1984 Honda TRX200 ATV Service Manual
Shop manual for Honda TRX200 with complete engine, transmission, and suspension service procedures. Documents valve clearance (0.05mm), torque specifications, and carburetor settings. PN PDSSB
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Sample pages from the 1984 Honda TRX200 ATV Service Manual manual
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Models Covered & Key Technical Specifications
Honda TRX200 — 1984 Specialist Manufacturing Expert | TRX200 Folder.
- Verified Alignment Specs: 192 cc is designed for maximum displacement architecture within the single-cylinder 4-stroke configuration.
- Key Wattage Specs: For peak output, 13.0 BHP at 7,000 rpm controls the rated horsepower framework.
- Principal Operating Temps: The compression ratio reaches 7.8:1 — is measured at standard combustion efficiency Protocol.
- Advanced Angular Speed: The maximum torque rating requires 1.46 kg-m (0.6 ft-lb) at 5,500 rpm for optimal output Norms.
- Design Optical Resolution: Tank volume indicates 9.5 liters (2.5 US gal) specified as fuel storage capacity Bounds.
- Designated Play Limits: The engine oil capacity is specified as 1.8 liters (1.9 US qt) after disassembly Topology.
Professional Workshop Service Manual & Technical Specifications
Applied undefined Safety Manual: 1984 Honda TRX200 ATV Service Manual Factory-Standards
Model-Portfolio: Honda TRX200 (1984 Model) // Technical-Domain: Engine and drivetrain systems / ignition logic // Unit-Designations: Service documentation with torque specifications and adjustment data.
Carefully calling for attention to the comprehensive nature of this 277-page service resource, the document encompasses detailed coverage of engine removal and installation procedures, alongside transmission and crankshaft servicing modules. The reference material documents specifications for cylinder head assemblies, valve adjustments, and clutch system configurations that technicians encounter during Honda TRX200 ATV maintenance operations.
Technical Methodology
Systematizing the service groups into organized sections, the manual includes chapters addressing fuel system components, electrical system diagnostics, and brake system architecture. Testing requirements are specified for spark plug gap measurements, valve clearance inspection using feeler gauges, and cylinder compression verification at prescribed engine states. The document references intake and exhaust valve specifications with dimensional tolerances and clearance measurements that define proper operating parameters for the single-cylinder overhead camshaft engine configuration.
Operational Logic-Path
Clearance measurements are addressed for piston-to-cylinder relationships, rocker arm-to-shaft tolerances, and valve stem-to-guide dimensions throughout the manual's technical sections. Reference tables provide standard torque values ranging from small fasteners through major engine mount applications, documenting the specifications necessary for assembly operations. The carburetor section includes float level adjustment procedures, jet identification data, and pilot screw positioning information for fuel mixture calibration.
Integrated Standard
Special procedures are addressed for final drive gear assembly operations, including backlash inspection protocols and bearing preload measurement techniques. The sub-transmission and output gear sections contain detailed guidance on shift fork inspection, gear dog condition assessment, and bearing replacement methodologies using specialized extraction and installation tools. Pinion and ring gear tooth contact pattern verification procedures are documented with reference data for pattern interpretation and gear spacing adjustment.
Modular Sequences
Verification procedures are included for brake system fluid levels, brake lining thickness measurement protocols, and wheel cylinder bore dimension specifications. The document contains comprehensive sections on steering system maintenance covering kingpin inspection, knuckle bushing replacement, and front shock absorber spring free-length verification. Suspension component specifications include front and rear arm bushing dimensions, shock absorber mounting requirements, and steering stem bearing configuration details.
Structured Standard
Repair information is provided for electrical system components including alternator output testing at specified engine speeds, spark plug electrode inspection criteria, and ignition coil primary-to-secondary resistance measurements. The lighting system section documents headlight disassembly procedures, taillight bulb socket configurations, and wiring connection points for charging and lighting circuits. Battery fluid level checking procedures and specific gravity testing methods are included along with distilled water refill specifications to maintain electrolyte concentration within prescribed ranges.
| Section Category | Documentation Type | Technical Coverage |
|---|---|---|
| Engine Systems | Specifications and procedures | Cylinder compression, valve clearances, camshaft bearing tolerances |
| Transmission | Gear and bearing data | Shift fork dimensions, gear I.D. tolerances, backlash standards |
| Electrical Systems | Test parameters and wiring | Alternator output, ignition timing, charging system voltage regulation |
| Brake Systems | Component specifications | Drum dimensions, lining thickness limits, wheel cylinder clearances |
| Chassis Components | Assembly and inspection data | Steering stem bearings, suspension bushings, shock absorber preload |
Reference chapters include extensive detail on fuel system carburetor assembly operations covering throttle valve positioning, jet needle placement, and choke cable routing specifications. Engine lubrication points are systematically documented with grease application locations for cable pivots, brake cams, and wheel bearing races. Final drive oil capacity and viscosity recommendations are included alongside maintenance schedule intervals specifying service periods for oil changes, filter element replacement, and fluid condition monitoring protocols.
The manual documents torque specifications for the clutch lifter components to ensure proper engagement reliability. Additional sections address spark arrester cleaning procedures, brake adjustment methodologies, and tire pressure specification tables for front and rear wheel applications. Wiring diagram illustrations show electrical circuit routing for the ignition system, battery charging circuit, and starter motor connections with color-coded conductor identification for diagnostic purposes.
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