1986-1988 Honda TRX200SX Fourtrax ATV service manual

Product Information

Table of contents

GENERAL INFORMATION

1. General Safety
   • Safety Precautions
   • Proper Handling
2. Service Rules
   • General Guidelines
   • Tool Usage
3. Model Identification
   • Identifying Features
   • Serial Number Locations
4. Specifications
   • Torque Values
   • Tools
   • Cable & Harness Routing

LUBRICATION

1. Lubrication Points
   • Engine Oil
   • Transmission Oil
2. Recommended Lubricants
   • Oil Types
   • Lubricant Specifications

MAINTENANCE

1. Maintenance Schedule
   • Regular Maintenance Intervals
   • Periodic Maintenance Tasks
2. Inspection Procedures
   • Pre-Ride Inspections
   • Detailed Component Checks

FUEL SYSTEM

1. Fuel Tank
   • Removal and Installation
   • Cleaning Procedures
2. Carburetor
   • Disassembly and Cleaning
   • Reassembly and Adjustment

ENGINE REMOVAL/INSTALLATION

1. Engine Removal
   • Preparation Steps
   • Removal Procedure
2. Engine Installation
   • Installation Steps
   • Final Adjustments

CYLINDER HEAD/VALVES

1. Cylinder Head
   • Removal and Inspection
   • Installation and Adjustment
2. Valves
   • Valve Clearance Adjustment
   • Valve Timing

CYLINDER/PISTON

1. Cylinder
   • Removal and Inspection
   • Installation and Adjustment
2. Piston
   • Piston Ring Installation
   • Piston Clearance

CLUTCH/GEARSHIFT LINKAGE

1. Clutch
   • Clutch Adjustment
   • Clutch Plate Replacement
2. Gearshift Linkage
   • Inspection and Adjustment
   • Linkage Repair

ELECTRIC STARTER/ALTERNATOR

1. Electric Starter
   • Inspection and Replacement
   • Wiring Checks
2. Alternator
   • Charging System Inspection
   • Alternator Replacement

FRONT WHEEL/SUSPENSION/STEERING

1. Front Wheel
   • Removal and Installation
   • Tire Replacement
2. Suspension
   • Front Suspension Inspection
   • Shock Absorber Replacement
3. Steering
   • Steering Adjustment
   • Steering Component Replacement

BRAKES

1. Front Brakes
   • Brake Pad Replacement
   • Brake Fluid Change
2. Rear Brakes
   • Drum Brake Adjustment
   • Brake Shoe Replacement

REAR WHEEL/SUSPENSION

1. Rear Wheel
   • Removal and Installation
   • Tire Replacement
2. Rear Suspension
   • Rear Shock Absorber Replacement
   • Swingarm Inspection

FENDERS/EXHAUST/MUFFLER

1. Fenders
   • Removal and Installation
   • Repair Procedures
2. Exhaust System
   • Muffler Replacement
   • Exhaust Pipe Inspection

IGNITION SYSTEM

1. Spark Plug
   • Inspection and Replacement
   • Spark Plug Gap
2. Ignition Coil
   • Coil Testing
   • Coil Replacement

BATTERY/CHARGING SYSTEM

1. Battery
   • Battery Maintenance
   • Charging Procedures
2. Charging System
   • Voltage Regulator Inspection
   • Alternator Testing

STARTER SYSTEM

1. Starter Motor
   • Inspection and Testing
   • Replacement Procedure
2. Starter Relay
   • Relay Testing
   • Relay Replacement

LIGHTS/SWITCHES

1. Headlights
   • Bulb Replacement
   • Headlight Adjustment
2. Switches
   • Switch Inspection
   • Switch Replacement

TROUBLESHOOTING

1. Engine Problems
   • No Start Condition
   • Poor Performance
2. Electrical Problems
   • Battery Drain
   • Lighting Failures
3. Drive Problems
   • Belt Slippage
   • Transmission Issues

INDEX

1. Index
   • Alphabetical Index
   • Page References

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