1985 - Honda MPE
 ATC200X
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*e OPERATOR ONLY. NO PASSENGERS.
This vehicle is designed and ‘constructed as an operator-only model. The vehicle load limit and seating
configuration do not safely permit the carrying of a passenger.
e FOR OFF-ROAD USE ONLY.
This vehicle is designed and manufactured for off-road use only. It conforms to US EPA Noise Emission
regulations, but does not conform to Federal Motor Vehicle Safety Standards or US EPA regulations, and
operation on public streets, roads, or highways is illegal. The vehicle is equipped with a USDA approved
spark arrester. Obey local laws and regulations.
® READ THIS OWNER'S MANUAL CAREFULLY
Pay special attention to statements preceded by the following words:
Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.
CAUTION :
Indicates a possibility of personal injury or equipment damage if instructions are not followed.
NOTE: Gives helpful information.
This manual should be considered a permanent part of the ATC and should remain with the ATC when
resold.
AN SS
®
ALOLLLI DOLLS LILDLDLLL LLL DLDLLDODOLDIDL SASS SA SASS SSAA,
HONDA ATC200X 1985
OWNER’S MANUAL
All information in this publication is based on the latest product information available at the time of ap-
proval for printing. HONDA MOTOR CO., LTD. reserves the right to make changes at any time without
notice and without incurring any obligation.
No part of this publication may be reproduced without written permission.
© Honda Motor Co., Ltd. 1984
NNN NNN NNN NNN NNN NNN 2 R EF A CE Saini TTT
This booklet is your guide to the basic operation and proper maintenance of your new Honda ATC200X.
Please take the time to read it carefully. Details necessary for riding the Honda ATC are given to acquaint the
new owner with special riding techniques to be learned. When service is required. remember that your Honda
dealer knows your vehicle best. If you have the required mechanical “know-how and tools, your dealer can
supply you with an official Honda Shop Manual to help you perform many maintenance and repair tasks.
Thank you tor selecting a Honda. We wish you continued riding pleasure in the miles ahead.
* The ATC 200X is a high performance machine, based on the latest technology. 1t is intended for use by
experienced riders only. Although it is a recreational vehicle, it is definitely NOT a toy.
NOTE:
* When reference to the right or left side of the vehicle is made, it is determined from the rider's view.
NON RN CONT EN TS SNS
Page
ATC SAFETY. ae. 1
DESCRIPTION ..................... 3
Parts Location .................... 3
Serial Numbers... ................. 5
Parts Function. . .................. 6
Fuel ...... raaroenderec donen. 10
Engine Qil....................... 12
Tires. . . oo. ._..erereraoecmeere. 14
Front Suspension. ................. 16
Rear Suspension .................. 17
ОРЕКАТТЮМ. ...................... 19
Pre-ride Inspection ................ 19
Starting the Engine. ................ 20
ВгеаК-11 .......... 2..2... 23
Riding .......................... 24
Parking. ......................... 32
MAINTENANCE . ................... 33
Maintenance Schedule .............. 33
Tool Kit......... aa. 35
Eingine Oil/Filter Screen. ........... 36
Engine Oil Filter Rotor. ............ 38
Fuel Filter . ...................... 39
Valves .... LL V 40
Page
Carburetor. ...................... 42
High Altitude . . ................... 43
Spark Plug ....................... 45
AirCleaner. . ..................... 46
Clutch ... aaa 47
Brakes ....... aaa 49
Throttle Cable ....... 53
Drive Chain ....... 54
CamChain............ 0... 56
Spark Arrester .......... LL. 57
STORAGE 120201111011 LL LL 58
TRANSPORTING ................... 59
NOISE EMISSION CONTROL SYSTEM . . 63
SPECIFICATIONS ....... 64
WIRING DIAGRAM -..... as 65
OPTIONAL PARTS .................. 66
NNN NNN NNN NNN A TC SAFETY aii TTT ITN
Read these WARNING LABELS before you ride!
[SAFETY REMINDER | Pa CAUTION |
2 OPERATOR WARNING |
[IMPORTANT INFORMATION| [DRIVE CHAIN CAUTION |
LE WARNING
+
ATC riding requires special efforts on your part
to ensure your safety. Know these requirements
hefore you ride.
SAFE RIDING RULES
*
Always make a pre-ride inspection (page 19) be-
fore you ride the ATC. You may prevent an acci-
dent or equipment damage.
Always obey local off-road riding laws and regula-
tions.
Obtain permission to ride on private property.
