1984 Honda TRX200 Fourtrax Service Repair Manual Instant Download

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nOmOH. RX2OO
V .E0N TO USE TFIS UAuAL Sections 1 through 3
apply' to the whole motomycle, while sections 4
through 10 describe parts of the motorcycle,
grouped according to location.
INTENTS OWEN RAL N R A
OLNUE R AT EMQA N NAN FUEL SYSTEM NEBNA R MOV L
ALL N R EA ONEL NDER
Ffd the section you want on this page, then turn
to the table of contents on page 1 of thst
section.

T ON
Most sections start with 8n assembly or sys- tem
illustration and all the required specifi-
cations torque values, gdneral inctrutions,
tooIt and troubleshooting 1or the sectién. The
subsequent pages give detailed proce- dures. If
you don't know the source of the trouble, see
Section 20, TROUBLESHOOTING.

L H OIL PUMP/GEARf?HlFT OIL ARTER ALTER
ATOR CSHTPAR ER LU SUB TR ON OUTPUT E
R TRANSMISSION/CRANISHAFT
FRONT WHEEL/SUSPENSION/STEERING
- R AR HE L U EN 0 F AL R VE CARRIERS/FENDER/EXHAU
ST MUFFLER
SBQAM ER A N G EMSTSART R LIGHTS/SW.ITCHES NTQROUB
LESH T

'Dta oi is.Quay.. 1sa4 0 HONDA MOTO.R.CO, LTD.
3
GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION
SPECIFICATIONS TORQUE VALUES TOOLS CABLE
HARNESS ROUTING
11 11 12 13 15 17 19
6E5ERAL SAKTY
If the engine musc be running to do some work,
make sure the area is 'ell-ventilated. Hever run
the enfne ii a closed a The exhaust contains
poisonous carbon monoxide gas
Gelatine u extremely flamable and is explosiw
under certain condition Do not smog or allow
flames or spnzks in your ark
be batter exczazes hydrogen has which can be
highly
The bolted electmlyce mncains sulfate acid.
Doieci your
battery, esterfly wlHlc e aryfng ii.
with the waterend cull a doctor if elecn'olytc
gen in your

• t. Use genuine HONDA or HONDA-recommended parts
  and lubricanu or their equivalents. Parts that
  don't meet HONDA's dasign specifications may
  cause damage to the vehicle.
• Use the special tools designed for this produm to
  avoid damage and incorrem assembly.
• Use only metric tools when servicing this
  vehicle. Metric bolts, nuts, and screws are not
  interchangeable with English fasteners.
• Install new gaskets, O-rings cotter pins, and
  lock plates when reassembling.
• When tightening bolts or nuu, begin with the
  larger-diameter or inner bolt first. Then tighten
  to the specified torque diago- nally in 1-4
  steps, unless a particular sequenoe is specified.
• Clean parts in non-flammable or high flash point
  solvent upon disassembly.
• Lubricate any sliding surfaces before reassembly.
• After reassembly, check all parts for proper
  installation and operation.

