Honda 1981 ATC 200 Manuals

Manuals and User Guides for Honda 1981 ATC 200. We have 1 Honda 1981 ATC 200 manual available for free PDF download: Shop Manual

Honda 1981 ATC 200 Shop Manual (229 pages)

Brand: Honda | Category: Motorcycle | Size: 32.63 MB

Important Safety Notice
2
Contents
3
How to Use this Manual
3
Model Identification
4
General Safety
5
Service Rules
5
Specifications
6
Torque Values Specification
8
Tools Specifications
10
Cable & Harness Routing
11
Maintenance Schedule
12
Lubrication
14
Service Information
15
Troubleshooting
15
Engine Oil Level Check
16
Engine Oil Change and Oil Filter Screen Clearing
16
Oil Filter Rotor Cleaning
17
Lubrication Points
18
Inspection/Adjustment Specifications
19
Air Cleaner
21
Spark Plug
22
Valve Clearance
23
Cam Chain Tension
24
Carburetor Idle Speed
24
Fuel Line
24
Fuel Strainer
25
Throttle Operation
25
Ignition Timing
26
Cylinder Compression
26
Drive Chain
27
Brake Shoes
29
Front Brake
29
Rear Brake
30
Clutch
31
Spark Arrester Cleaning
31
Nut, Bolts, Fasteners
32
Lighting Equipment
32
Tires
32
Steering Head Bearings
33
Fuel System
35
Fuel System Troubleshooting
36
Fuel Tank
37
Air Cleaner Case
38
Crankcase Breather
39
Carburetor Removal
40
Throttle Valve Disassembly
41
Float, Float Valve and Jets
41
Carburetor Assembly
42
Float Level Adjustment
43
Throttle Valve Assembly
43
Carburetor Installation
43
Pilot Screw Adjustment
44
High Altitude Adjustment
44
Engine Removal
48
Engine Installation
51
Cylinder Head/Valves
53
Cylinder Head/Valves Specifications
54
Camshaft Removal
55
Cylinder Head Cover Removal
57
Rocker Arm Inspection
58
Rocker Arm Shaft Inspection
58
Camshaft Bearing Inspection
59
Camshaft Bushing Inspection
59
Cylinder Head Removal
59
Cylinder Head Disassembly
60
Cylinder Head Inspection
60
Valve Spring Inspection
61
Valve/Valve Guide Inspection
61
Valve Guide Replacement
62
Valve Seat Inspection/Refacing
63
Valve Seat Grinding
63
Cylinder Head Assembly
65
Cylinder Head Installation
66
Camshaft Installation
69
Pulser Rotor Assembly
70
Cylinder/Piston Troubleshooting
73
Cylinder Removal
74
Cylinder Inspection
74
Piston Removal
75
Piston/Piston Ring Inspection
75
Pistol Ring Installation
77
Piston Installation
78
Cylinder Installation
78
Clutch/Oil Pump
80
Clutch/Oil Pump Specification
81
Clutch/Oil Pump Troubleshooting
82
Right Crankcase Cover Removal
83
Clutch Lifter Disassembly
83
Clutch Lifter Assembly
84
Centrifugal Clutch Removal
85
Weight Inspection
86
Clutch Drum Inspection
87
Clutch Installation
88
Manual Clutch Removal
91
Clutch Inspection
92
Manual Clutch Installation
93
Oil Pump Removal
95
Oil Pump Disassembly
95
Oil Pump Inspection
96
Oil Pump Assembly
96
Oil Pump Installation
97
Gearshift Linkage Disassembly
98
Gearshift Linkage Assembly
99
Starter/A.C. Generator Troubleshooting
103
Recoil Starter Removal
104
Recoil Starter Disassembly
104
Recoil Starter Assembly
106
A.C. Generator Removal
108
A.C. Generator Installation
109
Recoil Starter Installation
111
Transmission/Crankshaft/Kick Starter Specifications
113
Transmission/Crankshaft/Kick Starter Troubleshooting
113
Crankcase Separation
114
Crankshaft Removal
115
Crankshaft Inspection
115
Crankshaft Bearing Inspection
116
Timing Sprocket Installation
117
Transmission Disassembly
117
Shift Fork/Shift Shaft Inspection
117
Transmission Assembly
119
Crankcase Assembly
120
Front Wheel/Brake/Steering Specifications
123
Front Wheel/Brake/Steering Troubleshooting
124
Headlight Case Removal
125
Headlight Case Installation
125
Handlebar Removal
126
Handlebar Installation
126
Brake Lever Bracket/Throttle Lever Installation
127
Throttle Lever Disassembly
128
Throttle Lever Assembly
129
Front Wheel Removal
130
Front Axle Inspection
131
Wheel Bearing Inspection