Avoid posted areas and obey ‘no trespassing”
signs.
Know the terrain on which you are riding. 1f
you are not familiar with the terrain, ride cauti-
ously. Hidden rocks, holes or ravines could spell
disaster.
Your ability to operate safely is largely dependent
upon your proper judgement in operating the
machine.
PROTECTIVE APPAREL
* Always wear a helmet. You should also wear a
face shield or goggles.boots, gloves and protective
clothing.
The exhaust system becomes very hot during
operation and it remains hot after operation. Never
touch any part of the hot exhaust system. Wear
clothing that fully covers your legs.
MODIFICATIONS
* Modification of the ATC, or removal of original
equipment may render the vehicle unsafe or
illegal.
Spark arresters and mufflers are required in most
areas. Don't modify your exhaust system. Re-
member that excessive noise bothers everyone and
creates a bad image for off-road vehicles.
RRR DE S CRI PT TO IN Sinn
PARTS LOCATION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Fuel tank cap
Throttle lever
Front brake lever
Kick starter pedal
Footpeg
Rear brake pedal
Engine oil dipstick
LT i
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(8) Clutch lever/parking brake arm assy
(9) Headlight switch
(10) Engine stop switch
SERIAL NUMBERS
The frame and engine serial numbers are required The frame serial number (1) is stamped on the left
by your dealer when ordering replacement parts. side of the steering head. The engine serial number
Record the numbers here for your reference. (2) is stamped on the crankcase just above the left
foot peg.
FRAME NO. ENGINE NO.
(1) Frame serial number (2) Engine serial number
PARTS FUNCTION
Engine Stop Switch
The three position engine stop switch (1) is under the
headlight switch. When the switch is in the RUN posi-
tion, the engine will operate. When the switch is in
either OFF position, the engine will not operate.
Headlight switch
The headlight switch (2) is above the ignition switch
and turns the headlight on or off.
Headlight dimmer switch
With the headlight switch (2) ON, use the dimmer
switch (3) to select Hi for high beam or Lo for low
beam.
(1) Ignition switch
6
(2) Headlight switch (3) Headlight dimmer switch
Parking Brake
The clutch lever also functions as the parking brake
lever.
To apply the parking brake, push down the parking
brake arm pin (2), squeeze the clutch lever (1) and
lock it with the lock (3). Always apply the parking
brake when parking the ATC or starting the engine.
To release the parking brake, squeeze the clutch lever
(1) so the lock (3) automatically retracts.
NOTE:
* Use of the parking brake in freezing weather may:
cause the rear brake to freeze in the locked posi-
tion.
‚N
>
(1) Clutch lever
(2) Parking brake arm pin
(3) Lock
Front Brake
The front brake lever (1) is on the right handlebar.
To stop the ATC, apply the front and rear brakes
evenly, with the front wheel aimed straight ahead.
Throttle Lever
The throttle lever (2) is next to the right handlebar
grip and is operated by the rider's thumb. Pressing the
lever forward opens the throttle. When the lever is
released, spring tension closes the throttle auto-
matically.
(1) Front brake lever
(2) Throttle lever
Rear Brake Gearshift Pedal
The gearshift pedal (1) is near the left footpeg.
The rear brake pedal (1) is near the right footpeg. Depress the pedal to shift to a lower gear and raise
the pedal to shift to a higher gear.
(1) Rear brake pedal (1) Gearshitt pedal
8
Choke Lever
The choke lever (1) is on the left side of the carbu-
retor.
Raising the choke lever will close the choke valve.
When the lever is raised, the carburetor will deliver
a rich fuel mixture for starting the engine when cold.
Lower the lever to open the choke valve as the engine
attains normal operating temperature.
To restart a warm engine, it is not necessary to use
the choke.
(1) Choke lever
FUEL
Fuel Valve
The three way fuel valve (1) is on the left side of
the fuel tank.
OFF
When the fuel valve is in the OFF position, fuel can-
not flow from the tank to the carburetor. Tum the
valve off whenever the ATC is not in use.
ON
When the fuel valve is in the ON position, fuel will
flow from the main fuel supply to the carburetor.
RES
When the fuel valve is in the RES position, fuel will
flow from the reserve fuel supply to the carburetor.
Use the reserve fuel only when the main supply is
gone. Refill the tank as soon as possible after switch-
ing to RES. The reserve fuel supply is 1.4 2 (0.37 US
gal).
