Honda ATC200S Workshop Manual Download Page 71

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Summary of Contents for ATC200S

Page 2: ...some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe Please understand that those warn...

Page 3: ...cifications torque values general in structions tools and troubleshooting for the section The su bsequent pages give detailed procedures If you don t know the source of the trouble see sect ion 17 TRO...

Page 4: ...2...

Page 5: ...ICE RULES 1 Use genuine Honda Of HOf dl recommended parIS and lubricants or their equivalents Parts that do nOI meet Honda s deslgn specific ljons may damage the ATC 2 Use the 5pe illl lools designed...

Page 6: ...CATION The frame senai number is stamped on the left side of the steering head The ca rburetor idenlification number is on right side of the carburetor body 1 2 4 The engine serial number is tamped on...

Page 7: ...liters 10 42 US gal 0 35 Imp gal Caster 69 Trail 34 5mm 1 35 in Front oil capacity 90 2 5 cc 3 0 0 08 OZI ENGI NE Type Gasol ine air cooled 4 stroke OHC Cylinder arrangement Single cylinder inclined 1...

Page 8: ...Final reduction 3 909 Gear hift pattern Left foot operated retlJrn system N I 2 3 4 5 Drive chain 520 84 L ELECTRICAL Ignition CDI Ignition timing Initial lcr 2 BlOC at idle Full advance 30 2 BTDC at...

Page 9: ...iven pulley 6 x 1 0 10 14 1 0_1 4 7 10 Cam Chain tensioner adjust bolt 16 x l 0 15 22 1 5_2 2 11 16 Cam Chain tensioner Check bolt 6 x 1 0 8 10 0 8 1 0 6 7 Oecompresror lever pi Ol boll 6 x 1 0 5 7 0...

Page 10: ...Iider nut 2 6 x 1 0 0 6 0 9 4 3 6 5 Torque specifications listed above 3re for the most imp lrtant tightening points If a torque specification is rIOt liUed fOllow the standards given below STANDARD T...

Page 11: ...401 0010000 4 11 Pin spanner 07702 0020000 07902 0010000 07702 0010000 or 11 27 11 29 M9361 412 099788 Available in U S A Valve adjusting wrench lO x 12 mm 07708 0030200 07908 MBOOI00 36 Valve adjuste...

Page 12: ...tubes if they are contact shirp edge or COfner Clean the InlChing surllCe thoroughly btlfore applying tape Do not use a wire or harnen with a broken ir ulator Repair by rtQ ttlotm wit h protective ta...

Page 13: ...RAKE CABLE R NG BRAKE ENGI STOP SWITCH WIRE THROTTLE CABLE FRONT BRAKE CABLE BRAKE CABLE FRONT BRAKE CABLE BRAKE CABLE After 85 i GENERAL INFORMATIOM FRONT BRAKE CABLE After S4 S4 S5 REAR SRAKE CABLE...

Page 14: ...HIBITED Ftderl l I prohibiu the following acu or the Clusing thereof I Th remov l or rendering inoperative bV any person 011 111 than for purpas of rNintenanee rePiir or repllelment of anv device or e...

Page 15: ...13...

Page 16: ...LUBR ICATION n ROTOR CENTRIFUGAL CLUTCH OIL FILTER SCREEN 2 0 14...

Page 17: ...95 I 1 0 US qL 0 8 Imp ql after draining OIL VISCOSITY CHART Engine oil recommendation Use Honda 4 troke Oil or eqllivalellt API Service Classification SE or SF Viscosity SAE 10W 40 Other v i osi l ie...

Page 18: ...filter screen cap Operale the recoil starler several times 10 completely drain any re idual oil Clean Ihe oilliller screen Make sure thaI Ihe oil filter screen sealing rubber screen cap and O ring are...

Page 19: ...the oillill rOlor cover Remove the cover gasket Clean the in ide of Ihe rotor COver and rOIor Inslall the oil filter rOl0r cover with a new gasket TORQUE 10 14 N m 11 0 1 4 kg m 7 10h lbJ InSlalithe d...

Page 20: ...n is gi en Apply oil or grease 10 any 2 sliding surfllCe and cables nOt shown here _m CAM _m WHEEL BEAR ING 2 4 I I I LUBRICANT DR IVE CHAIN i _m BRAKE PEDAL 18 _m THROTTLE LEVER CABLE LUBRICANT __ 1C...

Page 21: ...old Intake Exhaust Throttle lever free play Idle peed Cylinder compression 3 MAINTENANCE 3 1 CHASSIS 3 3 DRI VE CHAIN BRAKE SHOES 3 4 FRONT BRAKE 3 5 REAR BAAKE 3 6 CLUTCH 3 7 SPARK ARRESTER CLEANING...

Page 22: ...ter cover Cam chain tensioner adjllsting bolt Rear a le bearing holder bolt Clutch adjllsting SCrew lock nut Valve adjllsting SCrew lock nllt 3 2 15 20 mm 15 8 3 4 in 15 20 mm 15 8 3 4 in 15 20 mm 15...

Page 23: ...DLE I FUEL LIN YEA FUEL FILTER YEAR I I I I I YEAR I BAAKE I I ONlYI NUT I HEAD I I I YEAR I SHOULD BE SERVICED BY AUTHORIZED HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MEC...

Page 24: ...ove the Three w ing bolts allaching the air cleaner case cover Remove The air cleaner case cover Remove The ai r cleaner element assem y from the air cleaner case Remove the bracket f rom the elemeOl...

Page 25: ...constant thickness Discard the spark plug if there i apparent wear or if the insulator is cracked or chipped Measure the gap with a wire type feeler gauge and adjust by carefully bending the side elec...

Page 26: ...t The intake d e hau s l valve clear cances by imerTing the feeler gauge between the adjuST ing screw and valve stem VALVE CLEARANCES Intake 0 06 mm 0 002 in E haourt 0 05 mm 10 002 in Mjust by l oo e...

Page 27: ...the thrOltle cable al the upper end Thoroughly lurnicate the cable and pivot point with a commercially available coble lubricant 10 prevent premature wear Install the t hrottle cable Make sure the th...

