Honda TRX200/TRX200D 1990–1997 Service Manual

155 Pages • 15.00 MB • Instant, Printable PDF

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Honda Models Covered & Key Technical Specifications

Models: Honda TRX200, Honda TRX200D

Sub-models / Variants: 1990-1991 TRX200, 1991-1997 TRX200D

Model Years: 1990–1997

Technical Data:

  • Engine displacement: 199.1 cc

  • Compression ratio: 8.4:1

  • Cylinder compression: 883–1079 kPa (128–156 psi)

  • Transmission type: 4-speed constant mesh with reverse (TRX200), 5-speed constant mesh with reverse (TRX200D after '91)

  • Fuel tank capacity: 8.1 liters

  • Valve clearance (IN/EX): 0.16 ± 0.02 mm

  • Idle speed: 1,400 ± 100 rpm

  • Drive chain slack: 15–25 mm (5/8–1 in)

Technical Specifications
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Document Number / Seller:
24922 / Laura Stewart
File Size:
15.00 MB
File Type:
PDF
Language:
English
Pages:
155
Printable:
Yes
Category:
ATV
Last updated / verified
Jun 1, 2026

Honda Manual Features & Content Preview

  • Official Honda OEM publication covering 1990–1997 TRX200 and TRX200D ATVs (including 4-speed and 5-speed transmission configurations).
  • Includes 47 exploded-view diagrams and 12 component removal charts for precise engine and chassis work.

Documented Systems and Coverage

This 155-page manual eliminates guesswork on the bench by providing the exact specifications used by factory technicians. It is available as an instant download so you can get right to work.

You will find complete teardown procedures for the cylinder head, piston, and crankshaft, alongside clutch and gearshift linkage servicing. The chassis sections detail critical maintenance for the front suspension, steering components, and brakes. For diagnostic work, the electrical chapters clearly map out the charging and ignition sequences for the AC-CDI system. Always remember to observe standard shop safety protocols and ensure proper ventilation when referencing these procedures in your workspace.

Specification Highlights

Having accurate technical data is essential for a reliable rebuild. This document features comprehensive torque tables and fluid capacity charts specific to the 1990–1997 production run.

Key measurements include:

  • Piston-to-cylinder clearance: 0.018–0.048 mm
  • Valve clearance (intake and exhaust): 0.16 ± 0.02 mm
  • Main fuse capacity: 15 A
Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

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