10
NOTE:
* Do not operate the ATC with the fuel valve in the
RES position after refueling. You may run out of
fuel, with no reserve.
(1) Fuel valve
Fuel Tank
Fuel tank capacity is 9.72 (2.56 US gal) including
1.42 (0.37 US gal) in the reserve supply. To open
the fuel tank cap (1), pull out the breather tube (2)
from the steering stem nut. Then turn the fuel tank
cap counterclockwise.
Any automotive gasoline with a pump octane num-
ber (B4M) of 86 or higher, or research octane
number of 91 or higher may be used.
If “knocking” or “pinging” occurs, try a different
brand of gasoline or a higher octane grade.
After refueling, be sure to tighten the fuel tank cap
firmly by turning clockwise until the arrow (3) on
the cap faces forward. Insert the breather tube into
the steering nut.
* Gasoline is extremely flammable and is explosive
under certain conditions. Refuel in a well venti-
lated area with the engine stopped. Do not smoke
or allow open flames or sparks in the area where
the vehicle is refueled or where gasoline is stored.
* Do not overfill the tank (there should be no fuel
in the filler neck). After refueling, make sure
the tank cap is closed securely.
* Avoid repeated or prolonged contact with skin
or breathing of vapor. KEEP OUT OF REACH
OF CHILDREN.
(1) Fuel tank cap
(2) Breather tube
(3) Arrow
11
ENGINE OIL
Engine Oil Level Check
Check the engine oil level each day before operating
the ATC.
The oil filler cap (1) is on the right crankcase cover
and contains a dipstick for measuring the oil level.
The oil level must be maintained between the upper
(2) and lower (3) level marks on the dipstick.
1. With the ATC on level ground, remove the oil
filler cap/dipstick and wipe it clean.
2. Reinsert the dipstick without screwing it in. Re-
move the oil filler cap/dipstick again and check the
oil level.
3. If required, add the specified oil up to the upper
level mark. Do not overfill.
4. Reinstall the filler cap/dipstick.
CAUTION:
* Running the engine with insufficient oil can
cause serious engine damage.
12
(2) Upper level mark
Engine Oil Recommendation
USE HONDA 4-STROKE OIL OR AN EQUIVA-
LENT.
Use only high detergent, premium quality motor
oil certified to meet or exceed US automobile
manufactures’ requirements for Service Classifica-
tion SE or SF.
Motor oils intended for Service SE or SF will show this
designation on the container. The use of special oil
additives is unnecessary and will only increase oper-
ating expenses.
CAUTION:
* Engine oil is a major factor affecting the perform-
ance and service life of the engine. Non-detergent,
vegetable, or castor based racing oils, are not re-
commended.
Recommended Oil Viscosity:
SAE 10W-40
Other viscosities shown in the chart below may be
used when the average temperature in your riding
area is within the indicated range.
SAE 20W-50
SAE 20W-90
SAE IOW-40
SAE IOW-30
о 20 40 60 80 100 °F
L | | ] A | |
-20 -10 о 10 20 30 40 °C
13
TIRES
The ATC200X is equipped with low pressure tubeless
tires to promote comfortable riding. Although the
: ; > Recom- Standard
tires are designed specifically for vigorous off-road mended | tire circum-
use, they are not immune to punctures. Always select pressure ference
your riding area with care. Front| 3.3 psi 1901 mm
(23 kPa, (74.8 in)
0.23kg/cm?)
* Th is not designed to be ridden on paved
The ATC is not desig be rid Р Rear | 24psi | 1766 mm
surfaces. Handling and control will be severely (17 kPa, | (69.5 in)
affected. 0.17kg/cm?)
For normal use, the tires should be inflated to the
recommended pressure. A manually operated tire Tire Size
pump should be used rather than the high pressure Front : 23.5x8-11
systems found in service stations. This will minimize Rear :22X11.0-8
the possibility of tire damage from overinflation.
NOTE:
* Tire pressure should be checked when the tires
are “cold,” before you ride.
If no air pressure gauge is available to accurately
measure a recommended pressure, this value can be
estimated by measuring the circumference of the tires
with a measuring tape. When inflated to the recom-
mended pressure, the maximum tire circumference
measured over the tread ribs will be approximately
standard tire circumference. The relationship between
tire pressure and actual circumference varies slightly
with factors of wear and stretching that occur
14 through use.
CAN
* Maintain proper tire air pressure. Improperly in-
flated tires may adversely affect maneuverability
and may cause loss of control.
