The 1986 Honda TRX200SX is a four-wheel ATV featuring a 192cc air-cooled four-stroke engine, five-speed transmission with reverse, shaft drive, front and rear suspension, front and rear drum brakes, and electric start. This parts manual provides comprehensive information for maintenance, repair, and replacement of all components. Below are key sections covering specifications, engine parts, chassis components, electrical system, and ordering information.
Key specifications for the 1986 Honda TRX200SX ATV.
| Specification | Details |
|---|---|
| Engine Type | 192cc air-cooled four-stroke single cylinder |
| Bore x Stroke | 65.5mm x 57.8mm |
| Compression Ratio | 9.6:1 |
| Transmission | 5-speed with reverse |
| Drive System | Shaft drive |
| Suspension Front | Double wishbone |
| Suspension Rear | Swingarm |
| Brakes Front/Rear | Drum brakes |
| Tire Size Front | 22 x 8-10 |
| Tire Size Rear | 22 x 10-9 |
| Fuel Capacity | 2.4 gallons |
| Dry Weight | 313 lbs |
Complete breakdown of engine parts and assemblies.
WARNING! Always disconnect battery before engine work. Use proper torque specifications.
Frame components and structural parts.
CAUTION! Inspect frame for cracks regularly. Replace damaged components immediately.
Drum brake components and maintenance parts.
Front Brakes: 110mm drum, cable actuated
Rear Brakes: 110mm drum, foot pedal actuated
Components: Brake shoes, springs, drums, cables, levers, pedals, return springs. Maintenance: Adjust cable tension, replace worn shoes, clean drum surfaces.
5-speed transmission with reverse and shaft drive system.
Tip: Use Honda HP4 or equivalent 10W-40 motorcycle oil.
Complete electrical components and wiring.
WARNING! Disconnect battery before electrical work. Follow wiring diagram precisely.
Plastic body panels and trim components.
Supports: Fenders, fuel tank cover, seat cover, headlight bezel, rear cargo racks, decals and emblems.
Recommended maintenance intervals and procedures.
| Service | Interval | Procedure |
|---|---|---|
| Oil Change | Every 100 hours | Replace engine oil and filter |
| Air Filter | Every 50 hours | Clean and oil foam element |
| Spark Plug | Every 200 hours | Replace with DR8ES-L |
| Brake Adjustment | Every 100 hours | Adjust cable and pedal freeplay |
| Valve Clearance | Every 200 hours | Adjust to 0.08mm intake, 0.10mm exhaust |
How to identify and order genuine Honda parts.
Use Honda part numbers from this manual. Contact authorized Honda dealers with part numbers for ordering. Include model year (1986), model (TRX200SX), and part description. Most parts still available through Honda dealerships or online parts suppliers.
CAUTION! Use only genuine Honda parts for proper fit and performance.
| Symptom | Possible Cause | Corrective Action |
|---|---|---|
| Hard starting | Fuel system, spark plug | Check fuel flow, replace spark plug, clean carburetor |
| Poor performance | Air filter, carburetion | Clean air filter, adjust carburetor, check compression |
| Transmission noise | Low oil, worn gears | Check oil level, inspect transmission gears |
| Electrical failure | Battery, connections | Test battery, check grounds, inspect wiring |
| Brake issues | Worn shoes, adjustment | Replace brake shoes, adjust cables |
Service: Contact authorized Honda service center for major repairs.
Parts Support: Honda Customer Relations 1-866-784-1870