HONDA ATC 200X Workshop Manual 1983-1985

SHOP MANUAL ATC200X

- IMPORTANT SAFETY NOTICE -- '4 2 i ;iiiiilfi I"dicau$ a strong possibility of !it'pu(' {"Tsonal injury or loss of IifI' if im/ructions ar(' nOf follo .... d. CAUTION: Indica/cs II pouibilily 0/ per sOIIll/ injury or ei/Uipmefll damage If instruetiom are no/ follo .... ed. NOTE: Gives helpiul informat i on . Deta iled descr ipt ions of standard w orkshop proced ur e •. safety princip l e, and service operat i on, are nOI included . II is import ant to nOle Ihat th is manual com a ins:some warnings and caut i ons against some ,pecific service methods which could cause PERSONA L INJURY to service personnel or could damage a vehicle or render it un.afe. Plea", understand t hat those warnings could nOI COve r all conceivable ways in which service, whether or nOI ,e;;ommended by Honda might be done or of the possibly hazardou~ comequeoces of each cooceivable way. oor could Hooda i o"es~igate all such way. Aoyone usiog service procedures or tools. whether Of nOt recommeoded by Honda must UI( isfy him$l!1f thoroughly that oeither personal safety oor vehicle safety woll be jeopardiled by the service method or tools se lected_

HOW TO USE THIS MANUAL Sec tion 1 through 3 apply to the whole motorcycle, wh ile sections 4 through 16 describe parts of the moto rcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most secti ons start with an assembly or system illustrati on and all the required specifi- cations, torque values, general instructions, too ls and troubleshooting for the section. The subsequent pages give detailed procedures. If you don't know wh at the source of the trouble is, go to section 17. w Z '" Z w CONTENTS GENERAL INFORMATI ON LUBR ICAT ION MAINTENANCE FUEl SYSTEM ENG I NE AEMOVAL!lNSTALLATIQN CYL IND ER HEAO !VA LV ES CYL I NDER /PISTON A LTER NATOR TRANSMISSION/CRANKSHAFT/ REAR WHEEl/DA IVE MECHANISM REAR SUSPENS I ON BRAKE MECHANISM RE AR FENDER/ EXHAUST PIPE EL ECTR IC AL SYSTEM TROUBLESHOOT I NG

1.GENERAL INFORMATION GENERAL SAFETY ,-, SERVICE RU L ES ,-, MODEL IDENTIFI CA TION ' -2 I- SPEC IFIC ATIONS '-3 TORQUE VA LUES , -" TOO LS ,-6 CABLE & HARNESS ROUTI NG ' -7 GENERAL SAFETY '3 tiAiiii iJ 1\ Ii;iii@i If {he e"gi"e mU5/ be running to do lome W(lrk, mD/i.e Jurt! fh~1 (Jrt!(l is ..... U·''efl/i/uted. NelJ(!l '1m the mgi" .. in a c/Q~d arro. '/'hf' exhaus/ cOn/ains poisonous carbon monoxide ,~ Gawline is extremely j1llmmabie and is exp /osil't! under (,(,flai" conditions. Do not smoke or Q/lo'" {laml's or sPIITks in your wqrk (Jrt?/l. SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants Or their equivalent. Pans that don't meet HO NDA', de,ign specifi cations may damage the mOlorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect anembly, 3. Use only metric tOOls when servicing this motorcycle. Met ric bolts. nUtS , and screws are not interch,mgeable wit h Engl ish fasteners, 4. Install new gaskets. O-rings. coner pins, l oc k plates, etc. when reassembling. 5 . When to rquing bolts or nuts, begin with the larger·d iameter or in ner bolt fi rst. Then tighten to the specified torque dia· gonally in 2-3 steps. unless a particular ~Quenct is spec if ied. 6. Clean parts in non·flammable Or high fl ash poin t solvent upon disassembly. 7. Lubr ic ate any ,Iiding surfaces before reassembly. 8. After reassembly. check all pam for proper install at ion and operation. 1 -1

GENERA L INFORMATI ON MOOEL IDENTIFICATION The frame serial numbe r i. $tamped on the steering head lift side, The carburet or i de ntificat i on number is on the carburetor body righ t side. 1 - 2 Th e engine ser ial numbe r is stam ped on the crankcase lower rig ht . ide.

