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86-88 TRX 200SX Fourtrax
Honda 86-88 TRX 200SX Fourtrax User Manual
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2
Table of Contents
Contents
3
General Safety
4
Service Rules
4
Model Identification
5
Specifications
6
Torque Values
8
Special Tools
10
Cable and Harness Routing
12
Lubrication
17
Service Information: Specifications
18
Troubleshooting
18
Engine Oil Level
19
Engine Oil Change
19
Oil Filter Rotor and Screen
19
Oil Pump Removal
21
Oil Pump Inspection
22
Oil Pump Installation
23
Lubrication Points: Control Cables
24
Maintenance
26
Maintenance Schedule
27
Fuel Line
28
Fuel Strainer Screen
28
Throttle Operation
28
Carburetor Choke
29
Air Cleaner
29
Sprak Plug
30
Valve Clearance
31
Carburetor Idle Speed
31
Cylinder Compression
32
Drive Chain
32
Brake Fluid
33
Brake Shoe Wear
33
Brake System
34
Reverse Lock System
35
Clutch System
36
Suspension
36
Spark Arrester
36
Nut, Bolt, Fastener
37
Wheels/Tires
37
Steering System
37
Fuel System: Specifications
40
Fuel System: Table of Contents
40
Fuel System Troubleshooting
41
Fuel Tank Removal/Installation
42
Air Cleaner Case Removal/Installation
43
Throttle Valve Disassembly
44
Carburetor Removal
44
Carburetor Disassembly
45
Carburetor Assembly
46
Carburetor Installation
48
Throttle Valve Assembly
48
Air Screw Adjustment
49
High Altitude Adjustment
49
Engine Removal/Installation
51
Engine Removal/Installation: Specifications
52
Engine Removal/Installation: Table of Contents
52
Engine Removal
53
Engine Installation
54
Cylinder Head/Valves
55
Cylinder Head/Valves: Table of Contents
56
Cylinder Head/Valves: Specifications
56
Cylinder Head/Valves: Troubleshooting
57
Cylinder Head Cover Removal
58
Cylinder Head Cover Disassembly
58
Camshaft Removal
60
Cylinder Head Removal
60
Cylinder Head Disassembly
61
Valve Guide Replacement
63
Valve Seat Inspection/Refacing
64
Cylinder Head Assembly
66
Cylinder Head Installation
67
Camshaft Installation
68
Cylinder Head Cover Assembly
70
Cylinder Head Cover Installation
70
Cylinder/Piston: Specifications
74
Cylinder/Piston: Troubleshooting
74
Cylinder/Piston: Table of Contents
74
Cylinder Removal
75
Cylinder Inspection
75
Piston Removal
76
Piston Inspection
76
Piston/Cylinder Installation
78
Piston Ring Installation
78
Clutch/Gearshift Linkage
81
Clutch/Gearshift Linkage: Table of Contents
82
Clutch/Gearshift Linkage: Specifications
82
Clutch/Gearshift Linkage: Troubleshooting
83
Right Crankcase Cover Removal
84
Manual Clutch Lifter Mechanism
84
Centrifugal Clutch Removal
85
Manual Clutch Removal
89
Manual Clutch Inspection
90
Manual Clutch Installation
91
Gearshift Linkage Removal
93
Gearshift Linkage Installation
94
Right Crankcase Cover Installation
96
Recoil Starter/Alternator/Starter Clutch
97
Recoil Starter/Alternator/Starter Clutch: Table of Contents
98
Recoil Starter/Alternator/Starter Clutch: Troubleshooting
98
Recoil Starter/Alternator/Starter Clutch: Service Information
98
Recoil Starter Removal
99
Recoil Starter Disassembly
99
Recoil Starter Assembly
100
Recoil Starter Installation
102
Left Crankcase Cover Removal
102
Neutral/Reverse Switch Replacement
103
Alternator/Starter Clutch
104
Stator Replacement
104
Flywheel Removal
104
Starter Clutch Inspection
105
Flywheel Installation
106
Left Crankcase Cover Installation
107
Crankcase/Crankshaft/Transmission
109
Crankcase/Crankshaft/Transmission: Table of Contents
110
Crankcase/Crankshaft/Transmission: Service Information
110
Crankcase/Crankshaft/Transmission: Specifications
110
Crankcase/Crankshaft/Transmission: Troubleshooting
111
Crankcase Separation
112
Transmission Disassembly
113
Transmission Inspection
113
Bearing Replacement
114
Transmission Assembly
116
Crankshaft Removal
118
Crankshaft Inspection
119
Crankshaft Installation
120
Crankcase Assembly
120
Front Wheel/Suspension/Steering
123
