1986 Honda TRX200 Field Service Manual

The 1986 Honda TRX200 is a rugged all-terrain vehicle featuring a 192cc four-stroke engine, full-time four-wheel drive with dual-range transmission, shaft drive system, independent front suspension, and durable steel frame. This service manual covers maintenance procedures, troubleshooting, specifications, and repair instructions for the complete vehicle system including engine, transmission, electrical, brakes, and suspension components.

1. Technical Specifications 2. Maintenance Schedule 3. Engine Service 4. Transmission & Drive System 5. Electrical System 6. Brake System 7. Suspension & Steering 8. Fuel System 9. Troubleshooting Guide 10. Torque Specifications 11. Wiring Diagrams

Technical Specifications

Complete technical data for the 1986 Honda TRX200 ATV system components.

Component	Specification
Engine Type	4-stroke, air-cooled, single cylinder OHC
Displacement	192cc
Bore x Stroke	65.5mm x 57.8mm
Compression Ratio	9.2:1
Carburetor	22mm piston-valve type
Transmission	5-speed with reverse, dual-range
Drive System	Shaft drive with full-time 4WD
Front Suspension	Independent double wishbone
Rear Suspension	Swingarm with dual shocks
Brakes	Drum brakes front and rear
Fuel Capacity	3.2 gallons (12 liters)
Dry Weight	386 lbs (175 kg)

Maintenance Schedule

Recommended service intervals for optimal performance and longevity.

Daily/Pre-ride: Check fuel level, tire pressure, brake operation, controls.
Monthly: Clean air filter, check battery terminals, inspect drive shafts.
Every 3 months: Change engine oil and filter, check valve clearance.
Every 6 months: Clean carburetor, inspect brake pads/shoes, check wheel bearings.
Annually: Replace spark plug, check suspension components, inspect frame for cracks.

WARNING! Always perform maintenance in well-ventilated area. Use proper safety equipment.

Engine Service

Complete engine maintenance and repair procedures.

Oil Change: Drain plug located bottom center of engine case, capacity 1.6 quarts.
Valve Adjustment: Intake 0.004 in (0.10 mm), Exhaust 0.005 in (0.12 mm).
Spark Plug: NGK DR8ES-L, gap 0.028-0.031 in (0.7-0.8 mm).
Compression Test: Normal range 142-171 psi, minimum 128 psi.
Timing Chain: Adjust tensioner per service procedure.

CAUTION! Engine must be cool before performing service. Use metric tools only.

Transmission & Drive System

Transmission Oil: Capacity 1.1 quarts, change every 1000 miles.
Shift Pattern: L-1-2-3-4-5-R (left foot shifter).
Drive Shaft: Inspect boots for cracks, lubricate splines annually.
Front Differential: Oil capacity 0.42 quarts, 80W-90 gear oil.
Rear Differential: Oil capacity 0.53 quarts, 80W-90 gear oil.
Transfer Case: Provides full-time 4WD engagement.

Electrical System

12-volt DC system with CDI ignition and electric start.

Battery: 12V 8Ah, maintain specific gravity 1.260-1.280.

Charging System: AC generator output 130W at 5000 RPM.

Ignition: CDI system, timing fixed at 15° BTDC at 1700 RPM.

Lights: Headlight 35W/35W, taillight 8W, brake light 27W.

Fuses: Main 20A, headlight 10A located near battery.

Brake System

Drum brakes front and rear with mechanical linkage.

Front Brakes: Adjust via cable adjuster at handlebar lever.
Rear Brakes: Adjust via rod adjuster at brake pedal.
Brake Shoes: Replace when lining thickness below 0.08 in (2.0 mm).
Brake Drums: Maximum diameter 5.12 in (130 mm).

Tip: Test brakes at low speed after adjustment before riding.

Suspension & Steering

Independent front suspension with rack-and-pinion steering.

Front Shocks: Pre-load adjustable, check for oil leaks.
Rear Shocks: Five-position pre-load adjustment.
Steering Play: Maximum 0.8 in (20 mm) at handlebar ends.
Wheel Bearings: Check for play by lifting wheels off ground.
Tire Pressure: Front 3.6 psi (25 kPa), Rear 3.6 psi (25 kPa).
Toe-in: 0-0.4 in (0-10 mm) measured at tire centers.

WARNING! Always support vehicle securely when working on suspension.

Fuel System

22mm piston-valve carburetor with manual choke.

Carburetor Settings: Pilot screw 2-1/8 turns out, float level 0.59 in (15 mm).
Fuel Filter: Replace annually or when restricted.
Fuel Lines: Inspect for cracks, replace if hardened.
Choke Operation: Verify full open and close positions.
Throttle Cable: 0.04-0.12 in (1-3 mm) free play at handlebar.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Hard starting	Fouled spark plug, stale fuel	Replace spark plug, drain old fuel, check choke operation.
Poor performance	Clogged air filter, carb issues	Clean air filter, adjust carburetor, check compression.
Transmission noise	Low oil, worn gears	Check oil level, inspect gears for wear.
Electrical failure	Bad battery, loose connections	Test battery voltage, clean terminals, check grounds.
4WD not engaging	Shift mechanism, differential	Inspect shift linkage, check differential oil level.
Brake drag	Stuck cables, worn shoes	Lubricate cables, replace brake shoes if worn.

Torque Specifications

Critical fastener torque values for proper assembly.

Component	Torque Value
Cylinder Head Bolts	20 ft-lb (27 Nm)
Spark Plug	13 ft-lb (18 Nm)
Engine Drain Plug	18 ft-lb (24 Nm)
Wheel Nuts	40 ft-lb (54 Nm)
Swingarm Pivot Bolt	65 ft-lb (88 Nm)
Front Axle Nut	87 ft-lb (118 Nm)
Rear Axle Nut	145 ft-lb (196 Nm)

Wiring Diagrams

Complete electrical schematics for troubleshooting and repair.

Color Codes: R=Red, B=Black, W=White, G=Green, Y=Yellow, Br=Brown, Lg=Light Green

Main Harness: Follows frame left side, protected by plastic conduit.

Connectors: All weatherproof, ensure tight connections and dielectric grease.

Ground Points: Engine case, frame near battery, handlebar clamp.

Service Note: Use multimeter for continuity and voltage testing.