Page 28: ...1 5 2 2 kg m 11 16ft lb NOTE DO not IIttempT to loosen the check bolt while adjusting CARBURETOR IOLE SPEEO NOTE Insp c and adjust the idle sp lId aller all other maintenllnce itams are within specil...

Page 29: ...is a gned with the index mark on the left crankcase cover 8t idle CYLINOER COMPRESSION Warm up the 8r gine Stop the engine and remove the spark plug Insert I compression gauge Riise the choke leve all...

Page 30: ...n Adjust as follows Loosen Ihe rear a lc bearing hOlder boilS Tum The chain adjUSTer to obTain Ihe specified free play ReTighTen the Cal Ie be8fing holder botlS Check lhe rear wheels fo r free rOTatio...

Page 31: ...er pin and the axle nut Remove the rear wheel Remove The k id plaTe by removing Ihe four bolts Remove the sealed cover by removing the Ihree bolts as shown Pull off T he chain cover clips and remove t...

Page 32: ...cing the chain Clean the drive chain with kerosene and wipe dry CAUTION Do nOI UU a Jleam cleaner high pres SIITe washers OT wll l ms as Ihl e will damage Ihe Q rings Lubricate the drive chain with SA...

Page 33: ...Prockets or a WQrn chain on new sprockeu Both chain and sProckeTS must be in good condition Or The new replacemenT chain Or sprockets w ill wear rapidlv To remove the drive sPrOCkeT remOve The left cr...

Page 34: ...ir if necessary Disconnect the brake cable at the upper end Thoroughly lubricate the cable and pivot point with a commerCially available cable lubricant to prevent premature wear Install the brake cab...

Page 35: ...r Mdal end Thoroughly lubricaTe the cable and their piVOT poims with a commercially available cable lubricalll TO prevent premature wear Install the cables FREE PLAY INSPECTION Measure the brake Mdal...

Page 36: ...ever adjustments are made aT the upper adjusTer Loo en the lOCK nut and turn the adjuster CLUTCH SlOP The engine Loosen The ClUTCh adjUST ing screw lock nut Slowly turn the adjUSTing screw counTer clo...

Page 37: ...e accumulated car bon from the e haust W lem by momentarily revv ing up the engine scv lfal l imes SlOP Ihe engine and allow the exhaust pipe to COO l Install the muffler plate NUTS BOLTS FASTENERS Ti...

Page 38: ...e pressure NOTE Tire pressure should be che ked when the t ires are COLD TI RE PRESSURES R cOmm8nded prenu 8 2 2 psi 15 kPa 0 15 kg cm Minimum p en e 1 8 psi 112 kPa O 12kg cm Maximum p en e 2 6 psi 1...

Page 39: ...31...

Page 40: ...FUEL SYSTEM 4 0 38...

Page 41: ...l ame When disassembling fuel system parts nOle the locatiom 01 the a rings Replace them during reassembly The carburetor float bowl has a drain screw that Can be loosened to drain gasoline SPEC IF IC...

Page 42: ...speed incorrect 2 Ignition mal function 3 Rich mixture 4 Lean mixture 5 Air cleaner dirty 6 Irnulator leaks Llln mixture 1 Carooretor fuel jet clogged 2 Fuel cap vent blocked 3 Fuel filter clogged 4...

Page 43: ...t fuel flows freely out of the lUl l valve II flow is restricted clean The fuel strainer Page 3 7 Install the fuel tank and conne t the fuel tube In tail lhe seat NOTE Be sure the fro nl fuel lank Ixa...

Page 44: ...seat Remove the rear fender upper mOUn 0011 Remove the right and left side bolts Remove the right and left rear fender bracket mounting OOln Remove the rear fender Loosen the conne ting lube bands 4 4...

Page 45: ...r cleaner cover wing bolts and cover the element assembly from air cleaner case the element from element hOlder For ail Cleaner element ser ice refer to PiI9 3 4 CONNECTING TUSE SANDS 43 FUEL SYSTEM...

Page 46: ...FUEL SYSTEM CRANKCASE BREATHER Route the crankcase bfeather tube as shown 84 85 CRANKCASE BREATHER TUBE After BS I BREATH ER 4 6 44...

Page 47: ...3 6 51t lbl INSULATOR Remove the seal Turn lhe luel valve OFF and disconnect Ihe fuel Ii Remove Ihe fuel lank Loosen the d in screw and drain the gasoline Uncrew the Carburl lor lOP and pull the I ro...

Page 48: ...EMBLY Remove The throtTle cable from the throttle valve while compressing the throttle valve pring Remove the needle clip retainer jet ne lle and need le cl ip InsPect the throttle valve and jeT needl...

Page 49: ...e carburetor top to align the holes in the tOP w ith the grooves in the cable end Insert the ends of the U clip thrOugh the holes in the top and into the grooves in the cable end Press the clip in wit...

Page 50: ...ats li j tly The pilot screw can then be retlJrned to it original position dlJring reassembly without performing pilot screw ad junment Remove the pilot screw Inspect the pilot screw throttle stop scr...

Page 51: ...body Measvre The floaT level wilh the 1I0at tang JUSt resting againsI the lIoal valve FLOAT LEVEL 14 0 mm 0 55 i Replace Ihe floal if the float level is not withm specifIcatIon The fioal is not ad Ju...

Page 52: ...auled PILOT SCREW ADJUSTMENT NOTE The pi lot screw is facTory pre el Ad justment is not necessary unless the carburetor is overhauled or a new pi lot screw installed CAUTION Damage 10 the pl70t Crew s...

Page 53: ...emove and disassemble the carbY reto Page 4 7 and 4 9 Replace the standard main jet with the high altitude type 90 Assemble and inSfalithe carburetor Start the engine and adjust the idle speed at high...

