1990-1997 Honda TRX200/TRX200D Service Manual
Complete service documentation for TRX200 (1990-1991) and TRX200D (1991-1997) models. Covers engine service, transmission, brakes, suspension, electrical systems. Comprehensive repair procedures with torque specifications and maintenance schedules.
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Sample pages from the 1990-1997 Honda TRX200/TRX200D Service Manual manual
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Models Covered & Key Technical Specifications
Honda TRX200/TRX200D — 1990–1997 Licensed Strategic Commercial Set.
- Engineered DPI Rating: 199.1 cc is specified as the engine displacement cubic capacity Benchmarks.
- Design Fastening Values: For optimal compression, 8.4:1 is measured at the rated engine compression ratio Range.
- Documented Fluid Capacity: 8.1 liters — controls the fuel tank volume capacity Sequences.
- Principal End Play: The crankshaft requires 0.10 mm (0.004 in) maximum runout clearance Baseline.
- Advanced Cooling Specs: Operating temperature reaches 883–1079 kPa (128–156 psi) cylinder compression Requirements.
- Primary Resolution Data: Maximum horsepower governs 20.9 kW (28 hp) net flywheel output Threshold.
Professional Workshop Service Manual & Technical Specifications
Comprehensive Assembly Diagnostic Manual: Honda TRX200/TRX200D 1990-1997 ATV Service Guide
Specification-Class: TRX200, TRX200D // Design-Core: Engine and transmission procedures / Hydraulic brake logic // Year-Coverage: 1990-1991, 1991-1997.
| Performance-Element | System-Path | Validation-Data |
|---|---|---|
| Engine Top-End | Camshaft, Cylinder Head, Valve Train | Complete assembly procedures documented |
| Transmission | Mainshaft, Countershaft, Shift Drum | Component configuration and clearance specifications included |
| Brake System | Hydraulic Master Cylinder, Wheel Cylinders, Drum Brakes | Fluid type and operational procedures referenced |
Cataloging major assemblies into the service protocol, this document covers the TRX200 and TRX200D ATVs from 1990 through 1997, incorporating engine and transmission systems, suspension and steering mechanisms, brake and charging system maintenance, and the complete electrical network. The manual presents general information and specifications, addresses frame and body panel service, organizes lubrication points, and covers fuel system procedures together with detailed cylinder head and piston service, clutch operation, crankcase separation, suspension assembly, brake system maintenance, and ignition timing verification.
Engineered Interface
The manual provides comprehensive coverage of the engine compartment, documenting camshaft installation procedures, cylinder head gasket placement, valve clearance reference data, and piston ring configuration. Oil circulation pathways are included for the forced pressure and wet sump system, with lubrication specifications for crankshaft, transmission gear teeth, and cam chain operation. The document includes references to tool requirements for valve guide installation, spark plug specifications, and ignition coil testing protocols.
Strategic Interface
Detailed procedures address the transmission assembly with mainshaft gear configurations (M3, M4, M5 models) and countershaft arrangements (C1, C2, C3, CR gears), including bushing clearance specifications and shift fork positioning. The manual documents clutch system components with reference to centrifugal drum operation, manual clutch disc thickness, and one-way clutch function. Final drive gear backlash data is provided for rear axle assembly, and the document includes information on drive chain slack measurement and sprocket engagement.
Advanced Framework
The front and rear suspension systems are comprehensively outlined, with double wishbone and swingarm pivot documentation, shock absorber mounting specifications, and wheel bearing assembly procedures. Brake system information covers both hydraulic front drum brake operation and cable-operated rear brake configuration, including wheel cylinder piston sizing and brake shoe lining thickness. Steering system components include kingpin assembly details, ball joint positioning, and tie-rod adjustment reference data.
Structured Benchmarks
Electrical system documentation encompasses the charging system with alternator wire connector specifications, battery capacity information (12V-10AH), and regulator/rectifier voltage ranges. The ignition system section includes spark plug specifications, CDI unit connector arrangements, and pulse generator coil resistance reference values. The starter motor assembly is documented with brush spring tension data and motor disassembly component listing, alongside lighting system bulb specifications and switch continuity testing procedures.
Diagnostic Threshold
Troubleshooting sections address engine starting issues, compression testing indicators, fuel flow diagnostics, and brake system performance verification. The document includes handling and suspension noise identification, poor performance assessment at varying engine speeds, and wheel wobbling diagnostic procedures. Wiring diagram documentation and integrated circuit continuity charts provide verification methods for ignition switch operation, engine stop switch function, and change switch positions for transmission neutral and reverse detection.
The manual documents torque specifications for the engine mounting hardware to ensure proper assembly security.
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