Description
This Clymer Honda ATC250 & Fourtrax 200/250 1984 1985 1986 1987 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1984-1987 Honda ATC250 & Fourtrax 200/250 ATVs, including Honda TRX200, Honda ATC250SX, Honda ATC250ES, and Honda Fourtrax 250 ATCs with shaft drives. This book will help you service your three wheeler / ATV properly.
Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, front suspension, rear axle, rear suspension, final drive, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and 382 illustrated pages.
Table of Contents
CHAPTER ONE, GENERAL INFORMATION
Notes, cautions and warnings, Service hints, Torque specifications, Safety first, Special tips, Expendable supplies, Parts replacement, Serial numbers, Tune-up and troubleshooting tools, Basic hand tools, Mechanic’s tips, “Off the road” rules, Safety
CHAPTER TWO, TROUBLESHOOTING
Operating requirements, Emergency troubleshooting, Engine starting, Engine performance, Engine noises, Excessive vibration, Front suspension and steering, Brake problems
CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-checks, Service intervals, Tires and wheels, Crankcase breather system (U.S. models), Battery, Periodic lubrication, Periodic maintenance
CHAPTER FOUR, 200 CC ENGINE
Engine principles, Engine cooling, Servicing engine in frame, Engine, Cylinder head cover and camshaft, Cylinder head, Valves and valve components, Cylinder, Piston, piston pin and piston rings, Ignition pulse generator, Oil pump and right-hand crankcase spacer, Alternator, Starter gears, Recoil starter, Camshaft chain and tensioner, Crankcase and crankshaft, Break-in procedure, Service and adjustment
CHAPTER FIVE, 250 CC ENGINE
Engine principles, Engine cooling, Servicing engine in frame, Engine, Cylinder head cover and camshaft, Cylinder head, Valves and valve components, Cylinder, Camshaft chain tensioner, Piston, piston pin and piston rings, Oil pump and primary drive gear, Starter reduction gears, Alternator, pulse generator and starter clutch, Kickstarter, Right-hand crankcase cover, Left-hand crankcase cover, Crankcase and crankshaft, Break-in procedure, Service and adjustment
CHAPTER SIX, CLUTCH AND TRANSMISSION (200 CC ENGINE)
Clutch operation, Centrifugal, Manual clutch, Manual clutch inspection, Clutch lifting mechanism, External shift mechanism, Transmission and internal shift mechanism, Dual-range subtransmission and reverse, Output gear case
CHAPTER SEVEN, CLUTCH AND TRANSMISSION (250 CC ENGINE)
Clutch operation, Centrifugal clutch, Manual clutch, Manual clutch inspection, Clutch lifting mechanism, Reverse lock mechanism, External shift mechanism, Transmission and internal shift mechanism, Output gear case
CHAPTER EIGHT, FUEL AND EXHAUST SYSTEM
Carburetor operation, Carburetor service, Carburetor (200 cc models), Carburetor (250 cc models), Cleaning/inspection (all models), Cold starting problem (1985 250 cc models), Carburetor adjustments, Throttle cable, Fuel shutoff valve, Fuel tank, Fuel level gauge (Fourtrax 250), Air filter air box, Exhaust system
CHAPTER NINE, ELECTRICAL SYSTEM
Charging system, Voltage regulator, Alternator, Capacitor discharge ignition, Ignition coil, Ignition pulse generator, Electric starting system, High oil temperature warning indicator system (Fourtrax 250), Lighting system, Switches, Fuses
CHAPTER TEN, FRONT SUSPENSION AND STEERING
Front wheel (3-wheeled models), Front wheel (4-wheeled models), Tires and wheels, Front hub/brake drum and axle (3-wheeled models), Handlebar (3-wheeled models), Steering stem (ATC250SX), Front fork (ATC250SC), Steering stem and upper front fork (ATC250ES), Lower front fork (ATC250ES), Handlebar (4-wheeled models), Steering shaft (4-wheeled models), Tie rod, Front suspension arm and steering knuckle
CHAPTER ELEVEN, REAR AXLE SUSPENSION AND FINAL DRIVE
Rear wheel (all models), Rear axle (200 cc models), Rear axle (250 cc models), Rear axle and left-hand bearing housing (all models), Final drive unit and universal joint (200 cc models), Final drive unit (250 cc models), Shock absorber, Swing arm water sealing problem (1985 ATC250ES and ATC250SX models), Swing arm, drive shaft and universal joint (TRX200, ATC250ES models), Swing arm (ATC250SX, Fourtrax 250 models), Rear axle housing (Fourtrax 250, 1986 ATC250SX and ATC250ES models), Right-hand axle bearing housing (1985 ATC250SX and ATC250ES models)
CHAPTER TWELVE, BRAKES
Front brakes (3-wheeled models), Front brakes (4-wheeled models), Rear drum brake (200 cc models), Rear drum brake (250 cc models), Brake cable replacement (all models), Master cylinder (4-wheeled models), Brake hose replacement (4-wheeled models), Bleeding the system
CHAPTER THIRTEEN, BODY
Front fender, Front fender and front carrier, Rear fender/seat (ATC250SX), Rear fend and carrier (ATC250ES), Rear fender and rear carrier (4-wheeled models)
SUPPLEMENT, 1987 SERVICE INFORMATION
INDEX