Page 54: ...ENGINE REMOVAL INSTALLATION 5 0 6 9 N m 10 6 0 9 kg m _ 4 3 6 5 ft Ib I 60 80 N m 44 57 ft Ibl 6 0 8 0 kg m l _ 40 48N m 23 27 N m 2 3 2 7 kg m 17 20 ft lb 4 0 4 8 kg m 29 35 fI lb 52...

Page 55: ...tor Engine o il capacity TORGUE VA LUES Upper engine hanger nut Front engine hanger 8 mm nul 10mm nul Rear engine hanger lower 10mm nut Upper 10 mm nut Carburetor mounting nu t Rear axle bearing holde...

Page 56: ...ve the seat Turn the fuel valve OFF discoone t the fuel tube and remove the fuel tan k Page 4 3 Shift the transmission to neutral Remove the exhaust pipe Disconnect the crankcase breather tube from th...

Page 57: ...gearshifT pedal Remove the drive sprockeT cover Loosen the rear wheel bearing holder attach Ing boll and drive chain adjuster Move the rear wheel bearing holder forward h HONDA C_ _ 7 ENGINE REMOVAL I...

Page 58: ...ve sprocket ret ining plat bv turning it about 30 in either direction Remove the drive sprocket with the drive chain Remove the front engine hanger boll and plates Remove the upper engine hanger bolt...

Page 59: ...u i 9 the correct bolt in their proper poitio s Tighten the engine hanger bolts to the secified torque values after they are installed loosely ENGINE REMOVAL I NSTALLATION 10mmBOLTS 23 27 N m 40 48 4...

Page 60: ...ar hilt pedal Route Ind conne et the alternator iIr Id pulse 9I nefltor wires Connect the CflnkCK breather Connect the ark plug NOTE Alter in ling the engine prform The fol lowing inlPe etions and itd...

Page 61: ...59...

Page 62: ...LINDER HEADIVALVES 12 19 N m 11 1 1 9 k m 6 0 60 6 12N m 9ft 1 b 0 6 1 2 k9 m 6 10 14 N m 7 1 0 It Ib 10 14 kg m i c 7i Ni m k m 3 5ft lbJ 8 12 N m 6 9tt lb 10 8 1 2 kg m 4 7 N m I 10 4 O7k m 3 5 ft l...

Page 63: ...ice the cylinder head and valves To remove the cylinder head COVer or the rocker arm engine remova l is not reQuired Camshaft lubricat ion oil is led ta Ihe cylinder head through an oil control orific...

Page 64: ...984 O980000 07742 0020200 rO 07942 3290200 07742 0010100 or 07942 3290100 07757 0010000 or 07957 3290001 Engine top end problems u uslly affect engine performance These problems can be diagnosed by a...

Page 65: ...cover Remove the pulse generator screws and remove pulse generator Remove pulse rOlor by removing the bolt and wa her Remove the dowel pin and pulse base CYLINDER HEADIVALVES PULSE COVER PULSE GENERA...

Page 66: ...Push the tensioner down with rewdriver as shown while tightening the adjusting bolt Install the check bolt and rubber cap Remove the timing mark hole cap Turn the cranhhalt with the recoil starter unt...

Page 67: ...CAMSHAFT INSPECTION MeaSllre the camsllafl O D with micro meter SERVICE LIMITS R 19 90 mm 0 784 in L 33 90 mm 1 335 in Using a micrometer measure The heighT 01 each cam lobe height and insPecTil for...

Page 68: ...bol ts and 8 mm cap nUIS Remove the cvliJlder head cover Remove Ihe camshaft busi1 ing and dowel pins Remove TM rocker arm shalt set plale Screw a 6 mm bolt inlO lhe rocker arm Ilall Ihruded end pun o...

Page 69: ...Or clogged oil holes NOTE If any rocker arms require servicing Or replacement inspect the cam lobes lor scoring chipping or flat spOTS Measure the I D of ach rocker arm SERVICE LIMI T 12 05 mm I 0 474...

Page 70: ...004 in CAMSHAFT BUSHING INSPECTION MeaslJre the cam haft bushing I D SERVICE LIMIT 20 05 mm 10 789 in Calculate the camshaft bushing to camshaft clearaoce SERVICE LIMIT O OS mm 0 003 in CYLINDER HEAD...

Page 71: ...ustion chamber Clean off any gasket matterial from Ihe cylinder head surfiICl CYLINDER HEAD INSPECTION Check the spark plug hole and valve area lor cracks OIeck the cylinder head diagonallv for war pa...

Page 72: ...ITS INTAKE 5 42 mm 10 213 in EXHAUST 5 40 mm 10 213 in Ream the guides to remove any carbon build up before checkil l J the valve guide 1 0 Measure and record the valve guide 1 0 Calculate the stem to...

Page 73: ...de Drive in the guide from the top of the head NOTE Inspect the valve guide for damage Ream the new valve guide after installation NOTE Use cutting oil on the reamer during this operation Rotate the r...

Page 74: ...C SERVICE LIMIT 2 0 mm 0 08 in CAUTION 77te tab e callnot be ground Ifthe alve face is brl ned or hadly wom or if it COil acts Ihe seal lI e cnly replace lire a ve Inspect each valve seal If the seat...

Page 75: ...the H sting valve seat material U e a 60 degree cutler to remoVe the lower 1 4 of the old seat Remove the cutter and inspect the area you have just cut Install a 45 degree finish cutler and cut the s...

Page 76: ...must be raised using a 60 degrll inner cutter Refinish the seat to specifications uSlrlg a 45 degree eat cutter After cutting the eat apply lapping com pound to the va l e face and lap the valve using...

Page 77: ...astic hammer to firmly seat the cotters CAUTION Support the cylinder head above he work bench rurface w pr f lIt possible valve darrwge CYLINDER HEAD INSTALLATION Clean off any gasket material from th...

Page 78: ...nder head PoUt oil into lhe cv l i r hud oil poCkets so the cam lobes will be lubricated CYLINDER HEAD COVER INSTALLATION Install the decompressor lever and thrust washer Tighten the deoomprenor leve...