131
Brake Drum Inspection
131
Front Wheel Disassembly
132
Tire Removal
133
Tire Repair(with Cold Patch)
134
Tire Repair(with Rubber Plug)
135
Tire Assembly
135
Front Wheel Assembly
137
Front Brake Lining Inspection
138
Brake Panel Disassembly
139
Brake Panel Assembly
139
Fork Top Bridge Removal
140
Front Fork Removal
140
Steering Stem Installation
141
Top Bridge Installation
142
Rear Wheel/Brake/Drive Mechanism Specifications
145
Rear Wheel/Brake/Drive Mechanism Troubleshooting
146
Rear Wheel Removal
147
Rear Tire Disassembly/Assembly
147
Rear Wheel Installation
147
Rear Axle Removal
148
Final Driven Sprocket Inspection
150
Axle Inspection
151
Rear Wheel Bearing Holder Removal
151
Brake Lining Inspection
152
Rear Brake Drum Inspection
152
Rear Brake Disassembly
152
Rear Wheel Bearing Holder Disassembly
153
Rear Wheel Bearing Inspection
153
Rear Wheel Bearing Holder Assembly
154
Final Driven Flange Assembly
155
Rear Axle Installation
156
Rear Fender Removal
159
Rear Fender Installation
159
Exhaust Pipe Removal
160
Exhaust Pipe Installation
160
Ignition System Troubleshooting
163
Ignition System Specifications
163
Ignition Coil Removal
164
Ignition Coil Inspection
164
Generator
164
Lighting/Exciter Coil
164
CDI Unit Removal
165
CDI Unit Inspection
165
Pulser Generator
166
Ignition System Ignition Timing
166
Lights/Switches Troubleshooting
167
Lights/Switches Specifications
167
Headlight Disassembly
168
Headlight Assembly
168
Taillight Disassembly
168
Taillight Assembly
168
Light/Dimmer Switch
169
Engine Stop Switch
169
Wiring Diagram
171
Clutch Technical Features
173
Full Troubleshooting
175
Engine Does Not Start or Is Hard to Start
175
Engine Lacks Power
176
Poor Performance at Low and Idle Speeds
177
Poor Performance at High Speeds
178
Poor Handling
178
81 Addendum: Contents
179
General Information Specifications ATC185S
180
ATC200 Specification
181
Torque Values
183
Cable and Harness Routing
184
Regular Maintenance Schedule
185
Inspection/Adjustment
186
Air Cleaner and Case
186
Clutch Inspection/Adjustment
187
Crankcase Breather Inspection/Adjustment
187
Front Wheel/Brake/Steering
188
Fork Bridge Installation
189
Rear Wheel/Brake/Drive
190
Lighting Switch
192
1982 Addendum: Contents
195
1982 Addendum General Information Specifications
196
1982 Addendum Torque Values
196
1982 Addendum Maintenance Schedule
197
1982 Addendum Cable and Harness Routing
198
1982 Addendum Lubrication
199
1982 Addendum Oil Recommendation
199
1982 Addendum Inspection/Adjustment
199
1982 Addendum Air Cleaner and Case
199
1982 Addendum: High Altitude Adjustment
201
1982 Addendum: Front Wheel/Brake/Steering
202
1982 Addendum: Front Wheel Removal
203
1982 Addendum: Front Wheel Installation
203
1982 Addendum: Rear Wheel/Brake/Drive Mechanism
204
Rear Wheel(ATC200)
205
Rear Brake(ATC200)
205
Brake Drum Cover Removal
205
Drive Mechanism (ATC200)
207
1982 Addendum: Wiring Diagram
208
1982 Addendum: Recoil Starter Disassembly
209
1982 Addendum: Recoil Starter Inspection
211
1982 Addendum: Decompression System Inspection
211
1983 Addendum: Contents
215
1983 Addendum: General Information Specifications
216
1983 Addendum: Cable and Harness Routing
218
1983 Addendum: Maintenance Schedule
219
1983 Addendum: Lubrication
220
1983 Addendum: Oil Recommendation
220
1983 Addendum: Air Cleaner and Case Inspection/Adjustment
220
1983 Addendum: High Altitude Adjustment
221
1983 Addendum: Front Wheel/Suspension Removal
222
1983 Addendum: Front Wheel/Suspension Installation
222
1983 Addendum: Drive Chain and Sealed Brake(ATC185S)
226
1983 Addendum: Wiring Diagram
227

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Honda 1981 ATC 200 Shop Manual (229 pages)

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