If you have a flat tire, use the plug method to
make temporary repairs. The plug method 1s the
same as that for conventional tubeless tires. A plug
type repair kit, which is available at most auto part
stores or service stations, provides a plug, an installa-
tion tool, tire cement, and an instruction sheet.
Follow the instructions provided in the repair kit
to make a temporary repair until the tire can be
permanently repaired by the cold patch method.
Any tire which cannot be repaired by the plug
method should be replaced.
Whenever the ATC is to be operated far from
service facilities or available transportation, we re-
commend that the rider carry a tire pump and a
suitable repair kit.
Emergency Puncture Repairs
If you have a flat tire, and a plug type repair kit is not
available. use one of the following methods to make
temporary repairs: Stuff a narrow strip of cloth
kneaded with chewing gum into the hole or plug the
hole with a nail or screw.
15
FRONT SUSPENSION
The front suspension system uses air assisted front
forks. The forks may be adjusted for the rider's
weight and riding conditions by adjusting the air
pressure. |
Air pressure adjustment
The standard front fork air pressure setting is for nor-
mal loads and riding conditions. The air pressure can
be increased for heavier loads and rougher riding
conditions.
Check and adjust air pressure when the fork tubes are
cold and with the front wheel off the ground, for
accurate pressure readings.
1. Place a support under the engine to raise the front
wheel oft the ground.
2. Remove the air valve caps (1) and check the air
pressure with the pressure gauge (2).
Standard air pressure: O psi (0 kPa, 0 kg/cm?)
16
3. To increase the air pressure, add air with a bicycle
air pump. To decrease air pressure, depress the
valve core.
Some pressure will be lost when using the gauge.
Determine the amount of loss and compensate
accordingly.
Also. be sure that the air pressure in both fork
tubes is equal.
NOTE: |
* Use of more than 10 psi (70 kPa, 0.7 kg/em*) is
not recommended because fork action becomes
very stiff.
45 Л E
(2) Pressure gauge
[= 9
(1) Air valve caps
REAR SUSPENSION
The ATC200X has a shock absorber with two adjust-
ments for the rider’s weight and riding conditions.
The spring adjuster nut (1) adjusts spring preload for
changes in the rider’s weight.
The rebound damping adjuster (3) adjusts damping
from soft to firm to provide the desired ride with
changes in the rider’s weight and riding conditions.
CAUTION:
* Make sure the engine is off and the parking brake
is applied before adjusting the rear suspension.
(1) Adjuster nut (A) Increase
(2) Lock nut (B) Decrease
To adjust spring preload:
1. Remove the seat/rear fender by sliding the lever.
2. Place a support under the engine to raise the rear
wheel off the ground.
3. Measure the spring length.
Standard: 195 mm (7.7 in)
Minimum: 190 mm (7.5 in)
Maximum: 200 mm (7.9 in)
4. To adjust preload, loosen the lock nut (2) with a
pin spanner and turn the adjuster nut (1).
NOTE:
* An optional pin spanner for adjusting the rear sus-
pension is available at your authorized Honda
dealer.
5. Tighten the lock nut and measure the spring
length again, make sure the adjustment is with-
in the minimum or maximum allowable adjust-
ment length. Reinstall the seat /rear fender,
making sure they are securely attached.
17
To adjust rebound damping:
There are four detent rebound damping adjustment
positions. The damping adjuster (3) is located at
the bottom of the shock and is marked for each
adjustment position.
Turn the damping adjuster (3) by hand to the desired
adjustment.
a -
Adjuster Position Damping force at
0.3m (0.98 ft)/sec.
Soft 1 450 kg (990 Ib)
2 475 kg (1045 1b)
3 500 kg (1100 1b)
Firm 4 550 kg (1213 1b)
NOTE:
* Be sure the damping adjuster is not between posi-
tions but is located in a detent.
18
CET
* The rear shock absorber damper body, reservoir
and hose contain pressurized nitrogen at (284 psi,
1961 kPa, 20 kg/em?). Do not attempt to disas-
semble the shock body.
* Do not disconnect the reservoir hose, or disassem-
ble or refill the reservoir.
* Keep fire and heat away from the shock and its
reservoir.
* If you replace the shock absorber, take the old
unit to your authorized Honda dealer for disposal.
(3) Damping adjuster
ANN OPERA TTON Ai TTR оф
PRE-RIDE INSPECTION
* If the Pre-ride Inspection is not performed, seri-
ous damage or an accident may result.
Inspect your ATC every day before you ride it.