Page 79: ...kg m 20 22 ft fbj Install and tighten the 6 mm socket bolts TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft lb NOTE Tighten the B mm cap nuts and 6 mm bolts in a crisscross panern in 2 3 steps Connec the decompre...

Page 80: ...on the cylinder head cover Tighten the cam sprocket bolt TORQU E 8 12N mIO 8 1 2klt m 6 9 ft lbI Press in a new oil seal and install the new o ri and gasket On the pulse base NOTE Do not turn the o il...

Page 81: ...roove Toghlen the pulse rOlor bolt TORaUE 8 12 N m 0 8 1 2 m 6 9 ft lb Install the pulse generalOf Turn the crank ft counterclockwise and al ign the F miltk with Ihe crankC l5l cover index mark Align...

Page 82: ...the oil pockets in the cylinder head so that the cam lobes are submerged Do the followifl9 after installing the pulse generator cover AdiuM val e clearance Page 3 6 Adjust cam chain tension Page 3 8 I...

Page 83: ...81...

Page 84: ...CYLINDER PISON 7 0 82...

Page 85: ...s are in place before installing the cylinder head SPECIFICATIONS Cylinder Piston piston pin piston rings graov Piston ring TROUBLESHOOTING Low or unliable comprellion 1 Worn cyl inder or piston ring...

Page 86: ...ove the cam chain guide NOTE Keep the cam chain from falling into the crankc8 e when removing the cvlin der Remove the cylinder Remove the gasket and dowel pins Clean off any gasket material from the...

Page 87: ...alculate the taper and out of round SERVICE LI MIT Taper 0 10 mm 0 0039 in Out of round 0 10 mm 0 0039 in Inspect the top of the cyl inder for warpage SERV ICE LI MIT 0 10 mm 0 0039 in PISTON REMOVAL...

Page 88: ...0 004 in SECOND 0 09 rnm 0 004 in Inspect me pinon lor wear or damage Insert each piston ring into the cylinder and measure the ring end gap SERVICE LIMIT TOP O S mm 0 02 in SECOND 0 5 mm 0 02 in Me...

Page 89: ...and install the ston rings NOTE Avoid piston and piston ring damage during instal lation Install the piston rings with the markings lacing up 00 not interchange the top and second rings_ Space the pt...

Page 90: ...not let the crop fall into the crankcase CYLINOER INSTALLATION Install the base gasket and dowel pins Coat the cylinder bore and piston rings with engine oil Imtallthe cylinder NOTE Avoid piston ring...

Page 91: ...89...

Page 92: ...CLUTCH OI L PUMP 8 0 10 1 1 N m 1 0 1 1 kg m 7 10ft lb 3 7 N m 0 3 0 7 kg m 2 5 ft lb 8 12 N m 0 8 1 2 kg m 6 9 I 105 11 10 5 11 5 kg m 76 83 fHbl 90...

Page 93: ...0 20mm 0 006 0 008 in Oil pump Rotor tip clearance 0 15mm 0 006 in Rotor to body clearance 0 30 0 36 mm 0 012 0 0 14 in TORQUE VALUES Oil filter rotor cover bolu Manual clutch lock nut Centrifugal clu...

Page 94: ...rcycle creep with clutch diHll989IId 1 Faulty centrifugal clutch 2 Plates warped Clutch apatltion f 1f rough _ Outer drum lot rough Hlrd to shift 1 Stopper plate damaged 2 Incorrect clutch adjustment...

Page 95: ...o er bolts and cover Remove the gasket and dowel pins Remove the gasket and dowel pim CLUTCH LIFTER DISASSEMBLY Remove the clutch adjusting screw lock nut washer and ing Remove the Clutch lifter lever...

Page 96: ...e disassembled parts for damage or wear and replace the parts if necessary CLUTCH LIFTER ASSEMBLY Insta ll the joint and joint pin o n the lifter lever Install the circlip and screw irl the dutch adju...

Page 97: ...L Remove the recoil starter from the lelt crank case cover Page 9 2 Inslall a FLYWHEEL HOLDER or serew driver to prevent the crankshaft Irom turning Remove the oil filter rotor cover slide friction sp...

Page 98: ...emove the lock nut by turning it clock wi e NOTE The lock nut ha left hand threads Remove the plain washer Remove the centrifugal clutch weigt1ts Remove the springs Remove the cl ips and centrifugal c...

Page 99: ...LIMIT 4 1 mm 0 16 in Me sure the weight spring free length SERVICE LIMIT 282 mm 11 1 in Replace the spring with a new one if it is longer than the service limit Remove the clutch plate Al ign the clu...

Page 100: ...RVICE LIMIT 116 3 mm 1 4 58 inl CENTRIFUGAL CLUTCH INSTALLATION Install the clutch centrifugal clutch drum igoing the clutch outer CUtOUt with the drive gear Install the one way clutch sprag InStill t...

Page 101: ...he clutch hub with the linb and cli Instill I the centrifugal clutch s pring using a Crewdriver Install the centrifugal dutch weight usembly onto the clutch drum Install the lock washer and lock nut 9...

Page 102: ...as left hand threads Stake the lock nut P1ace the oil fi lter rotor CO er gasket ontO the dutch hUb i p a new O ring onto the crankshaft Install the thrust washer side friction spring and oil filter r...

Page 103: ...ral indicator Page 9 12 MANUAL CLUTCH REMOVAL Remove the enlJifugal clutch Page 8 5 Remove the lifter plate and clu tch springs by removing the clutch 0011 Remove the lifter guide and bearing from the...

Page 104: ...d thrust washer INSPECTI ON O1eck the slots o f the clutch outer lor nicks cuts or indentat ions made by the clutch discs Replace il necessary Meuure the I D 01 the clutch outer guide SERVICE LIMIT 21...

Page 105: ...d disc w rpaoge on surf ce pl te using feeler gauge SERVICE LIMIT 0 20 mm 10 008 inJ INSTALLATION Assemble the clutch pre ure plate discs plate and clutch center NOTE CLUTCH CENT Stack the discs and p...