GENEAAl l NFOAMA TION SPECIFICATIO. ~ NS '-r-_ ____ _ ---,-___ _ DIMENSIONS FRAM E EN GINE r CA RBU RETOR L Overlil lengl~ Overall widlh Ov er all he ig ht Wheel b~se Stat height Fool peg heillhl Ground clnr.nee P ry weighl T,,,. Front suspension. tr.vel Rear ",spension, travel F, onl t irlsilt. pres""e Rear l ire si ze, pressure Front brake Rear brake Fuel c8pilCil ~ Fuel reserve capacity Caster Tra il Fron t fork Oil c.pxil~ T ". Cylinder arrlngement Bore ~ stroke Di~plxtm""t Compression rat io Valve train Max imu m hor$-tpower Ma~ imum lo rque Oil capacity LUbrieltion W\lem Air fill.ation system Cylinder compression Intake v,l..,. Ex haust v.lv8 V.lve clearance T,,,, Ma in jet Pilot screw opening Flolt levil Idle spe&d Bore OPEN CLOSES OPEN CLOSES IN EX 1.850 mm (72.8 inl 1.050 mm (4 1.3 inl 1,040 mm 140.9 in) 1.2 10 mm 147.6 in) 105 mm 127 .8 inl 290mmll1 .4 ini 125mm (4.9 inl 128.0 k\l 1282.21bj Sem i-double cr~le Telescopic .i r lark. 185 mm p.3 ,n) Sw ingll<m. 170 mm 16.7 in) 23.5 x 8- 11 . 23 kPa 10.23 kg /em f , 3.3 psi) 22 x 1 1-8. 17 k Pa 10.17 kglem 1 , 2.4 psll Singl. disc Single disc 9.7 li t 12,56 US gal .. 2.14 Imp ga l) 1.4 Ii ! 10,37 USgal .. 0.3 1 Imp gal) ,, ' 35 mm (1.38 in) "'. " =- ( 1983 I 209 cc I 171 US 59l mpol) After 214 cc 1983 I (1.2 US oz. 6.0 Imp ozl Glfo-lin •• ai r-cool~ 4-st roke Sin\lle cvl inde r ind inoo 150 65.0 ~ 57 .8 mm 12.56 x 2.28 inl 191 .8 ern) (1 ' .JOeu·in) 9.6: 1 O_erhud cam5h alt ch a in d. iven 18 ps/8,000 rpm 1.7 kg.",/6.ooo rpm 1.2 Iii n .3 US qt. 1. 1 Imp Qt) 1.0 Iii n.1 US qt. 0.9 Imp QI) Fo.ted p!uw,e a!ld WIl~ wmp Oil~ polyurethane foam 1. 128 kPa 111 .5 k9 / cml. 164 PSlj 35 0 ABOC S ' BTDC } 350 BBDC al 1.0 mm lift 5° ATDC 0,08 mm (0.003 in) (Cold) 0.08 mm (0.003 in ) (Cold ) Pi ston v,lve I :: 1983 I 1983 Alte, 1983 14.0 mm 10.55 In) 1,300: 100 rpm 24 mm (0.94 illl >;' 110 ,.108 I 3/4 tu rn OOt 1- 112 tutn OU I I I , I I I 1-3

GENERA L IN FO RMATI ON DRIVE TRAIN Clutch Wet multi·plate Transm is sion 5·spe.ed constant mesh Pr im ary reduction 3.333 Gear ratio I 2.769 Ge~r ratio II 1.94 1 Gear ratio III 1.450 Gear rat io IV 1.130 Gear ratio V 0.923 Final reduction 3.333 Gearshift pattern Left f oot operated return $V.tem, 1- N- 2- 3- 4- 5 Drive chain size/links 520/ 88 ELECTR ICAL Ign ition system eDI Igni tion tim ing initi ~1 1983 10° i t BTDC al idle Aft o' !t + 2' BTDC al id le I 1983 Full advance ~ 30' , " eTOe ~:: j 30' 1 2° BTDC Al ternator 68W/5,OOO 'p m I Spark plug N GK DR8ES·L I ND X24ESR ·U CHAMPION RA6YC Spark plug gap 0.6-0.7 mm (0.0 24-0.028 in) I Headlight 12V-60/ 60W Taillight 12V·5W 1-4