Front Wheel/Suspension/Steering: Table of Contents
124
Front Wheel/Suspension/Steering: Specifications
124
Handlebar Removal
126
Handlebar Installation
127
Throttle Housing Disassembly
129
Throttle Housing Assembly
129
Front Wheel Removal
130
Front Wheel Installation
130
Front Tire Removal
131
Tire Repair
132
Tire Mounting
133
Tie-Rod Removal
134
Tie-Rod Inspection/Assembly
134
Tire-Rod Installation/Adjustment
135
Kingpin/Knuckle Removal
135
Kingpin/Knuckle Inspection
136
Knuckle Bushing Replacement
136
Kingpin/Knuckle Installation
137
Front Arm/Knuckle Holder Removal
138
Front Arm/Knuckle Holder Installation
139
Front Shock Absorber Removal/Disassembly
140
Spring Free Length Inspection
141
Front Shock Absorber Assembly/Installation
141
Steering Shaft Removal
142
Steering Bearing Replacement
144
Steering Shaft Installation
145
Brakes
147
Brakes: Table of Contents
148
Brakes: Specifications
148
Brakes: Troubleshooting
149
Front Brake Fluid Draining
150
Brake Fluid Filling
150
Brake Bleeding
151
Brake Hose Inspection
151
Front Brake Drum
151
Brake Lining Inspection
153
Brake Shoe/Wheel Cylinder/Adjuster
153
Master Cylinder
157
Master Cylinder Assembly
158
Rear Break Drum Removal
159
Rear Brake Drum Inspection
160
Rear Brake Lining Inspection
160
Rear Brake Panel
161
Rear Brake Drum Installation
163
Rear Brake Pedal Removal
164
Rear Brake Pedal Installation
164
Rear Wheel/Suspension
165
Rear Wheel/Suspension: Specifications
166
Rear Wheel/Suspension: Table of Contents
166
Rear Wheel/Suspension: Troubleshooting
167
Rear Wheel Removal
168
Rear Wheel Installation
168
Rear Axle/Bearings
168
Rear Axle Removal
168
Rear Axle Inspection
169
Rear Bearing Inspection/Replacement
170
Rear Axle Installation
171
Rear Shock Absorber Removal
172
Rear Shock Absorber Disassembly/Assembly
173
Swing Arm Removal
174
Swing Arm Installation
175
Pivot Bushing Replacement
175
Fenders/Exhaust Muffler
177
Fenders/Exhaust Muffler Table of Contents
178
Front Fender Removal/Installation
178
Rear Fender Removal/Installation
179
Exhaust Pipe/Muffler Removal/Installation
179
Ignition System
181
Ignition System: Table of Contents
182
Ignition System: Specifications
182
Ignition System: Troubleshooting
182
Ignition Coil Removal
183
Ignition Coil Inspection
183
Ignition Coil Installation
183
Alternator Exciter Coil
183
CDI Unit Inspection
184
Pulse Generator
185
Ignition Timing
185
Battery/Charging System
187
Battery/Charging System: Table of Contents
188
Battery/Charging System: Specifications
188
Battery/Charging System: Troubleshooting
188
Battery Removal/Inspection
189
Battery Charging
189
Battery Installation
189
Charging System Leak down Test
189
Charging Output Test
190
Regulator/Rectifier Inspection
190
Regulator/Rectifier Replacement
191
Alternator Charging Coil Inspection
191
Starter System
193
Starter System: Table of Contents
194
Starter System: Specifications
194
Starter System: Troubleshooting
194
Starter Motor Removal
195
Starter Brush Inspection
195
Starter Case Inspection
196
Starter System Assembly
197
Starter Relay
198
Lights/Switches: Table of Contents
200
Lights/Switches: Service Information
200
Lights/Switches Troubleshooting
200
Headlight Bulb Replacement
201
Taillight Bulb Replacement
201
Indicator Lamp Bulb Replacement
202
Indicator Housing Removal
202
Neutral/Reverse Switch
202
Ignition Switch Inspection
203
Ignition Switch Removal
203
Handlebar Switch
203
Lights/Switches Wiring Diagram
204
Engine Does Not Start or Is Hard to Start
206
Engine Lacks Power
207
Poor Performance Low and Idle Speed
208
Poor Performance at High Speeds
209
Poor Handling
209
Index
210
4
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Honda 86-88 TRX 200SX Fourtrax Specifications
General
Brand
Honda
Model
86-88 TRX 200SX Fourtrax
Category
Offroad Vehicle
Language
English
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