1986 Honda 200X Service Manual

The 1986 Honda 200X is a three-wheeled ATV featuring a 192cc four-stroke air-cooled engine, 5-speed transmission with manual clutch, front and rear suspension systems, front disc brake, rear drum brake, and electric start. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for proper servicing and operation.

General Information

This manual provides technical information for the 1986 Honda 200X ATC. Includes identification numbers, safety precautions, and general maintenance guidelines.

Specifications

• Engine Type: 192cc 4-stroke air-cooled single cylinder
• Bore x Stroke: 65.0mm x 57.8mm
• Compression Ratio: 9.6:1
• Carburetor: 22mm piston valve
• Ignition: CDI
• Transmission: 5-speed manual with clutch
• Final Drive: Chain
• Suspension Front: Telescopic fork
• Suspension Rear: Swingarm with dual shocks
• Brakes Front: Hydraulic disc
• Brakes Rear: Mechanical drum
• Tire Size Front: 22x11-8
• Tire Size Rear: 22x11-8
• Fuel Capacity: 2.4 gallons

Periodic Maintenance

Regular maintenance schedule for optimal performance and longevity.

1. Engine Oil: Change every 6 months or 600 miles
2. Oil Filter: Replace with oil change
3. Air Filter: Clean every 300 miles, replace as needed
4. Spark Plug: Clean/gap every 600 miles, replace every 1200 miles
5. Valve Clearance: Check every 1200 miles
6. Chain Adjustment: Check every 300 miles
7. Brake Fluid: Check level monthly
8. Tire Pressure: Check before each ride

WARNING! Always perform maintenance in well-ventilated area. Allow engine to cool before servicing.

Engine Service

Complete engine maintenance and repair procedures.

1. Engine Removal: Disconnect battery, fuel line, cables, and mounting bolts
2. Cylinder Head: Torque bolts to 20 ft-lbs in crisscross pattern
3. Valve Adjustment: Intake 0.002 in, Exhaust 0.003 in (cold)
4. Piston Installation: Ring gaps staggered, arrow toward exhaust
5. Cam Chain: Check tensioner adjustment
6. Clutch: Adjust free play at lever (10-20mm)

CAUTION! Use proper torque specifications. Do not overtighten bolts.

Fuel System

Carburetor service and fuel system maintenance.

1. Carburetor Removal: Drain fuel, disconnect cables and fuel line
2. Float Level: 12.5mm from bowl mating surface
3. Main Jet: #112
4. Slow Jet: #38
5. Needle Clip: Middle position
6. Fuel Screw: 1-3/4 turns out
7. Fuel Filter: Replace annually

Tip: Use fresh fuel and stabilizer for storage periods.

Electrical System

Wiring, charging system, and electrical component service.

Testing procedures for stator, CDI unit, and ignition coil included in detailed sections.

Chassis

Frame inspection and maintenance procedures.

1. Frame Inspection: Check for cracks or damage at stress points
2. Swingarm Pivot: Lubricate every 1200 miles
3. Wheel Bearings: Check for play, repack annually
4. Chain Adjustment: 1-1.5 inches free play
5. Sprockets: Replace if teeth are hooked or worn

WARNING! Always support vehicle securely when working underneath.

Suspension & Steering

Front fork and rear shock service procedures.

1. Front Fork Oil: 172cc per leg (10W)
2. Fork Seal Replacement: Use proper seal driver tool
3. Steering Stem: Adjust bearing preload, lubricate annually
4. Rear Shocks: Check for oil leaks, replace if damaged
5. Wheel Alignment: Check and adjust as needed

Brakes

Front disc brake and rear drum brake service.

1. Front Brake Pads: Replace if less than 1mm thickness
2. Brake Fluid: DOT 3 or DOT 4
3. Bleeding Procedure: Start with caliper bleed screw
4. Rear Brake Shoes: Replace if worn beyond service limit
5. Brake Adjustment: Adjust cable at lever and rear hub

CAUTION! Brake fluid damages paint. Clean spills immediately.

Troubleshooting

Technical Support: Contact authorized Honda dealer for complex repairs.