1986 Honda ATC 350X Service Manual

The 1986 Honda ATC 350X is a three-wheel all-terrain vehicle featuring a 350cc four-stroke engine, 5-speed transmission with manual clutch, front and rear suspension systems, hydraulic front disc brake, and rear drum brake. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for proper operation and longevity of your ATC 350X. Below are key sections for safety, features, maintenance, specifications, operation, and troubleshooting.

Features at a Glance

Key components: 350cc air-cooled four-stroke engine, 5-speed manual transmission, front suspension with 7.1 inches travel, rear suspension with 7.9 inches travel, hydraulic front disc brake, rear drum brake.

Safety Precautions

Always wear proper safety gear and follow safe operating procedures.

1. Wear helmet, eye protection, gloves, and protective clothing.
2. Inspect vehicle before each use for proper operation.
3. Operate only in approved areas and obey local regulations.
4. Never carry passengers - designed for single rider only.

WARNING! ATCs can be hazardous to operate. Always follow safety guidelines and never operate under influence of drugs or alcohol.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

1. Engine oil change: Every 6 months or 600 miles
2. Oil filter replacement: Every 12 months or 1200 miles
3. Air filter cleaning: Every 3 months or 300 miles
4. Spark plug replacement: Every 12 months or 1200 miles
5. Brake inspection: Monthly or before each ride
6. Chain adjustment: Every 200 miles
7. Tire pressure check: Before each ride

CAUTION! Use only Honda Genuine Parts or equivalents for replacement components.

Specifications

• Engine: 350cc 4-stroke, air-cooled, single cylinder
• Bore x Stroke: 83.0 x 64.5mm
• Compression Ratio: 9.2:1
• Carburetor: 32mm Keihin
• Transmission: 5-speed manual
• Final Drive: Chain
• Front Tire: 23 x 8-11
• Rear Tires: 22 x 11-10
• Fuel Capacity: 2.6 gallons
• Oil Capacity: 2.0 quarts

Controls and Operation

Familiarize yourself with all controls before operation.

Left Handlebar: Clutch lever, choke, lighting switch, horn

Right Handlebar: Front brake lever, throttle, engine stop switch

Foot Controls: Gear shift lever, rear brake pedal

Starting Procedure: Turn fuel valve on, set choke for cold starts, kick start firmly. Allow warm-up before riding.

Engine Service

Engine maintenance procedures and specifications.

1. Oil Change: Warm engine, drain oil, replace filter, refill with 10W-40
2. Valve Adjustment: Intake 0.002 in, Exhaust 0.003 in (cold)
3. Spark Plug: NGK DR8ES-L, gap 0.028-0.031 in
4. Carburetor: Float level 12.5mm, main jet #132, pilot jet #42
5. Compression Test: Should read 156-185 psi

Tip: Always torque bolts to specified values using a torque wrench.

Transmission & Clutch

5-speed transmission with wet multi-plate clutch.

1. Clutch Adjustment: Adjust free play at lever (10-20mm)
2. Transmission Oil: SAE 10W-30, change every 1200 miles
3. Shift Pattern: 1-down, 4-up (N-1-2-3-4-5)
4. Chain Adjustment: 1.0-1.4 inches free play
5. Sprocket Teeth: Front 13T, Rear 40T

WARNING! Always check chain tension and sprocket wear regularly to prevent failure.

Brake Systems

Hydraulic front disc and mechanical rear drum brakes.

Front Brake: Check fluid level, pad wear, and rotor condition. Use DOT 4 brake fluid.

Rear Brake: Adjust cable free play, check shoe wear, adjust as needed.

Suspension & Steering

Front and rear suspension maintenance and adjustment.

1. Front Fork Oil: 10W, 180ml per leg
2. Rear Shock: Preload adjustable, check for leaks
3. Steering Head: Check for play, adjust as needed
4. Wheel Bearings: Check for play and smooth rotation

Electrical System

CDI ignition, lighting, and charging system.

• Battery: 12V 4Ah
• Charging Output: 12V 130W
• Spark Plug: NGK DR8ES-L
• Headlight: 12V 35/35W
• Tail Light: 12V 5/21W

Troubleshooting

Service: Contact authorized Honda dealer for major repairs

Parts: Use Honda Genuine Parts for optimal performance