1-1
Date of Issue May., 1984 HONDA MOTOR CO., LTD.
4
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TRX2OO
GENERAL INFORMATION
MODEL IDEETIFICATIOE
FRAME SER IAL NUMBER
E NG IN E SE RIA L NUMB ER
The frame serial number is stamped on the frame
cross member directly beneath the front fender.
The engine ser ial number is stamped on the
crankcase lower left side.
CARBURETOR IDENT I FICATION NUMBER
The carburetor identi fication number is on the
carburetor body right side.
member directly beneath the front fender.
1 -2
Date o f I ssLe Ma y ., 1984 HONDA MOTOR CO.,
LTD.
6
GENERAL INFORMATION
Overall length Overall width Overall height Wheel
base Seat height Foot peg height Ground clearance
Dry weight Type Rim size
DIMENSIONS
1,865 mm (73.4 in) 1,070 mm (42.I in) 1,005 mm
(39.6 in) 1,235 mm (48.6 in) 730 mm (28.7 in) 290
mm (1J.4 in) 150 mm ( 5.9 in) 205 kg (452 lbs)
FRAME
Semi-double cradle 5.5 x 10 DC 9.2 x 9.0 DC 21 x
7- 0 0.2 kg/cm (2.9 psi) 25 x 12-9 0.15 kg/cm
(2.2 psi) Hydraulic operated leading trailing
shoe Cable operated leading trailing shoe 9.5
liters (2.5 U5 gal, 2.09 Imp gal) 1.0 liters
(2.26 US gal, 0.22 Imp gal) 0 7.5 mm (0 0.30
inl
Front Rear
Front tire size, pressure Rear tire size,
pressure Front brake Rear brake Fuel tank Fuel
reserve capacity Toe in Caster angle Camber angle
Trail length Tread
42 mm (1.65 in) 800 mm (31.5 in) 800 mm (31.5
in) Gasoline, air-cooled 4-stroke Single cylinder
inclined 15 65.0 x 57.8 mm (2.56 x 2.28 in) 192
cc (11.7 cu in) 7.8 I Overhead camshaft chain
driven 13.0 BHP/7,000 rpm 1.46 kg-m (0.6
ft-lb/5,500 rpm) J.8 liters (1.9 US qt, 1.6 tmp
qt) 1.0 liter (1. US qt, 0.9 Imp qt) after
draining Forced pressure and wet sump 1 J.0 1.0
kg/cm 1156 14 psi)
Front Rear
Type Cylinder arrangement Bore x stroka
Displacement Compression ratio Valve
train Maximum horsepower Maximum torcjue Oil
capacity
ENGINE
Lubrication system Cylinder compression
Intake valve OPENS CLOSES 5 BTDC 35 ABDC
Exhaust valve OPENS 35 BBDC
CLOSES 5 ATDC
at 1 mm lift
Intake Exhaust
0.05 mm (0.002 in) 0.05 mm (0.002 in)
Valve clearance
(Cold)
1 -3
Date of Issue May., 1984 HONDA MOTOR CO.. LTD.
7
MM ISXOO
GENERAL INFORMATION
CARBU RETOR Type Venturi dia. Main jet Piston valve 22 mm (0.9 in) 98
Pilot screw opening 2-1/4 turns out
Jet needle 2nd
Float level 14 mm (0.55 in)
Idle speed 1,400 100 rpm
DRIVE TRAIN Clutch Wet multi -plate, semi automatic
Transmission 5-speed constant mesh wi th reverse
Primary reduction 3.333
Gear ratio I 2.841 (4.339)
(Posi -torque gear ratio) I I 1.767 (2.6981
iII 1.306 (1.995)
IV J.026 (1.567)
V 0.836 ( 1.277)
Reverse 4.616
F inal reduction 4.255
Gearshift pattern Left foot operated return system,
Forward N1 234-5, Reverse N 1
ELECT RICAL Ignition CDI
Ignition timing Initial 10 1 2 BTDC at idle
Full advance 30 2 BTDC at 3,350 rpm
A Iternator Capacity 70W/5,000 rpm
Battery 12V 14AH
Spark plug D R8ES L (NG K)
X24ESR -U (ND)
Spark plug gap Headlight Taill\ght Neutral and
reverse indicator ligh t
0.60.7 mm (0.0240.028 in) 12V 45W/45W 12V 3.4W
x 2 1 2V 3.OW x 2
1 -4
Date o f Issue May ., 1984 HONDA MOTOR CO., LTD.
8
TWmWW TRX2OO
GENERAL INFORMATION
T0RUEALUES ENGINE
Thread Sit !!
Torqus N-m 2830 5o60
Item
o
kg-m ft-Ib 2.83.0 2022
Cylinder head cap nut CI I Centrifugal
clutch lock nut
4 1 1 1 1 2 1 1 2 3
8 x 1.25
5.o6.0 3643 11.5 7683 1.92.5 1418
18x1.0
22 x 1.26 8 x 1.25 8 x 1.25 36 x 1.5 36 x 1.5 12
x t.25 6 x 1.0 6 x î.0
105115
Clutch adjustingscrew lock nut
tW25
Alternatorflywheel bolt Valve adjustar cover
Oil filter screen cap Spark plug p bol Oil filter
rotor cover bolt
4050
4.US.0 2A36
JŒ-14 915 1219 812 1Œ-14
J.Œ-1.4 0.91.5 1.21.9 0.â1.2 1.Œ-1.4
914 de 710


