Honda TRX350TE, TRX350TM, TRX350FE, TRX350FM FourTrax Rancher ATV Service Manual 2004-2006

Honda TRX350 FourTrax Rancher Service Manual - 2004-2006

This professional workshop manual establishes the authoritative engineering framework for the maintenance and overhaul of the 329cc longitudinally mounted powertrain and chassis. Operational longevity is anchored by the integrated dry sump lubrication system, which utilizes a dedicated crankcase internal reservoir to centralize mass and eliminate external plumbing vulnerabilities. Adherence to the precise 18.5 mm float level specification for the Constant Vacuum (VE type) carburetor is mandatory to prevent lean-mixture conditions and ensure maximum engine uptime in demanding environments.

Technical Applicability & Chassis Configuration Mapping

Technical procedures within this documentation are categorized by four distinct chassis and drive configurations. Primary vehicle identification is executed via the VIN stamped on the front frame spar and the Engine Serial Number located on the left rear crankcase.

Two-Wheel Drive (2WD) Chassis Architecture

• TRX350TM FourTrax Rancher: Manual shift configuration featuring a foot-operated gear selection system.
• TRX350TE FourTrax Rancher ES: Electric Shift Program (ESP) variant utilizing handlebar-mounted electronic solenoids.

Four-Wheel Drive (4WD) Chassis Architecture

• TRX350FM FourTrax Rancher 4X4: Manual shift 4x4 configuration with a foot-operated return system.
• TRX350FE FourTrax Rancher 4X4 ES: ESP-equipped 4x4 model featuring the A.P. Suretrac torque-biasing front differential.

Operational Reliability & Maintenance ROI

• System Synchronization: Precise calibration of the Electric Shift Program (ESP) angle sensor ensures rapid gear engagement and prevents shift-motor stall during high-torque duty cycles.
• Drivetrain Integrity: Defined tolerances for the A.P. Suretrac differential maintain optimum torque distribution, significantly reducing parasitic steering load and tire tread wear.
• Calibration Precision: Factory-grade torque sequences for cylinder head cap nuts (39 N·m) prevent thermal distortion and combustion leakages under peak thermal loads.

Technical Documentation Metadata

• Print Number: 61HN403
• Total Pages: 524
• Applicable Territory: US and International Markets

System Architecture & Factory Benchmarks

This technical documentation details an OHV single-cylinder engine with a bore and stroke of 78.5 x 68.0 mm. Specialized diagnostic protocols focus on the integration of the triple-phase output alternator and the DC-CDI ignition system, providing technicians with the exact peak voltage requirements (minimum 100V at the ignition coil) for electrical validation.

Precision Navigation & Visualization

System schematics and cable routing diagrams provide 1:1 spatial mapping for wire harness positioning and breather hose termination points. Exploded views within the "Front Driving Mechanism" section illustrate the complex cam-and-follower interaction within the Suretrac differential, essential for accurate backlash adjustments.

Table of Contents

• Section 1: General Information & Service Rules
• Section 2: Technical Features (Suretrac/ESP/Dry Sump)
• Section 3: Frame/Body Panels/Exhaust System
• Section 4: Maintenance Schedule & Procedures
• Section 5: Lubrication System (Oil Pump/Cooler)
• Section 6: Fuel System (VE Carburetor/Fuel Tank)
• Section 7: Engine Removal and Installation
• Section 8: Cylinder Head and Valve Train
• Section 9: Cylinder and Piston Tolerances
• Section 10: Clutch and Gearshift Linkage
• Section 11: Alternator and Starter Clutch
• Section 12: Crankcase, Transmission, and Crankshaft
• Section 13: Front Wheel, Suspension, and Steering
• Section 14: Rear Wheel and Swingarm Suspension
• Section 15: Hydraulic and Mechanical Brake Systems
• Section 16: Front Driving Mechanism (4WD Models)
• Section 17: Rear Driving Mechanism
• Section 18: Battery and Charging System
• Section 19: Ignition System Diagnostics
• Section 20: Electric Starter Motor Service
• Section 21: Lights, Meters, and Switchgear
• Section 22: Electric Shift Program (ESP) Logic
• Section 23: Full-System Wiring Diagrams
• Section 24: Troubleshooting (Fault-Tree Analysis)

Operational Limits & Fluid Specifications

• Engine Oil (SAE 10W-40): 2.0 Liters (After Draining/Filter Change).
• Differential Oil (Hypoid SAE #80): 241 cm³ (After Draining).
• Valve Clearance (Cold): 0.15 mm (0.006 in) Intake and Exhaust.
• Spark Plug Gap: 0.8–0.9 mm (DPR7EA-9 / X22EPR-U9).
• Idle Speed: 1,400 ± 100 RPM.
• Critical Torque: Clutch center lock nut: 108 N·m (80 lbf·ft).