1986 Honda ATC 200X Manual

The 1986 Honda ATC 200X is a three-wheel all-terrain vehicle featuring a 192cc four-stroke engine, 5-speed transmission with manual clutch, front and rear suspension, front disc brake, rear drum brake, and electric start. This manual covers safety procedures, maintenance schedules, technical specifications, troubleshooting, and repair procedures for optimal performance and longevity.

1. Features at a Glance 2. Safety Information 3. Maintenance Schedule 4. Specifications 5. Controls and Operation 6. Engine Maintenance 7. Transmission & Drive System 8. Brake System 9. Suspension & Steering 10. Troubleshooting 11. Warranty Information

Features at a Glance

Key components: 192cc air-cooled four-stroke engine, manual 5-speed transmission, front suspension with 6.7 inches travel, rear suspension with 5.9 inches travel, front hydraulic disc brake, rear mechanical drum brake.

Feature	Description
Engine Type	192cc air-cooled four-stroke single cylinder
Transmission	5-speed manual with wet multi-plate clutch
Starting System	Electric start with auxiliary kick starter
Front Suspension	Telescopic fork with 6.7 inches travel
Rear Suspension	Swingarm with single shock, 5.9 inches travel
Front Brake	Hydraulic disc
Rear Brake	Mechanical drum
Fuel Capacity	2.1 gallons (8 liters)
Dry Weight	269 lbs (122 kg)
Ground Clearance	6.7 inches (170mm)

Safety Information

Always wear proper protective equipment and follow safety guidelines.

Always wear DOT-approved helmet, eye protection, gloves, and protective clothing.
Never operate on public roads or paved surfaces.
Do not carry passengers - designed for single rider only.
Inspect vehicle before each use for proper operation.
Ride only in designated areas and avoid steep slopes.

WARNING! Three-wheel ATVs require special riding skills. Always complete proper training before operation.

Maintenance Schedule

Regular maintenance ensures optimal performance and safety.

Pre-ride inspection: Check tires, brakes, controls, and fluid levels.
Every 100 miles: Clean air filter, check chain tension and lubrication.
Every 500 miles: Change engine oil and filter, inspect spark plug.
Every 1000 miles: Check valve clearance, inspect brake pads/shoes.
Seasonal: Change coolant, inspect suspension components.

CAUTION! Use only Honda Genuine parts for replacement to maintain performance and warranty.

Specifications

Engine: 192cc air-cooled four-stroke SOHC
Bore x Stroke: 65.0mm x 57.8mm
Compression Ratio: 9.6:1
Carburetor: 26mm piston-valve type
Ignition: CDI with electronic advance
Transmission: 5-speed constant mesh
Final Drive: #520 chain
Front Tire: 22x11-8
Rear Tires: 22x11-8
Fuel: Unleaded gasoline 86 octane or higher

Controls and Operation

Familiarize yourself with all controls before operation.

Right Handlebar: Throttle control, front brake lever, engine stop switch, electric start button.

Left Handlebar: Clutch lever, headlight switch, choke lever.

Operation: Start engine with transmission in neutral. Use clutch when shifting gears. Gradually apply throttle and brakes. Avoid sudden maneuvers.

Engine Maintenance

Regular engine maintenance ensures reliability and performance.

Oil Change: Drain when warm, replace with 10W-40 motorcycle oil (1.7 quarts).
Air Filter: Clean with solvent and re-oil with foam filter oil.
Spark Plug: NGK DR8ES-L, gap 0.024-0.028 inches.
Valve Clearance: Intake 0.002 inches, exhaust 0.003 inches (cold).
Carburetor: Main jet #112, pilot jet #38, needle clip 3rd position.

Tip: Always check for oil leaks and unusual noises during operation.

Transmission & Drive System

5-speed transmission with chain final drive.

Clutch Adjustment: Adjust free play at lever (10-20mm).
Chain Tension: 1.0-1.2 inches vertical movement at midpoint.
Gear Oil: SAE 80 or 10W-30 motorcycle oil (0.69 quarts).
Sprockets: Front 13T, rear 42T.

WARNING! Never operate with loose or damaged chain. Regular lubrication required.

Brake System

Front hydraulic disc and rear mechanical drum brakes.

Front Brake: Check fluid level, inspect pads for wear (minimum 0.08 inches).
Rear Brake: Adjust cable tension, inspect shoes for wear.
Brake Fluid: DOT 3 or DOT 4, change every 2 years.
Bleeding: Required if spongy feel or air in system.

Suspension & Steering

Front telescopic fork and rear swingarm suspension.

Front Fork Oil: 10W, 7.4 ounces per leg.
Rear Shock: Preload adjustable, check for oil leaks.
Steering Head: Check for play, adjust if necessary.
Wheel Bearings: Inspect for smooth rotation and replace if rough.

CAUTION! Do not attempt suspension disassembly without proper tools and knowledge.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel flow, spark plug, compression (142 psi minimum).
Poor performance	Carburetor, air filter	Clean carburetor and air filter, check ignition timing.
Hard shifting	Clutch adjustment, oil	Adjust clutch free play, change transmission oil.
Brakes weak	Pads, fluid, adjustment	Replace worn pads/shoes, bleed hydraulic system.
Chain noise	Tension, lubrication	Adjust chain tension, clean and lubricate chain.

Service: Contact authorized Honda dealer for major repairs.

Warranty Information

Limited warranty coverage for 6 months from date of purchase. Coverage excludes normal wear items, improper maintenance, accidents, or modifications. Keep purchase receipt for warranty claims. For service, contact authorized Honda dealerships.