Clutch liher stopper bolt
1
8 x 1.25

1825
1.82.5

1W18
1 2 2 2 1 1 1 1 3
6 x 1.0 5 x 0.8
710 W5 US
Gearshift drum stopper arm bolt
1014
1.01.4
Pulse generator screw Pulse cover screw V ve
adjuster lock nut
W7
0.40.7
5 x 0.8
47
0.40.7
6 x 0.75 6 x 1.0
1W18
1.51.8
1113
812 1W22
Gearshaft stopper plate bolt
0.81.2

A9
16 x 1.0 6 x 1.0
Cam chain tensioner adjusting bolt
1.W2.2

1116
Cam chain tensioner check bolt
810
67 W7 69
t Decompressor pivot bolt
6 x 1.0

45
Right crankcase protemor screw
Self tapping screw
0. - L7
2.25
Carburetor mounting nut
2
6 x 1.0
0.60.6
W7
4 " 1 3
Cylinder head œver socket bolt
6 x 1.0
â12
0.-t.2
Æ9
8 x 1.25 8 x 1.25 70 x J.5
1825 2630 9I t XI 7Œ-80 ŒI100 7Œ-80
Change lever mount nut
1.82.5
1318
2.63.0 9.Œ-10.0 7.Œ-8.0 9.Œ-10.0 7.Œ-B.0
Output driven gear bearing holder
J922
t 1 1 1
6572 5158
Drive gear bearing outar race
Drive gear bearing inner race
28 x 1.0
Driven gear bearing outer race Driven gear
bearing inner raœ
56 x 1.5
6572
24 x 1.0
5158
1-5
Date of Issue May., 1984 O HONDA MOTOR CO., LTD.
9
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nWmWW TRXOO
GENERAL INFORMATION
FRAME
Torque
Thread Size (lTlM)
Item
Ct'ty
N-m
kg-m
ft-lb
t
Front engine hanger nut 2 8x1.25 2327 2.32.7 1720
Front engine lower hanger nut 1 10 x J.25 4W53 4.5-5.3 3338
Front engine hanjpr nut 2 10x 1.25 40-48 4.4-4. 2935
Engine mount plate nut 1 10x J.25 48 4.04.8 2935
Engine mount upper bracket nut 1 8x1.25 2025 2.02.5 1418
Handlebar upper holder bolt 4 8x1.25 IB30 1.8-3.0 1322
Handlebar lower holder nut 2 10x 1.25 4048 4.04.8 2935
Steering top thread 1416 1.41.6 J012
Steering stem nut 16 x 1.6 7080 7.08.0 5158
Front axle nut 2 18 x 1.5 8Q-100 8.010.0 5872
Front/rear wheel nut 16 8 x 1.25 2025 2.02.5 1418
Ball joint/Tierod nut 8 10 x 1.25 3543 3.54.3 2531
Kingpin lock nut 2 8x1.25 2025 2.02.5 1418
Front/rearshock absorbermountnut 6 10x 1.26 I 4050 4.05.0 2936
Frontarm hinge bolt 2 35 x J.5 80100 8.010.0 5872
Arm hinge mount bolt 4 J 2 x 1.25 6080 6.08.0 4358
Left rear fork pivot bolt 1 30 x 1.5 9I120 9.012.0 6587
Rear fork pivot lock nut 1 30 x 1.6 1 130 J0.013.0 7294
R ight swingarm pivot bolt 1 30 x 1.5 1A20 I 1.62.0 t214
Foot peg mount bolt 8 8 x 1.25 2025 2.02.5 1418
Front/rear fender mudguard 20 6 x J.0 69 0.60.9 47
Front inner fender bolt 6 6 x 1.0 A9 0.60.9 47
2 6 x 1.0 69 0.6-0.9 W7
2 5 x 0.8 1.52.5 0.150.25 I2
Gearshift pedal mount bolt 1 6 x 1.0 1214 1.21.4 910
Air cleaner case bolt 4 6 x J.0 1.53 0.15-0.30 12
Master cylinder cap bolt 2 4 x 0.7 12 0.10.2 0.71.4
Brake hose bolt 3 10 x 1.25 2535 2.5-3.5 1825
Rear brake cover 6 8x1.25 2W30 I 2.W3.0 ! 1722
Brake drum inner nut 1 32x1.0 4050 4.0-5.0 2936
Brake drum outer nut J 32x1.0 J20140 i 12.0J4.0 87J01
Rear axle nut 2 18x1.5 80100 8.010.0 5872
Pinion retainer 1 58 x J.5 10I120 J0.0-12.0 72-87
Gearcasecover 8 8x1.25 2W30 2.43.0 1722
Pinionnut 1 J6x1.5 80100 8.010.0 5872
