1986 Honda TRX200SX Repair Manual

The 1986 Honda TRX200SX is a four-wheel ATV featuring a 192cc air-cooled four-stroke engine, front and rear suspension, shaft drive, electric start, and manual clutch. This repair manual covers maintenance, troubleshooting, and repair procedures for engine, transmission, chassis, electrical systems, and more. Below are key sections for specifications, maintenance schedules, engine repair, transmission service, chassis maintenance, electrical systems, and troubleshooting.

Specifications

Technical specifications for the 1986 Honda TRX200SX ATV.

Maintenance Schedule

Regular maintenance intervals for optimal performance.

1. Engine Oil: Change every 100 hours or 6 months
2. Oil Filter: Replace every 200 hours
3. Air Filter: Clean every 50 hours, replace as needed
4. Spark Plug: Check every 100 hours, replace every 200 hours
5. Valve Clearance: Check every 200 hours
6. Drive Shaft: Lubricate every 100 hours
7. Brake Fluid: Check level monthly
8. Tire Pressure: Check before each ride

WARNING! Always perform maintenance on level ground with engine off and cool.

Engine Repair

Procedures for engine disassembly, inspection, and reassembly.

1. Remove engine mounting bolts and disconnect electrical connections
2. Drain engine oil and coolant if applicable
3. Remove cylinder head and inspect valves
4. Check piston and cylinder for wear
5. Inspect crankshaft and connecting rod
6. Replace gaskets during reassembly
7. Torque bolts to factory specifications
8. Adjust valve clearance after reassembly

CAUTION! Use proper tools and follow torque specifications precisely.

Transmission Service

• Gear Inspection: Check for worn teeth and proper engagement
• Shift Mechanism: Inspect shift forks and drum
• Clutch Assembly: Check plates for wear and proper clearance
• Transmission Fluid: Use recommended 10W-30 motor oil
• Drive Shaft: Inspect universal joints and splines
• Reverse Gear: Test engagement and disengagement

Chassis Maintenance

Frame, suspension, and steering component maintenance.

Frame Inspection: Check for cracks or damage. Suspension: Inspect bushings, ball joints, and shock absorbers. Steering: Check for play and lubricate bearings.

1. Clean frame thoroughly before inspection
2. Check all welded areas for stress cracks
3. Inspect suspension components for wear
4. Lubricate steering stem bearings
5. Check wheel bearings for smooth rotation

Electrical Systems

Battery, charging system, ignition, and lighting.

1. Battery: 12V 8Ah, maintain proper fluid level
2. Charging System: Test stator and regulator/rectifier
3. Ignition System: Check CDI unit and spark plug
4. Lighting: Test headlight, taillight, and indicators
5. Wiring: Inspect for damage and proper connections

Tip: Use multimeter for electrical testing and diagnosis.

Fuel System

Carburetor service and fuel delivery system.

1. Remove carburetor and disassemble
2. Clean all jets and passages with compressed air
3. Check float level and needle valve
4. Inspect fuel lines for cracks or leaks
5. Test fuel pump operation
6. Adjust idle mixture and speed
7. Check throttle cable free play

WARNING! Work in well-ventilated area away from ignition sources.

Brake System

Drum brake maintenance and adjustment procedures.

Suspension

Front and rear suspension service and adjustment.

Front suspension: Double wishbone with shocks. Rear suspension: Swingarm with dual shocks. Adjust preload as needed for riding conditions.

Troubleshooting

Service: Consult authorized Honda dealer for complex repairs.

Parts: Use genuine Honda parts for optimal performance.