45 N.m (26-33 ft.-lbs.) on shaft on each side between the final drive housing and
models after 1987. Tighten axle nut to 80-100 N.m steering knuckle. Each axle shaft is equipped with a ball
(59-74 ft.-lbs.). Tighten wheel nuts to 65 N.m (48 ft.-lbs.). joint at each end.
To remove axle shaft, first remove steering knuckle
as outlined in FRONT AXLE section. Move steering
STEERING knuckle and brake assembly away from axle shaft.
Support knuckle/brake assembly so brake line is not
INSPECTION. Support the front of the vehicle so the pulled or twisted; do not allow assembly to hang from
wheels are off the ground. Rotate the handlebar to full brake line. Withdraw axle shaft whiie pulling inner shaft
left and right and check for excessive looseness, binding end straight out from drive housing so seal in housing
and roughness. Be sure cables do not prevent full is not distorted.
movement. Clean and grease components if binding or Move shaft in normal range of motion and check for
excessive wear and damage. Axle shaft is available only
as a unit assembly. If any components are defective,
excluding the boot, then entire shaft assembly must be
renewed. The axle boot may be renewed. Boot should
be renewed if cracked, torn or otherwise damaged. Boot
bands should be renewed if removed. Pack boot with
molybdenum disulfide grease before installation.
Reassemble by reversing disassembly procedure.

FRONT SWING ARM AND

DRIVE ASSEMBLIES
Service on front swing arm and drive assemblies
should be performed by a Honda service technician
equipped with the special tools required for overhaul.

SHOCK ABSORBERS

Fig. HI3-19—Toe-in shouid be 0 mm (0.00 in.). See text Spring tension is not adjustable on front shock ab-
for measurement procedure. sorbers. Spring tension on rear shock absorbers can be

125
HONDA TRX350 AND TRX350D

adjusted by rotating adjusting sleeve. Both ends of the

shock absorbers are secured by a bolt through the
mounting eye.
When installing front shock absorber tighten lower
bolt to 60-80 N.m (44-59 ft.-lbs.). Tighten upper bolt to
60-80 N.m (44-59 ft.-lbs.) on models prior to 1988 or to
35-45 N.m (26-33 ft.-lbs.) on models after 1987. If
removed, discard upper shock retaining nuts on models
after 1987.
When installing rear shock absorber tighten upper
retaining nut on 1986 and 1987 models to 40-50 N.m
(29-37 ft.-lbs.) on models prior to 1988 or to 35-45 N.m Fig. H13-21—Rear brake lever free play, measured at
(26-33 ft.-lbs.) on models after 1987. Tighten lower bolt (F), shouid be 15-20 mm (5/8-3/4 in.). Minor brake iever
adjustment can be accompiished by turning cable ad-
to 60-80 N.m (44-59 ft.-lbs.) on models prior to 1988 or
juster (A). Otherwise, rotate lever adjuster (R—Fig. H13-
to 35-45 N.m (26-33 ft.-lbs.) on models after 1987. If 20) at rear brake to adjust iever free travel.
removed, discard shock retaining nuts on models after
1987.
be 15-20 mm (%-% in.). Adjust pedal free travel by
rotating adjuster (J—Fig. H13-20) at rear brake.
REAR BRAKE SYSTEM Rear brake lever free play measured at (F—Fig.
H13-21) should be 15-20 mm (5/8-3/4 in.). Rotate lever
The front and rear brake systems are operated inde- adjuster (R—Fig. H13-20) at rear brake to adjust lever
pendently. The rear brake consists of a two-shoe, inter- free travel. Minor brake lever adjustment can be accom-
nally expanding drum brake mounted on the right end plished by turning cable adjuster (A—Fig. H13-21) on
of the rear axle housing. The brake may be actuated by lever assembly.
a brake lever attached to the left handlebar or a brake A rear brake lining indicator (I—Fig. H13-20) is attached
pedal near the right footpeg. to the brake cam. To externally check brake lining wear,
apply rear brake and note position of indicator (I) with mark
INSPECTION. The brake system should be inspected (M) on backing plate. Brake shoes should be renewed if
after every 30 days of operation. Service, repair or indicator aligns or passes mark (M).
renew any components that are inoperable or damaged.
R&R AND OVERHAUL. To remove rear brake shoes
ADJUSTMENT. Actuate the rear brake pedal and and drum, support rear of vehide and remove right tire
measure free travel at end of pedal. Free travel should and wheel.

WARNING: Inhaling asbestos brake dust is injuri-

ous to human heaith. Approved OSHA respiration
equipment must be worn when working on or
around brake drum and shoes. DO NOT use com-
pressed air to ciean brake drum, shoes or nearby
components as brake dust wili be biown into air.
Oniy vacuum equipment designed to pick up brake
dust shouid be used.

Unscrew axle nut and remove wheel hub from axle.

Unscrew and remove brake drum cover. Remove brake
drum.
Renew the brake shoes if thickness is less than 2.0
mm (0.08 in.). Renew the brake drum if inside diameter
exceeds 181 mm (7.1 in.). Inspect "O" rings and seals
and renew if deteriorated or damaged. Note that there
is an "O" ring located between the brake drum cover and
backing plate and a seal around the actuating camshaft.
If removed, discard backing plate retaining nuts on
Fig. H13-20—TO check brake iining wear, appiy rear
brake and note position of indicator (I) with mark (M) on models after 1987.
backing piate. Brake shoes shouid be renewed if indi- Reassemble by reversing disassembly procedure
cator aligns with or passes mark (M). and noting the following: Tighten backing plate retaining

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 HONDA TRX350 AND TRX350D

nuts to 50-60 N.m (37-44 ft.-lbs.) on modeis prior to SWING A R M A N D

1988 or to 35-45 N.m (26-33 ft.-lbs.) on models after R E A R DRIVE A S S E M B L I E S
1987. Apply a light coat of grease to brake shoe cam
and anchor pin. Do not allow grease on brake shoe
linings. Tighten wheel hub retaining nut to 120-160 N.m Service on swing arm and rear drive assemblies
(88-117 ft.-lbs.). Adjust rear brake as previously out- should be performed by a Honda service technician
iined. equipped with the special tools required for overhaul.

127