GENEAAL INF OAMATI ON TORQUE VALUES ENGINE THREAO TORQUE ITEM Q'TV DIA . lmm) N·m kg·m ft·lb Cylinder head nut 4 8 28 30 2.8- 3.0 20-22 Cylinder head COver 4 6 8- 12 0.8 -1.2 6- 9 Flywheel bolt , 8 45-55 4 .S-S.S 33- 40 Clutch lock nut , 16 40-50 4 .0-5.0 29 - 36 Oil filter rotor lock nut , 16 40-50 4 .0-S.0 29 - 36 Oil fil ter ,c ree n c~p , 36 10- 20 1.0- 2.0 7- 14 FRAME ITE M Q'TY THR EAO TORQUE N·m (kg·m, ft·lb) I DlA.lmm ) Steering stem nut , 24 70 100 (7.0 10.0.51 721 Steering top thread nut , 26 5.5-6.5 (0.55-0.65, 4.0- 4.7) Sw ingarm pivot bolt , )4 70- 110 (7.0- 1' .0. 51-80) Rear wheel hub nuts 2 " 80-100 (8.0- 10.0. 58- 72) Rear axle nut Inner , 32 35-45 (3.5 -4.5 , 2S- 33) Outer , J2 120-140112.0-1 4.0 ,87-1011 Front eng ine hanger plate 2 8 23- 27 (2.3-2.7. 17- 20) Front engine hanger bolts 2 8 23- 27 (2.3- 2.7. 17- 20 ) Bottom engi ne mount ing bol t , 10 4S- 53 14.5- 5.3. 32- 38) Lower engine hanger bolt , 10 40- 48 (4.0- 4.8. 29- 3S) Upper engine hanger bolt , 8 23- 27 (2.3-2.7, 17- 201 Upper engine hanger plate 2 8 23-21 (2.3- 2.7, 17- 201 Carooretor inlet pipe nuts 2 6 6- 9 (0.6-0.9. 4- 7) Torque $~, f'cat,ons hsted above are for t he most ,mportant t'ghtenlng PO ints . If a torque spec,f,cat,on " not I .. ted. fo ll oW t he starnlards gi ven be low. STANDARD TORQUE VALUES TYPE TORQUE TYPE TORQUE N·m (kg·m, ft ·lb) N·m (kg·m, ft·lb) S mm bolt. nut 4.5- 6.0 (0.45-0.6. 3.3-4.31 S mm screw 3.S- S.0 (0.3S- 0.S. 2.S- 3.6) 6 mm bol t, nut 8- 12 (0.8- 1.2. 6-9) 6 mm screw 7- 11 (0.7-1.1,S-81 8 mm bolt. nut 18- 2S (1.8- 2.5, 13-18) 6 mm flange bolt. nut 10- 140.0- 1. 4 ,7 - 101 10 mm bolt. nut 30- 40 (3.0- 4.0, 22- 29) 8 mm flange bolt. nut 24- 30 (2.4-3.0.17 - 22) 12 mm bolt. nut 50-60 (S.0-6 , O, 36-43) 10 mm flange bolt, nul 30- 40 (3.0-4.0. 22 - 29) 1 - 5