Page 106: ...he clulCh OOlt5 Tightet1 the lock nUl TOROUE 50 60 N m 5 0 6 0 k m 36 43 fl lb I n lIthe clulch wring and lifter plate Tighlen Ihe clutch boilS Innall the be ri J and l UVI rO l Install the centrifuga...

Page 107: ...move the manual clutch Page 8 11 Remove the clutch lifter cam ball retainer and clutch lifter Remove the right crankcase spacer by remov ing the lour bolts Remove the gasket and dowel pins CLUTCH O L...

Page 108: ...pump ening screws RelT lve the Q rinw OIL PUMP DISASSEMBLY Remove the oil pump cover and gasket Remove the oi l pump inner and outer rotors Remove the bolts and pump gear cover Remove the pump driven...

Page 109: ...body clearance SERVICE LIMIT 0 40 mm 10 016 inl Measure the pump t ip Iearance SERVICE LIMIT o 2Omm 10 008 inl Oil PUMP ASSEMBLY Install the pump gear and gear COver onto the Iii pump bodv CLUTCH OIL...

Page 110: ...ear shaft Tighten the screws O Ieek the opetltion 01 the pump by ollting the pUmp gear bVhand INSTALLATION Install the O rinlJl and inslall the PUmp NOTE Make sure that the Q ril19s remain in piKe whe...

Page 111: ...utch Iiiter Page 8 15 right crankcase spacer Page 8 151 oil pump Page 8 151 RemoVf the gear sh ift pedal Pull the gear shift spindle out Remove the thrust washer and circiip and disassemble the gearSh...

Page 112: ...owel pin Install the stopper arm with the return spring as shown Assemble the gearshift spindle Install the gearshift spindle assembly Install the gear sh ift pedal Install the oil pump Page 8 181 Ins...

Page 113: ...opper bolt on the crankcase spacer Install the manual clutch Page 8 131 Innall the centrifugal clutch Page 8 81 RIGHT CRANKCASE COVER INSTALLATION In5t811 the following dowel pins and gasket right cra...

Page 114: ...STARTER A C GENERATOR 10 14 Nom 1 0 1 4 kg m 7 10 ft lb 9 0...

Page 115: ...to section 14 TORQUE VALU ES Alternator rotor nut Re oil starter driven pulley bolt TOO LS Common Flywheel and Rotor Pul ler Spe ial Flywheel Holder TROUBLESHOOTING Engine does not turn when OPe 3ting...

Page 116: ...ble from the valve lifter Loosen the clamp and remoVe the cable from the clamp Shift the transmission into the neutral Remove the gearshift pedal Remove the cable from the clamp Remove the neutral ind...

Page 117: ...emove the recoil backing plate Pul l up the hook case ring and remove the hook plate from the cable as shown Remove the hook plate cushion from the hook case ring Remove the cable wIth grommet from th...

Page 118: ...ng Check the friction spring Remove the circlip Remove the thrust washer and ratchet cover Remove the ratchets and ratchet springs Remove the spring and thru 1 wa h er 9 4 HOOK CASE RI NG FR ICT ION W...

Page 119: ...and Slafler spring The spring can pop OUI of the housing ifCllfe is no used O1eck the reco il tarter spring for breakage Remove the starter spring if necessary RECOil STARTER INSPECTION Oleck the sta...

Page 120: ...pulley in a clockwise direction u vie llrom the ratchet ide IS s hown Apply grease to the pulley shaft Install the fpring by hooking the end to the starter houfing hook CAUTION Wear rye protection an...

Page 121: ...ns ciockwi e Thread and knot the rope end through the grip Apply grease to the ratchets Install the ratchets and ratchet springs Co at the thrust washer with grease and install it Install the spring I...

Page 122: ...decompression cable through the re oil starte case Install the hook plate cush ion on the hook case ing Route the cable through the groove of the hook plate and install the hook plate 85 shown Install...

Page 123: ...a screwdrtver 0 prevent the rotor from turning Remove the narter driven pulley and cooling fan Loosen Ihe Flywheel Holder setting bolts Remove the alternator rotor with the rotor poller 121 STARTERjA...

Page 124: ...Remove the alternator wire hrnder and clamp Drain the engine oil Remove the alternator housing Remove the stator coils from the housing ALTERNATOR INSTALLATION Install the alternator stator coil onto...

Page 125: ...l indicator shalt groove with the gearshift drum cut out Tighlen the housing bolts securely Install the alternator wire holder and clamp Innall the dr ive sprocket cover Connect the alternator wire co...

Page 126: ...10 ft Ib Install the Flywheel Holdel nllhlen the rOtor rtUt TORQUE 65 15 N m 6 5 1 5 I g m 47 54 ft lb RECOIL STARTER INSTALLATION Irt l3l1lh eooi 1tarter Irtllall the neutral indicator by aligrting...

Page 127: ...Connect the decompre ion cable to the valve lifter CI mp the c ble and tighten the screw Make ure that the valve lifter operation is smooth by operatir g the recoil starter 125 STARTER ALTERNATOR 9 13...

Page 128: ...TRANSM ISSION CRAN KSHAFTIKICK STARTE R 10 0 8 12 N m i 0 8 1 2 kg m 6 9 fHb 126 8 12 N m 0 8 1 2 kg m 6 9 ft Ib...

Page 129: ...4715 0 4722 in Crankshaft 1Conne ting rod small 15 010 15 028 mm 0 5909 0 5917 in end L D Connecting rod big erxl 0 05 O lO mm 0 002 0 012 inl a i al clearance Connecting rod big eoo 0 0 008 rnm O O...

Page 130: ...ion 7 Section 8 Section 9 Remove the cam chain tensioner adjusting bolt and tension arm Remove the cam chain ten ioner and cam chain Remove the left crankcase 6 mm bolu Set the engine on the left cran...

Page 131: ...kcase CAUTION Bt Q jul not to domlJge th 0 1 ptt llUr l d Set the crankshaft on a nand Or V blocks and read the runout using dial indicators SERVICE LIMITS A 0 12mm 0 0047 in B C 0 08 mm 10 0031 In T...

