Honda 86-88 TRX 200SX Fourtrax Manuals

Manuals and User Guides for Honda 86-88 TRX 200SX Fourtrax. We have 2 Honda 86-88 TRX 200SX Fourtrax manuals available for free PDF download: Service Manual, Owner's Manual

Honda 86-88 TRX 200SX Fourtrax Service Manual

Honda 86-88 TRX 200SX Fourtrax Service Manual (212 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 30.1 MB

Table of Contents

3
Contents
4
General Safety
4
Service Rules
5
Model Identification
6
Specifications
8
Torque Values
10
Special Tools
12
Cable and Harness Routing
17
Lubrication
18
Service Information: Specifications
18
Troubleshooting
19
Engine Oil Level
19
Engine Oil Change
19
Oil Filter Rotor and Screen
21
Oil Pump Removal
22
Oil Pump Inspection
23
Oil Pump Installation
24
Lubrication Points: Control Cables
26
Maintenance
27
Maintenance Schedule
28
Fuel Line
28
Fuel Strainer Screen
28
Throttle Operation
29
Carburetor Choke
29
Air Cleaner
30
Sprak Plug
31
Valve Clearance
31
Carburetor Idle Speed
32
Cylinder Compression
32
Drive Chain
33
Brake Fluid
33
Brake Shoe Wear
34
Brake System
35
Reverse Lock System
36
Clutch System
36
Suspension
36
Spark Arrester
37
Nut, Bolt, Fastener
37
Wheels/Tires
37
Steering System
40
Fuel System: Specifications
40
Fuel System: Table of Contents
41
Fuel System Troubleshooting
42
Fuel Tank Removal/Installation
43
Air Cleaner Case Removal/Installation
44
Throttle Valve Disassembly
44
Carburetor Removal
45
Carburetor Disassembly
46
Carburetor Assembly
48
Carburetor Installation
48
Throttle Valve Assembly
49
Air Screw Adjustment
49
High Altitude Adjustment
51
Engine Removal/Installation
52
Engine Removal/Installation: Specifications
52
Engine Removal/Installation: Table of Contents
53
Engine Removal
54
Engine Installation
55
Cylinder Head/Valves
56
Cylinder Head/Valves: Table of Contents
56
Cylinder Head/Valves: Specifications
57
Cylinder Head/Valves: Troubleshooting
58
Cylinder Head Cover Removal
58
Cylinder Head Cover Disassembly
60
Camshaft Removal
60
Cylinder Head Removal
61
Cylinder Head Disassembly
63
Valve Guide Replacement
64
Valve Seat Inspection/Refacing
66
Cylinder Head Assembly
67
Cylinder Head Installation
68
Camshaft Installation
70
Cylinder Head Cover Assembly
70
Cylinder Head Cover Installation
74
Cylinder/Piston: Specifications
74
Cylinder/Piston: Troubleshooting
74
Cylinder/Piston: Table of Contents
75
Cylinder Removal
75
Cylinder Inspection
76
Piston Removal
76
Piston Inspection
78
Piston/Cylinder Installation
78
Piston Ring Installation
81
Clutch/Gearshift Linkage
82
Clutch/Gearshift Linkage: Table of Contents
82
Clutch/Gearshift Linkage: Specifications
83
Clutch/Gearshift Linkage: Troubleshooting
84
Right Crankcase Cover Removal
84
Manual Clutch Lifter Mechanism
85
Centrifugal Clutch Removal
89
Manual Clutch Removal
90
Manual Clutch Inspection
91
Manual Clutch Installation
93
Gearshift Linkage Removal
94
Gearshift Linkage Installation
96
Right Crankcase Cover Installation
97
Recoil Starter/Alternator/Starter Clutch
98
Recoil Starter/Alternator/Starter Clutch: Table of Contents
98
Recoil Starter/Alternator/Starter Clutch: Troubleshooting
98
Recoil Starter/Alternator/Starter Clutch: Service Information
99
Recoil Starter Removal
99
Recoil Starter Disassembly
100
Recoil Starter Assembly
102
Recoil Starter Installation
102
Left Crankcase Cover Removal
103
Neutral/Reverse Switch Replacement
104
Alternator/Starter Clutch
104
Stator Replacement
104
Flywheel Removal
105
Starter Clutch Inspection
106
Flywheel Installation
107
Left Crankcase Cover Installation
109
Crankcase/Crankshaft/Transmission
110
Crankcase/Crankshaft/Transmission: Table of Contents
110
Crankcase/Crankshaft/Transmission: Service Information
110
Crankcase/Crankshaft/Transmission: Specifications
111
Crankcase/Crankshaft/Transmission: Troubleshooting
112
Crankcase Separation
113
Transmission Disassembly
113
Transmission Inspection
114
Bearing Replacement
116
Transmission Assembly
118
Crankshaft Removal
119
Crankshaft Inspection