Final gearcasemounting bolt 2 12 x J.25 1ff0120 10.012.0 7287
Torque specifications listed above are for the
most important tightening points. If a torque
specification is not listed, follow the standards
given below. STANDARD TORQUE VALUES
Item 5 mm bolt, nut 6 mm bolt, nut 8 mm bolt, nut
t0 mm bolt, nut J 2 mm bolt. nut
Torque N-m (kg-m, ft-lb) 3.W5 (0.350.5
2.53.6 711 (0.71.1. 58)
Torque Nm (kg-m, ft-lb) 4.56 (0.450.6,
3.34.3) -12 (0.81.2, 69)
Item 5 mm screw 6 mm screw and 6 mm bolt with 8
mm head 6 mm flange bolt, nut
1-25 (1.82.5, IN-18) 40 (3.04.0, 2229) 5060
(5.06.0, 3 3)
1014 (J.01.4, 710) 2430 (2.43.0, 1722) 3W45
(3.54.5 2533)
8 mm flan9e bolt, nut 10 mm flange bolt, nut
1-6
Date of Issue May., 1684 O HONDA MOTOR CO., LTD.
11
WmWm RX2OO
GENERAL INFORMATION
SPECIAL
ALTERNATtVETOOL
TBOOLNEU
ERREF.PAGE
DESCRIPTION
TOOL NUMBER
Front shock absorber spring compressor
adaptor Kingpin driver Lock nut wrench, 30/40
mm Lock nut wrench attachment, 50 mm Pilot holder
attachment Propeller shaH dis/assembly tool A
Propeller shaft dis/assembly tool B Retainer
wrench Lock nut spanner, 41 mm Wrench set, 41
mm Wrench attachment, 41 mm
07067VM50100 07g65VM50000 079169690000
12-18 12-18 10-16, 10-23
079169690100 079249G90101 070679690100 07gG796
90200 07910ME80000 079169580200 079169580300 07
9169580400
10-17, 10-22 14-10, 14-17 14-6 14-6 14-10,
14-14 13-14, 13-20 13-14 13-14, 13-20
Collar
07964M800200
Axle nut holder wrench Not available in U.S.A.
Axle nut torque wrench adapter Equivalent
commercially available in U.S.A. Band strap wrench
07916958020A
07916958010A
8-6,8-10
07916PD10000
Socket wrench, 30 mm
8-12.8.15 10-17, 10-22 10-16, 10-17, 10-22,
10-23 14-10, 14-17 14-10 14-14 5, 10-9 5,
10-9, 10-18, 11-9 8-5, 10-9, 10-18, 11-9 10-21 i
10-J8, 11-9
Clutch center holder Lock nut wrench, 34/44 mm
Shaft holder
079239580000 07916ME50000 079236890101
07924ME40000 0793t ME40000 079314630300 079363
710300 079363710100
Pinion holder Shaft puller Bearing race insert
attachment Bearing remover, 17 mm Remover handle
077460030100
Driver
0774J 0010201
Remover weight
079363710200
Remove weight
079469690100 07936KC10500
I Side gear bearing driver attachment Bearing
remover, 15 mm Rear shock absorber compressor
attachment Remover shaH Driver Valve guide remer,
5.47 mm Bearing driver attachment Shock bit, 17 mm
14-24 14-7 14-22 6-12 14-7, 14-11 14-21, 14-23
07067KC10000 07065ME30000 079493710001 0798409
80000 0754533303IXI 077030020500
90010371003 079493710000
Flange bolt
079463710101
Commercially available in U.S.A. Lock nut wrench
adapter
070I84690001 07910MG30200 079143230001 07067G
A70101
14-21, 14-24 3-14 13-12 12-18
Pibot lock nut wrench Front wheel alignment
attachment Snap ring pliers Shock absorber
attachment
KWHBA08469
1 -7
Date of Issue May., 1984 O HONDA MOTOR CO., LTD.
12
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
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