1986 Honda Fourtrax 200SX Repair Manual
The 1986 Honda Fourtrax 200SX is a reliable all-terrain vehicle featuring a 192cc four-stroke engine, shaft drive system, reverse gear, front and rear racks, and electric start. This comprehensive repair manual covers maintenance procedures, troubleshooting, part replacement, and service specifications for optimal performance and longevity. Below are key sections for safety, specifications, maintenance, repair procedures, and troubleshooting.
Features at a Glance
Key components: 192cc air-cooled four-stroke engine, shaft drive system, reverse gear, front and rear cargo racks, electric start with backup recoil.
| Feature | Description |
|---|
| Engine Type | 192cc air-cooled 4-stroke OHC |
| Drive System | Shaft drive |
| Transmission | 5-speed with reverse |
| Starting System | Electric with backup recoil |
| Suspension Front | Independent double wishbone |
| Suspension Rear | Swingarm with dual shocks |
| Brakes Front | Drum brakes |
| Brakes Rear | Drum brakes |
| Fuel Capacity | 2.4 gallons |
| Dry Weight | 324 lbs |
Safety Precautions
Always follow safety procedures when performing maintenance and repairs.
- Work in well-ventilated area: Avoid inhaling fumes during fuel system work.
- Use proper tools: Ensure all tools are in good condition and appropriate for the task.
- Disconnect battery: Always disconnect negative terminal before electrical work.
- Support vehicle securely: Use proper stands when lifting or working underneath.
WARNING! Engine and exhaust components become extremely hot during operation. Allow sufficient cooling time before performing maintenance.
Specifications
- Engine Displacement: 192cc
- Bore x Stroke: 65.5mm x 57.8mm
- Compression Ratio: 8.5:1
- Carburetor: 22mm piston valve
- Ignition System: CDI
- Transmission: 5-speed with reverse
- Final Drive: Shaft
- Front Tire: 22 x 8-10
- Rear Tire: 22 x 10-10
- Oil Capacity: 1.6 quarts
Maintenance Schedule
Regular maintenance ensures optimal performance and extends vehicle lifespan.
- Engine Oil: Change every 100 hours or 6 months
- Oil Filter: Replace every 200 hours or 12 months
- Air Filter: Clean every 50 hours, replace every 300 hours
- Spark Plug: Replace every 200 hours or 12 months
- Brake Fluid: Check every 100 hours, replace annually
- Drive Shaft: Lubricate every 200 hours
- Valve Clearance: Check every 300 hours
CAUTION! Use only recommended lubricants and replacement parts.
Engine Repair
Complete engine service procedures including top-end rebuild and valve adjustment.
- Cylinder Head Removal: Remove exhaust, intake manifolds, and head bolts in sequence
- Valve Adjustment: Intake 0.15mm, Exhaust 0.20mm (cold)
- Piston Replacement: Measure cylinder bore wear limit 65.60mm
- Carburetor Service: Clean jets, set float height 18.5mm
- Ignition Timing: Set at 15° BTDC at 1700 RPM
Tip: Always use new gaskets during reassembly.
Transmission Service
Transmission and shaft drive maintenance procedures.
- Gear Oil Change: Drain and refill with 0.69 US qt of 10W-30
- Shift Mechanism: Adjust shift linkage for smooth operation
- Drive Shaft: Inspect universal joints for wear
- Reverse Gear: Check engagement mechanism
- Neutral Switch: Test and replace if malfunctioning
WARNING! Transmission must be cool before draining oil to prevent burns.
Electrical System
Complete electrical system diagnosis and repair.
- Battery: 12V 14Ah, specific gravity 1.280 at 20°C
- Charging System: Output 14V at 5000 RPM
- Starter Motor: Draw current 100A max
- Spark Plug: NGK DR8ES-L, gap 0.6-0.7mm
- CDI Unit: Test resistance values per specification chart
Brake System
Brake system maintenance and repair procedures.
- Brake Adjustment: Adjust cable tension for proper lever travel
- Brake Shoes: Replace if lining thickness below 1.5mm
- Brake Drums: Maximum inside diameter 130.7mm
- Cables: Lubricate and inspect for fraying
- Parking Brake: Adjust for secure holding
CAUTION! Test brakes at low speed after adjustment.
Suspension & Steering
Suspension components and steering system service.
- Front Shocks: Check for oil leaks, replace if damaged
- Rear Shocks: Adjust preload for load conditions
- Steering Stem: Check bearing play, adjust as needed
- Tire Pressure: Front 3.6 psi, Rear 3.6 psi (standard)
- Wheel Bearings: Repack annually or every 200 hours
Troubleshooting
| Symptom | Possible Cause | Corrective Action |
|---|
| Engine won't start | Fuel, spark, compression | Check fuel flow, spark plug, compression (142 psi min) |
| Poor performance | Carburetor, air filter | Clean carburetor jets, replace air filter |
| Hard shifting | Linkage, clutch | Adjust shift linkage, check clutch operation |
| Electrical failure | Battery, connections | Test battery voltage, clean connections |
| Overheating | Cooling, oil level | Check fins for debris, verify proper oil level |
Technical Support: Contact authorized Honda service center for complex issues.
Parts: Use genuine Honda parts for optimal performance and reliability.
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