Honda 86-87 TA200 FATCAT Manuals

Manuals and User Guides for Honda 86-87 TA200 FATCAT. We have 1 Honda 86-87 TA200 FATCAT manual available for free PDF download: Service Manual

Honda 86-87 TA200 FATCAT Service Manual

Honda 86-87 TA200 FATCAT Service Manual (207 pages)

Brand: Honda | Category: Motorcycle | Size: 24.17 MB

Table of Contents

Important Safety Notice
4
Contents
5
General Information
7
General Safety
7
Service Rules
7
Carburetor Identification Number
8
Engine Serial Number
8
Frame Serial Number
8
Model Identification
8
Specifications
9
Torque Values
11
Standard Torque Values
12
Tools
13
Valve Seat Cutter
14
Cable & Harness Routing
15
Noise Emission Control System
19
Lubrication Diagram
20
Lubrication Service Information
21
Lubrication Specifications
21
Lubrication Troubleshooting
21
Whitish Exhaust Gass
21
Engine Oil
22
Oil Change
22
Oil Filter Rotor and Screen
22
Oil Level Check
22
Oil Pump Removal
24
Oil Pump Inspection
25
Oil Pump Installation
26
Lubrication Points
27
Table of Contents
29
Maintenance
29
Fuel Line
30
Fuel Strainer Screen
30
Maintenance Schedule
30
- Fuel Line
  32
- Fuel Strainer Screen
  32
Throttle Operation
32
Air Cleaner
33
Carburetor-Choke
33
Spark Plug
34
Valve Clearance
35
Carburetor-Idle Speed
36
Chain Slack Inspection
36
Drive Chain
36
Chain Slack Adjustment
37
Brake Shoe Wear
38
- Drive Chain Slider
  38
- Front Brake
  38
- Rear Brake
  38
- Brake System
  39
Front Br Ake Lever Free Play
39
Rear Brake Pedal Free Play
40
- Rear Brake Pedal Height
  40
- Brake Lock Lever
  41
Clutch System
41
Headlight Aim
41
Gearshift Pedal Pivot
42
- Side Stand
  42
- Suspension
  42
- Spark Arrester
  43
- Nut, Bolt, Fastener
  43
Kg /CM
44
Psi
44
Wheel
44
- Steering Head Bearing
  44
- Cylinder Compression
  44
- Fuel System Service Information
  47
- Fuel System Specifications
  47
- Fuel System Tool
  47
- Engine Cranks but Won't Start
  48
- Fuel System Troubleshooting
  48
- Hard Starting or Stalling after Starting
  48
- Rough Idle
  48
- Fuel Tank
  49
- Air Cleaner Case
  50
- Carburetor Disassembly
  52
- Carburetor Removal
  52
- Throttle Valve Removal
  52
- Float and Jets
  53
- Carburetor Assembly
  54
- Float Level Inspection
  55
- Throttle Valve
  55
- Air Screw Adjustment
  56
- Carburetor Installation
  56
- High Altitude Adjustment
  57
Kg -M
58
- Engine Removal/Installation
  59
- Ft-Lbj
  59
  - Engine Removal
    60
  - Engine Installation
    62
  - Cylinder Head/Valves
    64
- Ft -Ib)
  64
Kg-M
64
- Cylinder Head/Valves Service Information
  65
- Cylinder Head/Valves Specifications
  65
- Cylinder Head/Valves Torque Values
  65
- Compression too High
  66
- Cylinder Head/Valves Tools
  66
- Cylinder Head/Valves Troubleshooting
  66
- Low Compression
  66
- Cylinder Head Cover Removal
  67
- Cylinder Head Cover Disassembly
  68
- Rocker Arm
  68
- Rocker Arm Shaft
  68
- Camshaft Removal
  69
- Cylinder Head Disassembly
  70
- Cylinder Head Removal
  70
- Velve Stem-Ta-Guide Clearance
  71
- Valve Guide Replacement
  72
- Valve Seat Cutters
  73
- Valve Seat Inspection/Refacing
  73
- Valve Seat Refacing
  74
- Cylinder Head Assembly
  75
- Cylinder Head Installation
  76