Page 132: ...big end with a feeler gauge SERVICE LIMIT 0 80 mm 0 032 inl Measure the radial clearance at the conne ting rod big end at two points in the direction ind icated by the arrow SERVICE LIMIT 0 05 mm 0 00...

Page 133: ...AXIAL 0 05 mm 0 002 in RADIAL 0 10 mm 0 004 in TIMING SPROCKET INSTALLATION Install the sprocket al igning any tooth center with the keyway center in the crankshah TRANSMISSION DISASSEMBLY Remove the...

Page 134: ...O1eck the shift fork for wear bending o r Mea ure the I D SERV ICE LIMIT 12 04 mm 0 414 in Mea ure the shift for k claw thickness SERVICE LIMIT 4 50 mm O ln ill Measure the shift fork shaft O D SERVI...

Page 135: ...ary TRANSMISSION ASSEMBLY Coat all parts with oil Assemble the transmission shafts and gears not ing the locations of the thrust washers and snap rings NOTE Make sure the snap rings are seated properl...

Page 136: ...Install the shift drum and shift forks Install the fo rk guide shaft Rotate th m ain hah ciy hand to be sure gears rotate frll e ly CRANKCASE ASSEMBLY InM 11 th crank haft Instal l the gasket and dowe...

Page 137: ...r and tensioner rod Install the cam chain and tensioner arm Install the tensioner lock cOllar and adjllsting bolt with a new O ring With the tensioner arm held down all the way tighten the adjllsting...

Page 138: ...EE L BRAKE STEERING 11 0 SO_7 N m lr 5 0 7 0 kg m 40 48 Nom if 1 4 0 4 8 kg m 29 35 ft o o 40 50 N m 1 4 0 5 0 k9 m Cdi 1 29 36 ft Ibl 10 14 N m 11 0 1 4 kg m 7 10 IHb 136 70 110 N m 7 0 11 0 kg m 51...

Page 139: ...l Front axle Front axle holder nul Front wheel hub nul Front brake drum bolt Front fork mounting bolt nul Front fork socket boll Radial Axial Spring A Spring B 8mm 10 mm 12 mm 22mm 14 mm 6 mm 8mm 8mm...

Page 140: ...00 07746 0040300 07746 0010300 or 07949 61 10000 07702 0010000 or M9361 412 099788 U S A onlyl 07747 0010100 or 07947 3550000 07747 0010400 3 Damaged st Hlring stem ball race or cone race 4 Insufficie...

Page 141: ...Remove the headlight by removing the screw Disconnect the wire connectors DISASSEMBLY Disassemble the headlight HEADLIGHT RIM SCREW i UN IT HOLDER SPRING 139 FRONT WHEEL BRAKE STEER ING BULB HEADLIGHT...

Page 142: ...lts securely HEADLIGHT ASSEMBLY INSTALLATION I mitioll tilt hudl gl t urn T I the headlight rim nd inn 1I the unit holder sprin J shown Inil lt the bulb in the headlight lOCket nd inlllil the bulb soc...

Page 143: ...the brocket in the reverse order of removal HANDLEBAR REMOVAL Remove the handlebar hOlder cover Remove the headlight and disconnect the wire onnectors Remove the wire bands and handlebar switch Discon...

Page 144: ...1 8 3 0 kg m 13 22 ft lbl Install the front brake lever and connect the front brake cable NOTE Do not tighten the brake lever holder at th i t ime 84 Align the cut out of throttle lever housing with t...

Page 145: ...rlt Rou e the handlebar swilCh wires as shown In lilll the wire bands Inltllllh hilndlebarcover InSlall the Ironl lind rear brake levers al the ngle mown Tighten the upper Crews first then l ighten I...

Page 146: ...Remove the screws THROTTLE LEVER ASSEMBLY 84 Install the throttle lever spring and rubber seal After 84 Install the throttle lever housing throttle lever and spring 84 and after Conne t the throttle...

Page 147: ...e ffonl holder screw firSl Ihen lighten the rear screw 84 and alter Adjusl the throttle Cilble free play Page 3 7 FRONT WHEEL FRONT WHEEL REMOVAL Raise the fronl wheel off Ihe grouoo by piKil i I blod...

Page 148: ...ual runout is 1 2 of the total indicator reading SERVICE LIMIT 0 5 mm 10 02 inl BRAKE DRUM Remove the brake paMI assembly and measure the brake drum I D SERVICE LIMIT 111 mm 4 4 inl FRONT WHEEL DiSASS...

Page 149: ...discard the bearings if the races do not turn Smoothly quietly or if they fi t loosely in the hub NOTE I Replace hub bearings ____ WHEEL HUB DISASSEMBLY Remove the dun seals Drive the wheel bearings...

Page 150: ...the threaded shaft and then put the wheel over the threaded shalt and adipter Lube the bead area with rubber lubricant preuin down on the tire sidewalilbead area in several places to allow the lubrica...

Page 151: ...mark on the presl block is alig 1ed with the top edge of the press head If Ihe rest 01 the beild cannot be pushed down into the center of the rim by hand loosen the press head bolt and the lever nut R...

Page 152: ...n the area with non flammable solvent NOTE Use a solvent that will not leave an oily r idue Do not use gasoline Apply rubber cement around the torn area and al low it to dry Remove the lining from the...

Page 153: ...ll the wav in the tire Twist the needle Se leral times Pull the needle waight out so that the plug is about 10 mm 3 8 in above the tread surface Trim the plug 2 mm 11 16 in above the surface Repeat th...

Page 154: ...Max Standard tire ci c m pr Ur pre pr f renc 22pSl 1 7pSl 26P I 159mm 115 i I 11 2kp o 118kp 169 3 n 1 0 1 5kglcm 0_ 12 g m IO l S g om l NOTE The rear t ires mUSI haye Ihe same circumference to prev...

Page 155: ...ake drum and lock plates Tighten the boilS to the specified torque TORQUE 2G 25 N m 12 0 2 5 klJ lTl 14 18 ft Ibl Bend the tabs of the lock plates up FRONT WHEE L INSTALLATION Install the axle collar...

