1987 Honda Fourtrax 200SX Repair Manual

The 1987 Honda Fourtrax 200SX is a reliable all-terrain vehicle featuring a 192cc air-cooled four-stroke engine, shaft drive system, front and rear suspension, electric start with backup recoil, dual-range transmission, and rugged off-road capabilities. This repair manual covers comprehensive maintenance, troubleshooting, and repair procedures for the complete ATV system. Below are key sections for safety, specifications, maintenance, engine repair, transmission, electrical, and troubleshooting.

Features and Specifications

Key components: 192cc OHC engine, shaft final drive, dual-range transmission, front and rear suspension, electric start system.

Safety Precautions

Always follow safety procedures when working on your Fourtrax 200SX.

1. Work in well-ventilated area: Engine produces carbon monoxide.
2. Use proper tools: Honda genuine tools recommended for specific procedures.
3. Disconnect battery: Before electrical work to prevent shorts.
4. Support vehicle securely: Use ATV stand or blocks when lifting.

WARNING! Gasoline is highly flammable; no smoking or open flames. Always wear safety glasses.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

1. Engine oil change: Every 100 hours or 6 months.
2. Oil filter replacement: Every 200 hours or 12 months.
3. Air filter cleaning: Every 50 hours or as needed in dusty conditions.
4. Spark plug replacement: Every 200 hours or 12 months.
5. Valve clearance adjustment: Every 600 hours or 36 months.
6. Drive shaft lubrication: Every 200 hours or 12 months.

CAUTION! Use only recommended Honda GN4 10W-40 motor oil or equivalent.

Engine Repair

• Cylinder Head Removal: Drain coolant, remove cam chain tensioner, disconnect exhaust.
• Piston Replacement: Remove cylinder, check piston clearance (0.02-0.04mm).
• Valve Adjustment: Intake: 0.15mm, Exhaust: 0.20mm (cold engine).
• Camshaft Service: Check cam lobe height, journal clearance.
• Crankcase Splitting: Requires special tools; mark cases before separation.
• Torque Specifications: Cylinder head bolts: 20 Nm, Spark plug: 13 Nm.

Transmission and Drive System

5-speed transmission with high/low range selection and reverse gear.

Transmission Oil: Change every 200 hours using Honda HP4 80W-90.

Shift Mechanism: Check shift drum stopper, shift forks for wear. Drive Shaft: Inspect universal joints, splines for wear. Final Drive: Drain and refill gear oil every 400 hours.

Electrical System

12V DC system with AC generator, CDI ignition, electric start circuit.

1. Battery: 12V 8Ah, check specific gravity (1.260-1.280).
2. Charging System: Stator resistance: 0.1-1.0Ω, output: 14V at 5000 RPM.
3. Ignition System: CDI unit, pulse generator resistance: 50-200Ω.
4. Starter Motor: Brush length min: 8.5mm, commutator diameter min: 22mm.

Tip: Use multimeter for electrical diagnostics; refer to wiring diagram.

Brakes and Suspension

Front and rear drum brakes with mechanical linkage.

1. Brake Adjustment: Turn adjuster nuts until proper lever/pedal free play.
2. Brake Shoes: Replace if lining thickness less than 1.5mm.
3. Front Suspension: Check bushings, ball joints for wear.
4. Rear Suspension: Inspect swingarm bearings, shock absorber operation.
5. Wheel Bearings: Check for play, replace if rough or noisy.

WARNING! Test brakes at low speed after adjustment. Replace worn components immediately.

Fuel System

22mm piston valve carburetor with manual choke.

1. Carburetor Cleaning: Disassemble, clean jets with compressed air.
2. Float Level: 18.5mm measurement from carburetor body.
3. Pilot Screw: Initial setting: 2-1/8 turns out from lightly seated.
4. Fuel Filter: Replace if clogged or every 200 hours.
5. Fuel Line: Inspect for cracks, replace if deteriorated.

CAUTION! Do not use wire to clean jets; may enlarge orifice.

Troubleshooting Guide

Compression Test: Should be 120-150 psi with throttle open.

Service: Contact authorized Honda dealer for genuine parts and technical support.