- Camshaft Installation
  77
- Cylinder Head Cover Assembly
  79
- Cylinder Head Cover Installation
  79
- Cylinder/Piston
  80
- Cylinder/Piston Service Information
  81
- Cylinder/Piston Specifications
  81
- Cylinder/Piston Troubleshooting
  81
- Low or Unstable Compression
  81
- Cylinder Inspection
  82
- Cylinder Removal
  82
- Piston Inspection
  83
- Piston Installation
  85
- Piston Ring Installation
  85
- Piston/Cylinder Installation
  85
- Cylinder Installation
  86
- Clutch/Kick Starter/Gearshift Linkage
  88
- Clutch/Kick Starter/Gearshift Linkage Service Information
  89
- Clutch/Kick Starter/Gearshift Linkage Specifications
  89
- Clutch/Kick Starter/Gearshift Linkage Tools
  89
- Clutch/Kick Starter/Gearshift Linkage Torque Values
  89
- Clutch Slips When Accelerating
  90
- Clutch will Not Disengage
  90
- Clutch/Kick Starter/Gearshift Linkage Troubleshooting
  90
- Hard to Shift
  90
- Right Crankcase Cover Removal
  91
- Right Crankcase Cover Disassembly
  92
- Centrifugal Clutch
  93
- Weight Lining Inspection
  93
- Manual Clutch Removal
  98
- Manual Clutch Inspection
  99
- Manual Clutch Installation
  100
- Gearshift Linkage
  102
- Kick Starter
  104
- Right Crankcase Cover Installation
  107
- Alternator/Starter Clutch
  108
- Alternator/Starter Clutch Service Information
  109
- Alternator/Starter Clutch Torque Values
  109
- Alternator/Starter Clutch Troubleshooting
  109
- Engine Does Not Turn When Operating Starter Motor
  109
- Left Crankcase Cover Removal
  110
- Flywheel Removal
  111
- Stator Replacement
  111
- Flywheel Installation
  113
- Starter Clutch Disassembly/Assembly
  113
- Starter Clutch Inspection
  113
- Left Crankcase Cover Installation
  114
- Crankcase/Crankshaft/Transmission
  116
- Crankcase/Crankshaft/Transmission Service Information
  117
- Crankcase/Crankshaft/Transmission Specifications
  117
- Crankcase/Crankshaft/Transmission Tools
  118
- Crankcase/Crankshaft/Transmission Torque Values
  118
- Crankcase/Crankshaft/Transmission Troubleshooting
  118
- Crankshaft Noisy
  118
- Crankcase Separation
  119
- Transmission Disassembly
  120
- Transmission Inspection
  121
- Transmission Bearing Replacement
  122
- Left Crankcase
  123
- Right Crankcase
  123
- Crankshaft Inspection
  126
- Crankshaft Removal
  126
- Crankshaft Installation
  127
- Crankcase Assembly
  128
- Front Wheel/Brake/Suspension/Steering
  130
- Front Wheel/Brake/Suspension/Steering Service Information
  131
- Front Wheel/Brake/Suspension/Steering Specifications
  131
- Front Wheel/Brake/Suspension/Steering Torque Values
  131
- Front Wheel Wobbling
  132
- Front Wheel/Brake/Suspension/Steering Tools
  132
- Front Wheel/Brake/Suspension/Steering Troubleshooting
  132
- Hard Steering
  132
- Handlebar Installation
  133
- Handlebar Removal
  133
- Front Wheel Inspection
  135
- Front Wheel Removal
  135
- Wheel Bearing
  136
- Tires Removal
  138
- Tire Repair
  141
- Tires Assembly
  142
- Brake Drum
  143
- Brake Lining
  143
- Brake Panel Disassembly
  143
- Brake Panel Assembly
  144
- Front Fork Disassembly
  145
- Front Fork Removal
  145
- Bushing/Back-Up Ring
  147
- Fork Tube/Fork Slider/Piston
  147
