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

Service Manual for Honda TRX350TE/TM/FE/FM FourTrax Rancher (2004-2006)

This official Honda Service Manual is the definitive resource for maintaining, troubleshooting, and repairing your Honda TRX350 FourTrax Rancher ATV. Specifically written for the 2004, 2005, and 2006 model years, this technical manual provides the professional-grade depth required for both routine maintenance and complex engine overhauls. Whether you are a dedicated DIY owner or a professional mechanic, this guide delivers the exact factory specifications needed to keep your Rancher in peak operating condition.

Comprehensive Model Coverage

This manual is tailored for the specific engineering differences across the 350 series Rancher lineup. It covers both the 2WD and 4WD platforms, as well as both manual and electric shift systems:

• Honda TRX350TM FourTrax Rancher (2WD, Left foot operated gearshift)
• Honda TRX350TE FourTrax Rancher ES (2WD, Electric Shift Program/ESP)
• Honda TRX350FM FourTrax Rancher 4x4 (4WD, Left foot operated gearshift)
• Honda TRX350FE FourTrax Rancher 4x4 ES (4WD, Electric Shift Program/ESP)

Technical Features & Serial Number Identification

To ensure you are using the correct data for your specific vehicle, the manual includes a dedicated section on Model Identification.

• Vehicle Identification Number (VIN): Stamped on the front side of the frame.
• Engine Serial Number: Stamped on the left side of the rear crankcase.
• Carburetor Identification Number: Stamped on the left side of the carburetor body (standard VE94EA).
• Color Label: Located on the frame crossmember under the seat for ordering exact matching body parts.

Exclusive Engineering Insights

Beyond standard repair steps, this manual explains the advanced systems that make the Rancher a leader in the ATV class:

• A.P. Suretrac Differential: Deep dive into the torque-biasing front differential used on FM/FE models, which utilizes a cam and follower principle to provide optimum torque balance without the steering load of conventional systems.
• Dry Sump Lubrication: Detailed diagrams of the mass-centralizing lubrication system where the crankcase itself acts as the oil tank.
• ESP System: Full schematics and diagnostic paths for the Electric Shift Program, including the angle sensor, shift control motor, and ECU logic.

What's Inside:

• General Information: Comprehensive service rules, standard torque values (from 5mm bolts to 20mm lock nuts), and lubrication points.
• Maintenance Schedule: Detailed intervals for 20, 100, and 200-hour service checks to comply with CARB emission standards.
• Engine & Drive Train: Step-by-step procedures for the OHV single-cylinder engine, including cylinder head/valve service, piston replacement, and centrifugal clutch maintenance.
• Chassis & Suspension: Service guides for the double wish-bone front suspension, swingarm rear suspension, and steering shaft holder bearings.
• Electrical System: Wiring diagrams and troubleshooting for the DC-CDI ignition, electric starter, and the triple-phase output alternator.
• Troubleshooting: A massive 25-page section dedicated to diagnosing engine performance, poor handling, and electrical faults.

Professional Specifications for Precision Repairs:

• Valve Clearance: IN/EX: 0.15 mm (0.006 in)
• Idle Speed: 1,400 ± 100 rpm
• Compression Pressure: 667 kPa (97 psi) at 450 rpm
• Tire Pressure: 2.8 psi (TM/TE) to 3.6 psi (FM/FE)
• Fuel Capacity: 3.67 US gal including 0.82 US gal reserve

Equip yourself with the same information used by factory-trained Honda technicians. This manual ensures that every bolt is torqued to spec and every system is calibrated for maximum durability on the trail or the farm.