GENERAL INFORMATION TOOLS SPECIAL DESCRIPTION NUMBER ALTERNATIVE TOO L NUMBE R REF. SECT. Val"" Guid~ Reome, 0 1984 - 09Boooo 6·12 CIY 'cn Ho lo., 01923- 1010001 8·5 .8·9 $t ... " ng St. ", Socke. 01916 _ 3710100 1 1·2 6 Ra.ce Remove, 01953-3330000 11·28 $,,,,'ing S. em O, iv., 07946-4300001 I s,ee' in9 St.m O,iver 07946 _ 3110601 ", 11 · 2"9 Steering St em O,i ve , and 01946 _ 3110600 St ee ,i n g St em O,i •• , A" ""~ m~r\' IU.S .A. Onl ~ ) NG- HT - 1)4 Lock Ny. Wre nc!> wit!> h, ,,dle. 01916-9580300 No. A.- i l.ble in U.S.A. 12-4. 12·5 41 mm Lock Nu. W,ench . 4 1 ", m 01916 _ 9580400 jEqui ... e" , T Doh Commercially t.= k NUI ~. 4) mm 01916 - 9580200 Av'; Jobl. in U. s.A. 12-4. 12·5 He •. W,,,,,c~ . 6 mm 019 17-3 230000 Equ ival ent Tool Commerc i .ll y 11-19. 11 ·23 Av.il ab l. in U.S.A. BO', ing Romo •• ,. 20 mm 01936-311 ()6()() } Swi ng. ,m Bu,h ingl 13·11 Rem o.e ' Hond le 07936 - 3710100 8N, i"ll Re m""" , M9G 7 X- 03S _ XXXXX 13· 11 R.rno"", Weigh, 07741--OO102<l1 (U.S.A. Only) 13·11 Snap Ring Ph,,, 0791 4- 3230001 14 -8.14 · 18 Ti,e O" . .. emb4i " g Tool GN·AH·958 ·86 1 IU.S.A. OnlY) 11 · 13 T i ~ 8 .. d 8, uker 07772 - 0050000 J No. A"" il oblo in U.S .A ( 8''' ~ ", Of m ) ( 077 72--0050200 ) 8 , • • ~ ., .,m <ompre" o' 07772- 0050100 COMMON DESCR IPTION NUM8ER ALTERNATIVE TOOL NUMBER REF. SECT. Va l "" Ad iu " 'n~ Wfenc !> . 07708- 0000200 JEQU,; .alont Tool, Comm. ,cial ly H 10 . 12mm A •• ,labl. in U.S,A. Val"" Ad l" " ' f 0 1108--0030300 Float Le•• 1 G.., ge 07 401--0010000 ., V.l v. Sp, ing Co m", .. ,o, 07757--0010000 V. I• • S!>rl ng Comp,"' o, 07851 -3 230001 6 -9 . 6 · 16 Valve O" id. Remo. er, 5 .5 mm 07742--00 10 100 Vo lvo Guide O, i "", 07942 _ 3200100 6· 11 loc I< Nu . W fenc~ . 2<l ~ 24 mm 077 16 _ 0020100 8· 5. 8-8. 8 -9 b, em ion 07716--OO2<l500 Equivalen, Tool Com mefci .ll y 8-5.8-8.8-9 A •• ilable in U,S.A. 11 -26 Un ... ".1 Hol~ . , 07725_0030000 8· 5. 8·S. 9·3 Ro to , Pull o, 01733--0010000 Ro'o ' Pu ll .. 07933- 2000000 ,., A" ""h men '. 32 ~ 35 mm 0J7A6--OO101oo 10· 7_ 13·12 Au "" hmon •• 42 ~ 47 mm 07746--0010300 10·7, 11 · 16 A" "" hment. 52 ~ 55 mm 07746 --00 10400 \O- J Pil o,.15 mm 07746.-{)()4OJOO 10·1, 11.(; Pilot,20 mm 0774 6.-{)()4 0500 10·7 .13-12 P,lo,. 30 mm 07746.-{)()4 0 7 00 10·7 O, i .e, 0774 9 -0010000 10 ·7 , 11 ·16, 13-12 Fo' . S• • I Drov er Body 01147-0010100 y FOf l< Sill O, i •• , 07947-3330000 11 ·23 Att ach m. nt 101 01147--0010500 11 ·23 LocI< Nu, W'M Ch , 30 . 32 mm 07716--0020400 EQu i vo le nt Tool Comme, cia ll y 11 · 26 A .. iloble In U.S ,A. Att achm. nt. 62 • 68 mm 07746--0010500 13-12 Pil O',3 5mm 07746-0040800 13· \ 2 OPTIONAL DE SCR IPT ION NUM8ER ALTERNAT IVE TOOL NUMB E R '" SEC r , pin Spanne , 89201 KA4 -t1 10 13·2 Pin Sp.anner 892<l2- KA4 -t1 10 13·2 V. I • • S• • , C""e,. ~mm 077 80--0010300 EQui •• le nt Too l. Comme,clolly 6-13 V.l ve Su, OJ" " , 35 mm 0 7780--0010400 A •• ilab le in U,S,A, 6-13 Valve Sea, OJ II O" 30 mm 07180--0014000 6-13 V.I"" Soot c""". 37.5 mm 07780-00 141 00 6·13 Val"" So. ' OJ" "'. 30 mm 07J80--OO12:lOO 6·13 V.I"" So. , Cutl er. 35 m'" 07780 _ 0012300 6·13 V.lve So. , OJ ... , Ho l de' 0 7781--0010100 6-13 1 - 6

CABLE & HARNESS ROUTING PARKI NG '''I'' CABLE / CABLE BRAKE HOSE THROTTLE CABLE OVERF LOW TUBE GENERAL INFORMAT ION A LTERNATOR , BREATHER TU BE TAI LLI GH T ., FRON T HOSE 1 - 7

HONDA ATC 200X Workshop Manual 1983-1985

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