- Front Fork Inspection
  147
- Fork Tube
  148
- Capacity
  150
- Recommended Oil
  150
- Specified Level
  150
- Steering Stem Removal
  151
- Bearing Races Inspection
  152
- Bearing Races Replacement
  152
- Steering Stem Installation
  153
- Rear Wheel/Brake/Suspension Service Information
  157
- Rear Wheel/Brake/Suspension Specifications
  157
- Rear Wheel/Brake/Suspension Torque Values
  157
- Rear Wheel/Brake/Suspension Tools
  158
- Rear Wheel/Brake/Suspension Troubleshooting
  158
- Soft Suspension
  158
- Wobble or Vibration in Motorcycle
  158
- Axle
  159
- Rear Wheel Inspection
  159
- Rear Wheel Removal
  159
- Rear Wheel Rim Runout
  159
- Wheel Bearings
  160
- Rear Wheel Assembly
  162
- Rear Wheel Installation
  162
- Brake Drum Inspection
  163
- Brake Lining Inspection
  163
- Shock Absorber Disposal Procedure
  167
- Spring Inspection
  167
- Swingarm Inspection
  169
- Swingarm Removal
  169
- Pivot Bushing Replacement
  170
- Swingarm Installation
  170
- Fenders/Exhaust Muffler Service Information
  173
- Seat Removal/Installation
  173
- Side Covers Removal/Installation
  173
- Front and Rear Fender Removal/Installation
  174
- Exhaust Pipe/Muffler Removal/Installation
  175
- Engine Starts but Stops
  177
- Ignition System Service Information
  177
- Ignition System Specifications
  177
- Ignition System Troubleshooting
  177
- CDI Unit
  178
- Performance Test
  178
- Alternator Exciter Coil
  179
- Ignition Coil
  179
- Primary Circuit Inspection
  179
- Secondary Circuit Inspection
  179
- Ignition Timing
  180
- Pulse Generator
  180
- Battery/Charging System
  182
- Battery/Charging System Service Information
  183
- Battery/Charging System Specifications
  183
- Battery/Charging System Troubleshooting
  183
- No Power - Key Turned on
  183
- Battery Charging
  184
- Battery Removal/Installation
  184
- Charging System Leaking Test
  184
- Charging Coil Inspection
  185
- Charging Voltage Inspection
  185
- Regulator/Rectifier
  185
- Starter System
  188
- Starter Motor will Not Turn
  189
- Starter System Service Information
  189
- Starter System Specifications
  189
- Starter System Troubleshooting
  189
- Commutator Inspection
  190
- Starter Motor Brush Inspection
  190
- Starter Motor Removal
  190
- Case Inspection
  191
- Starter Relay
  192
- Headlight Beams Do Not Shift When Hi-Lo Switch Is Operated
  193
- Light Does Not Come on When Light Switch Is Turned on
  193
- Lights/Switches Service Information
  193
- Lights/Switches Troubleshooting
  193
- Headlight Bulb Replacement
  194
- Headlight Case Removal/Installation
  194
- Neutral Indicator Lamp
  195
- Neutral Switch
  195
- Taillight Bulb Replacement
  195
- Engine Stop Switch
  196
- Handlebar Switch
  196
- Ignition Switch Inspection
  196
- Ignition Switch Removal
  196
- Wiring Diagram
  197
- Engine Does Not Start or Is Hard to Start
  199
- Troubleshooting
  199
- Engine Lacks Power
  200
- Poor Performance at Low (and High Speeds)
  201
- Poor Handling
  202
- Poor Performance at High Speeds
  202
- Under Charge/Over Charge of the Battery
  203
- Weak or no Spark
  204
- Index
  205

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