Honda FL350R Odyssey 350 ATV Shop Manual, 1985 (P/N 61VM001)

Covers the 1985 Honda FL350R, sold under the Odyssey 350 name. This is the Honda Shop Manual, Second Edition, issued November 1985, P/N 61VM001.

PDF Access, Wiring Detail, and Page Count

Search and diagram navigation: PDF text search and embedded bookmarks are not available. Small wiring-diagram labels require zooming; the complete diagram is also included on a separate landscape page.

Supplied as one printable English PDF in a ZIP download. The 209-page PDF includes two covers, two blank pages, five memo pages, and the additional landscape wiring-diagram page.

Engine, Salsbury Converter, and Chassis Service

This selected content overview highlights major repair areas rather than reproducing the full contents. Other topics include competition replacement schedules and exhaust spark-arrester maintenance.

• Engine repair: Engine removal, top-end disassembly and inspection, piston service, crankcase separation, crankshaft bearing replacement, and balancer-gear timing and assembly.

• Fuel system: PE32A carburetor removal and overhaul, float-level setting, air/stop-screw adjustment, fuel-pump and check-valve testing, and altitude-specific carburetor charts.

• Transmission and converter: Internal gear and shift-fork inspection, bearing and oil-seal replacement, control-cable adjustment, drive-belt service, and Salsbury pulley disassembly and assembly.

• Steering and suspension: Front and rear shock spring service, drive shafts, radius arms, wheel alignment, wheel bearings, steering bushings, and ball joints.

• Brakes: Front hydraulic drum brakes, rear disc brake, master cylinders, parking-brake mechanisms, fluid replacement, hydraulic bleeding, and operating checks.

• Electrical diagnosis: CDI ignition, alternator, charging, starter, relay, switch, and lighting tests, with resistance tables, circuit schematics, cable-routing views, and a complete wiring diagram.

The material is suited to technicians and mechanically qualified owners with basic shop knowledge and access to the required measuring and special tools. Standard workshop procedures and safety principles are not taught in detail.

Top-End and Crankcase Repair

The engine sections distinguish work that can be completed in the frame from repairs requiring engine removal or crankcase separation. These distinctions help plan dismantling before internal engine work begins.

Along with cylinder-head and piston measurements, the manual covers combustion-chamber and exhaust-port decarbonizing, piston-ring inspection, crankshaft runout and connecting-rod checks, double-lip crankshaft oil-seal handling, and crankcase bearing replacement.

Balancer service includes the punch-mark relationships between the crankshaft, drive gear, driven gear, and balancer weight—critical information when the gear train has been apart.

Carburetor, Fuel Supply, and Reed Valve

Fuel-system coverage follows the path from the tank, filter, pump, and one-way check valve to the carburetor and reed cage. The altitude chart changes main-jet, needle-clip, and air-screw settings by both elevation and temperature.

The related caution explains why leaving the high-altitude setup installed at lower elevations can overheat and damage the engine. Reed-valve inspection leads to assembly replacement when the stopper, reed, or seat is faulty; the manual prohibits disassembling the reed-valve assembly.

Transmission Internals and Salsbury Pulleys

Step-by-step procedures cover transmission removal, disassembly, inspection, and reassembly. Internal coverage includes the selector, shift fork and shaft, primary and counter gear sets, reverse gear, final gear, bearings, and oil seals.

The converter section addresses weight arms, rollers, torque-bearing sliders, center bearing, slippers, cam, and torsion/compression spring. Driven-pulley assembly includes spring preload and component indexing, extending beyond a belt-change procedure.

Alignment, Suspension, and Brake Detail

Wheel alignment: Front toe-out and rear toe-in receive separate checks and adjustments. Front camber and caster are fixed; rear camber and toe are corrected through upper-arm length and radius-arm washer placement.

Suspension repair includes wheel and drive-shaft bearing replacement, front-arm and steering-column bushings, ball joints, spherical bearings, and front and rear shock spring removal with a compressor.

Hydraulic brakes: The brake chapter distinguishes front and rear master-cylinder bores and covers front wheel cylinders and shoe adjusters, rear caliper overhaul, and parking-brake shaft inspection and assembly.

Electrical Tests and Fault Isolation

Electrical diagnosis includes the pulse generator, ignition coil, charging coil, regulator/rectifier, starter motor, starter relay, change switch, and lighting switches. Starter repair extends to brush measurements, commutator and field-coil checks, pinion inspection, and reassembly.

Troubleshooting charts relate hard starting, power loss, poor idle, high-speed performance, and handling complaints to specific checks and probable causes. They help separate fuel, ignition, compression, and drivetrain faults before repair work is selected.

Visual references include cable and wire-harness routing views, PE32A carburetor and recoil-starter assemblies, Salsbury pulley assemblies, starter and charging circuit schematics, and the complete wiring diagram.

Factory Tools and Repair Cautions

Section-level tables provide component torque specifications, fluid capacities for draining and disassembly, wear limits, running clearances, alignment data, carburetor settings, and electrical resistance checks.

The tool list identifies new-for-1985 crankcase assembly tool 07965-VM00000 and puller 07935-VM00000. It also lists shock absorber compressor 07959-3290001, wheel-alignment attachment 07910-MJ30100, and dedicated Salsbury holding, dismounting, and spring-compression hardware.

The manual flags two ways to damage parts: rotating the cylinder during installation can let a piston ring enter a port, while spring-loaded drive-pulley assemblies can recoil and suffer damage during separation.

For drivetrain, suspension, starter, and brake work, securely support the frame and isolate the battery wherever the factory procedure calls for it.

A Preview of Float-Level and Belt-Wear Specifications

Carburetor setup: The PE32A float-level specification is 16.0 mm (0.63 in), with a float-level gauge identified for the check.

Drive-belt inspection: Standard belt thickness is 30.2 mm (1.19 in), with a 27 mm (1.06 in) service limit. The maintenance and converter chapters connect these measurements with belt inspection and replacement.