120
Crankshaft Installation
120
Crankcase Assembly
123
Front Wheel/Suspension/Steering
124
Front Wheel/Suspension/Steering: Table of Contents
124
Front Wheel/Suspension/Steering: Specifications
126
Handlebar Removal
127
Handlebar Installation
129
Throttle Housing Disassembly
129
Throttle Housing Assembly
130
Front Wheel Removal
130
Front Wheel Installation
131
Front Tire Removal
132
Tire Repair
133
Tire Mounting
134
Tie-Rod Removal
134
Tie-Rod Inspection/Assembly
135
Tire-Rod Installation/Adjustment
135
Kingpin/Knuckle Removal
136
Kingpin/Knuckle Inspection
136
Knuckle Bushing Replacement
137
Kingpin/Knuckle Installation
138
Front Arm/Knuckle Holder Removal
139
Front Arm/Knuckle Holder Installation
140
Front Shock Absorber Removal/Disassembly
141
Spring Free Length Inspection
141
Front Shock Absorber Assembly/Installation
142
Steering Shaft Removal
144
Steering Bearing Replacement
145
Steering Shaft Installation
147
Brakes
148
Brakes: Table of Contents
148
Brakes: Specifications
149
Brakes: Troubleshooting
150
Front Brake Fluid Draining
150
Brake Fluid Filling
151
Brake Bleeding
151
Brake Hose Inspection
151
Front Brake Drum
153
Brake Lining Inspection
153
Brake Shoe/Wheel Cylinder/Adjuster
157
Master Cylinder
158
Master Cylinder Assembly
159
Rear Break Drum Removal
160
Rear Brake Drum Inspection
160
Rear Brake Lining Inspection
161
Rear Brake Panel
163
Rear Brake Drum Installation
164
Rear Brake Pedal Removal
164
Rear Brake Pedal Installation
165
Rear Wheel/Suspension
166
Rear Wheel/Suspension: Specifications
166
Rear Wheel/Suspension: Table of Contents
167
Rear Wheel/Suspension: Troubleshooting
168
Rear Wheel Removal
168
Rear Wheel Installation
168
Rear Axle/Bearings
168
Rear Axle Removal
169
Rear Axle Inspection
170
Rear Bearing Inspection/Replacement
171
Rear Axle Installation
172
Rear Shock Absorber Removal
173
Rear Shock Absorber Disassembly/Assembly
174
Swing Arm Removal
175
Swing Arm Installation
175
Pivot Bushing Replacement
177
Fenders/Exhaust Muffler
178
Fenders/Exhaust Muffler Table of Contents
178
Front Fender Removal/Installation
179
Rear Fender Removal/Installation
179
Exhaust Pipe/Muffler Removal/Installation
181
Ignition System
182
Ignition System: Table of Contents
182
Ignition System: Specifications
182
Ignition System: Troubleshooting
183
Ignition Coil Removal
183
Ignition Coil Inspection
183
Ignition Coil Installation
183
Alternator Exciter Coil
184
CDI Unit Inspection
185
Pulse Generator
185
Ignition Timing
187
Battery/Charging System
188
Battery/Charging System: Table of Contents
188
Battery/Charging System: Specifications
188
Battery/Charging System: Troubleshooting
189
Battery Removal/Inspection
189
Battery Charging
189
Battery Installation
189
Charging System Leak down Test
190
Charging Output Test
190
Regulator/Rectifier Inspection
191
Regulator/Rectifier Replacement
191
Alternator Charging Coil Inspection
193
Starter System
194
Starter System: Table of Contents
194
Starter System: Specifications
194
Starter System: Troubleshooting
195
Starter Motor Removal
195
Starter Brush Inspection
196
Starter Case Inspection
197
Starter System Assembly
198
Starter Relay
200
Lights/Switches: Table of Contents
200
Lights/Switches: Service Information
200
Lights/Switches Troubleshooting
201
Headlight Bulb Replacement
201
Taillight Bulb Replacement
202
Indicator Lamp Bulb Replacement
202
Indicator Housing Removal
202
Neutral/Reverse Switch
203
Ignition Switch Inspection
203
Ignition Switch Removal
203
Handlebar Switch
204
Lights/Switches Wiring Diagram
206
Engine Does Not Start or Is Hard to Start
207
Engine Lacks Power
208
Poor Performance Low and Idle Speed
209
Poor Performance at High Speeds
209
Poor Handling
210
Index

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Honda 86-88 TRX 200SX Fourtrax Owner's Manual

Honda 86-88 TRX 200SX Fourtrax Owner's Manual (73 pages)

HONDA

Brand: Honda | Category: Offroad Vehicle | Size: 2.2 MB

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