Page 156: ...the tab on the brake panel with the hole in the right front fo rk Insert the front axle fro m the left front for k Tighten the axle to the specified torque TORQUE 70 110 N m 17 0 11 0 k t m 51 80 ft I...

Page 157: ...es if the linings are thinner than the service limit BRAKE PANEL DISASSENBLY Expand and remove the brake 5hOC l by hand Di5engage the return spring Remove the brake arm bolt brake arm indica tor plate...

Page 158: ...he cam InUail the brake camshalt Install and engage the return spring as shown Install the wear indicator aligning the indica tor tab with the brake cam groove Innall the brake arm aligning the brake...

Page 159: ...ts arid remove the Iron fork Loosen Ihe fork boot clamp Remove Ike fork boot Hold the fO k slider in a vise with soft iawl or shop towel Remove the hex bolt CAUTION Do nOf o ertigillen the sUder in fh...

Page 160: ...lip A worys wear eye and face protection whenever operating a hydraulic preu Remove the fork tube from the press Remove the fork cap Remove the washer and fork springs Turn the fork tu be upside down...

Page 161: ...marks Sl ratches or abnormal wear Replace any components which ilre worn or damaged Check tile larkpiston ring lor wear of damage Ctltck tile rebound spring lor fatigue or damage Place the fork tube i...

Page 162: ...PR NG OIL SEAL FORK SLIDER J l Install the piston ring on the piston Place the rebound spring and piston into the fork tube Place the oil lock pit on the end of the piston and insert the fork tube int...

Page 163: ...l ider Apply ATF to the oil seal and drive it in with the fork seal driver The fork seal is seated when the groove in the slider is seen at the top of the seaJ Install the snap ring and dun seal Fill...

Page 164: ...and boot clamp NOTE Do not tighten the clamps lnt the forks are properly installed on the vehi cle Insert the from forks into the steering stem Install t he from fork upper bolt aligning the groove o...

Page 165: ...heel Page 11 91 front fender Remove the neering stem nUl and fork bridge bolts Remove the fork bridge FRONT FORK REMOVAL Remove the steering stem tOp thread nut FRONT WHEEUBRAKE STEER ING EXTENSION BA...

Page 166: ...and replace if necessary NOTE Replace the bal ls and ract s a a set when any component is damaged Remove the ball race STEERING STEM INSTALLATION Install the waSher and dust seal onto the steering st...

Page 167: ...es Slide the steering stem through the steering head from the bottom Install the top cone race Thread on the top thread nut Tithten the top thread nut until snug against the top ball race and back off...

Page 168: ...olts TOROUE 50 70 N m 15 0 7 0 kg m 36 51 ft lb Install the handlebar T hten the handlebar lower holder nllts TOROUE 40 48 N m 14 0 4 8 kg m 29 35 ft lb Install the following _ front fender front fork...

Page 169: ...167...

Page 170: ...L BRAKE DRIVE MECHANISM 12 0 6 9 N m 0 6 0 9 kg m 4 7It lbl 50 70 N m 5 0 7 0 kg m 36 SI IHbl jI 2S 30 N m 12 S 3 0 kg m 18 22 It lb 20_25Nom 1 12 0 2 S k9 m 14 18It lbl 60 80 N m 6 0 8 0 kg m 44 58 I...

Page 171: ...el hub nut Rear axle bearing holder bolt Drive chain Hder nut Rear axle nut TOOLS SPECIAL Lock nut spanner 41 mm LOCK nut wrench 41 mm Common Attachment 62 x 68 mm Driver Pilot 35 mm STANDARD SERVICE...

Page 172: ...3 Faulty rear a le bearing holder 4 Faulty tire 5 AKle not tightened properly POOl bt ke performlACe 1 Improper brake adjustment 2 Worn brake shoes 3 Brake linings oily greasy or d irty 4 Worn br ke c...

Page 173: ...wheel with the lire vatve facing out Tighten the wheel nu15 TORQUE 20 25 N m 2 0 2 5 kg m 14 18ft lbl REAR AXLE FINAL DRIVEN SPROCKET REAR AXLE REMOVAL Raise the rear wheels off the gorund w ith a iac...

Page 174: ...remove the skid plate Remove the sealed cover by removing the three bolts P JU oH tM chain cover clips and remove the drive chain cover by removing the two nuts UIown the bea ing hoide bolU md d i cha...

Page 175: ...chain Remove the brake drum nuts by using the special lools NOI available in U S A Remo the Pring washer nd CHing Remove the axle REAR WHEEUBRAKE ORIVE MECHANISM CLIP LOCK NUT WRENCH 41mm 07916 958030...

Page 176: ...lilCe the sprocket if necenary Check the condition of the final driven sprocket teeth Replace the sprocket if it is worn or damaged NOTE If the driven sprocket is worn Or damaged the drive chain and t...

Page 177: ...1 the total indiea tor reading SERVICE LIMIT 3 0 mm CO TZinl FINAL DRIVEN FLANGE ASSEMBLY Q WASHER f fo DRIVEN SPROCKET Instali Ihl final driven 5proc kll with the hub Inslill Ihe wMh and ll1ap ring C...

Page 178: ...r onto the axle Install the axle inner nut and tighten to the spl if ied torque TORQUE 35 45 N m 13 5 4 5 kg m 25 33 ft Ib Clean and grease or dirt off the axle threads and apply LOCKTILE or equivalen...

Page 179: ...e cha in cover rubber seal and chain COver Install the skid plate Coat the axle with grease Instal l the wheel hubs Install the lock washer with the word OUT SIDE facing oot Install and tighten the re...

Page 180: ...m cover boln Remove the drum cover and brake drum BRAKE DRUM COVER INSPECTION Remove the dust seal Check the brake drum cover gasket and dust seal lor damage and replace if necessary BRAKE DRUM COVER...

Page 181: ...ake shoe if the lining is thinner than the service limit REAR BRAKE DRUM INSPECTION Measure the brake drum I D SERV ICE LIMIT 141 mm 5 6 in REAR BRAKE DISASSEMBLY E pand and remove the brake shoes by...

Page 182: ...E DRIVE MECHANISM Disconnect the rear brake cables from the rear brake arm Remove the rear brake arm and indicator Remove the brake cam and return spring 12 12 180 BRA KE CABLES WEAR INDICATOR RETURN...

Page 183: ...tall the dust sea l Install the spring al igning the spring end with the cam shaft hole Install the wear indicator aligning the cam shaft groove with indicator tab BRAKE ARM REAR WHEEl BRAKE DRIVE MEC...

Page 184: ...f the linings Wipe HceSS grease off the cam BRAKE DRUM COVER DRUM INSTALLATI ON nstall the gasket on the cover and reinstall the cover Tighten the bolu in tWl or more steps in a criS5 r s pattern TORQ...

Page 185: ...hly and quietly Also check mat the bearing outer race fits tight ly in the hub Remove and discard the bearings il the races do nOI turn smoothly qUietly or if they l it loosely in the hub NOTE Replace...

Page 186: ...ks facing OUt Coat the dust seal lips with grease and drive the dust eals into the bearing holder REAR WHEEL BEARING HOLDER INSTALLATI ON Install the rear bearing holder and drive chain adjuster Insta...

Page 187: ...ack or block under the engine Remo e the following parts rear wheel drive chain axle Remove the chain slider Remove the chain case mount nUts and bolts Remove the chain case Install the chain case in...

Page 188: ...186...

Page 189: ...Remove the screws and mud guard Remove the rea fender stavs REAR FENDER INSTALLATION The installation sequence is the reverre order of rerrnwal NOTE Be sure 10 include the collar with the fender bolts...

Page 190: ...d remove the muff ler NOTE C 1ed the gasket aud piJ f wal for wear Replace with a new one if necessary SPAR K ARRESTER INSTALLATION The installat ion equence is essentially the reverse of removal NOTE...

Page 191: ...18...

Page 192: ...IGNITION SYSTEM ENGINE STeIP SWIT CH RKPLUG ALTERNATOR 84 ENGINE LIGHT t SPARK l After 84 LIGHT SWITCH COIL SPARK PLUG 14 0 190...

Page 193: ...released before di nnecting and must be aligned when econ necting To isolate an electrical failure check the continuity of the electrical path through the parI A continuity check can usual ly be made...

Page 194: ...ween pulw gr nentor and COl unit J Faully ignition coil 4 F ul y COl unit 5 F ully pulse generator 6 Faulty alternator 7 Improper pulse generator coil air gap En li lUlU but f UM pOOIly 1 Ignition pri...

Page 195: ...er 84 Remove the ignition coil by pulling ignition coil INSPECTION Ole k the resistances between the leads of the primary and se ondary coils Primary coil 84 0 2 0 4 Q After 84 0 16 0 20 0 Second ry c...

Page 196: ...TANCE 150 400f COl UNIT REMOVAL Remove the seat artd fuel tank Disconrtect the coupler Remove the COl unit from the mountirtg rubber INSPECTION Replace the COf unit it the readings are rtot within the...

Page 197: ...e cap Connect a timing light and tachometer Start the engine and check the ignition tim 9 At 1 300 t 100 rpm The index mark should be aligned with the F mark At 1 950 150 rpm Timing advance should sta...

Page 198: ...the ignition timing Check the p Jlse generator air gap as described below PULSE AIR GAP ADJUSTMENT Measure the air gap between the pul e genera tor and rotor AIR GAP 0 3 0 4 mm 0 012 0 016 in When adj...

Page 199: ...by simply disconnKting the wires and connecting a continuity tester or voltmeter to the terminals SPECIFICATIONS Head light Taillight TROUBLESHOOTING 12V 45 45 W l 1V 5W Light daft nOI come on wilen...

Page 200: ...SASSEMBLT ASSEMBLY Fleler to Page 11 3 and 11 4 lor disassembly and assembly TAILLIGHT DISASSEMBLY Remove the two screws and lens Remove the bulb TAILLIGHT ASSEMBLY Assemble the taillight in the rever...

Page 201: ...he terminals show jr the table for e ch switch position The switch is ormal if there is continuity belween the circuit marked 0 0 84 85 LIGHTING SWITCH WHITE YEllOW BROWN BLU E W LOW I HIGH Alter 85 i...

Page 202: ...200...

Page 203: ...16 WIR G DIAGRAM WIRING DIAGRAM 84 r 1 r I t t o 201 16 1...

Page 204: ...WIRING DIAGRAM 85 16 2 g i r C i W I m r i li f o o 0 o i 202 nill RJLJ...

Page 205: ...WIRING DIAGRAM After 85 r O 203 16 3...

Page 206: ...204...

Page 207: ...breather tube WEAK OR NO SPARK _ 1 FaUlty spark plug 2 Fouled spark plug 3 Faulty COl unit 4 Broken or shorted spark pll 9 wire 5 Faulty A C generator 6 Broken or shorted ignition coil P Fau lty pulse...

Page 208: ...NE SPEED NOT IN 111 Carburetor choke closed CREASED SUFFICIENTLY 121 Clogged air cleaner ENGINE SPEED INCREASED 31 Restricted flJelllow I Clogged fuel tank breather woo 151 Clogged muffler 5 Check ign...

Page 209: ...Fuel air mixture too lean 131 Ule of improper grade of fuel 141 Excessive carbon build up in combustion chamber 51 Ignition timing too advanced Faulty COl unit or iK vancer POOR PERFORMANCE AT LOW AN...

Page 210: ...1Il FUEL FLOW RESTR ICTED _ 111 Lack of fuel in tank 121 Clogged fuel lina 131 Clogged fual tnk breathar Clogged fuel valve CLOGGED 111 Clean INCORRECT i 1 Cam ock t lOt inn_lied properly WEAK _ 11 Fa...

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Honda ATC200S, Workshop Manual

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