The items listed here will only take a few minutes to
check, and in the long run they can save time expense
and possibly your life.
1.
2.
3.
. Drive chain-check condition (particularly the mas-
Fuel lever-fill the fuel tank when necessary (page
11). Check for leaks.
Brakes-check operation and fluid level (page 49—
52).
Tires-check condition and pressure (page 14).
ter link) and slack (page 54). If necessary, adjust
and lubricate (page 54).
. Throttle-check for smooth opening and closing in
all steering positions (page 53).
. Headlight switch-check for proper function (page
6).
. Engine stop switch — check for proper function
(page 6).
. Nuts, bolts, fasteners-check wheels to see that axle
nuts are tightened and secured by cotter pins.
Check the security of all other nuts, bolts and
fasteners.
Correct any discrepancy before you ride. Contact
your authorized Honda dealer for assistance if you
cannot correct the problem.
19
STARTING THE ENGINE Preparation
| ¥ WARNING | 1. Select a level surface and apply the parking-brake
ON.
2. Turn the fuel valve (1) to ON.
3. Make sure the engine stop switch (2) is at RUN.
* Never run the engine in a closed area. The ex-
haust contains poisonous carbon monoxide gas.
* Do not try to start the engine with the trans-
mission in gear. You may injure yourself or
damage the vehicle.
(1) Fuel valve (2) Engine stop switch
20
Starting Procedure (after Preparation)
To restart a warm engine, follow the procedure for
High Air Temperature.
Normal Air Temperature
10°—35°C (50° —95°F)
1. Raise the choke lever (3) to the Fully Closed posi-
tion (A).
2. Open the throttle slightly. (1/8—1/4)
3. Operate the kick starter (5) with a rapid, contin-
uous motion.
CAUTION:
* Do not allow the kickstarter to snap back freely
against the pedal stop as engine case damage could
result.
4
(4) Throttle
(3) Choke lever
4. Immediately after the engine starts, push the
choke lever down to the detent position (B).
5. About a half minute after the engine starts, push
the choke lever down all the way to Fully Open
(C).
6. If idling is unstable, open the throttle slightly.
High Air Temperature
35°C (95°F) or above
1. Do not use the choke.
2. Open the throttle slightly. (1/8—1/4)
3. Start the engine (See Step 3 under Normal Air
Temperature).
1
i
4
(5) Kick starter
21
Low Air Temperature
10°C (50°F) or below
1. Follow steps 1—4 under Normal Air Temperature.
2. Warm up the engine by opening and closing the
throttle slightly. (1/8—1/4)
3. Continue warming up the engine until it will idle
smoothly with the choke lever pushed down all
all the way to Fully Open (C).
CAUTION:
* Extended use of the choke may impair piston and
cylinder wall lubrication.
* Do not race the engine during the warm-up period.
Racing a cold engine wastes fuel and increases
engine wear.
22
Flooded Engine
If the engine does not start after several attempts,
it may have become flooded with excess fuel. To
clear the engine, turn the engine stop switch off, push
the choke lever down all the way toFully Open, hold
the throttle fully open, and operate the kick starter
several times. When the engine is cleared, turn the
ignition switch on and repeat the normal starting pro-
cedure, but do not use the choke.
BREAK-IN
During the first few days of riding, operate your
new ATC200X so that the engine neither pulls labor-
iousiy nor approaches maximum rpm in any gear.
Avoid full throttle operation, and select your gears
to spare the engine undue stress. A careful break-in
during initial operation will measurably extend the
service life of the engine.
23
RIDING
COI
* Review ATC Safety (page 1-2) before you ride.
* Avoid “wheelies” and “jumping” as they may
cause loss of control.
* Ride with both feet on the footpegs at all times.
If your feet are off the footpegs and touch the
ground while the ATC is moving, they may come
in contact with the rear wheels, causing injury.
* The ATC is not designed to be ridden on paved
surfaces. Handling and control will be severely
affected.
Under normal riding conditions it 18 not necessary
or desirable to touch the ground for balance.
For your initial riding practice, select a safe area
free of obstacles and with an even surface.
|. After the engine has been warmed up, release the
parking brake. The ATC is ready for riding.
2. While the engine is idling. pull in the clutch lever
and depress the gearshift pedal to shift into 1st
(low) gear.
3. Gradually release the clutch lever as you increase
engine speed by opening the throttle.
4. When the speed increases. close the throttle, pull
in the clutch lever. and shift to 2nd gear by raising
the gearshift pedal.
24
5. This sequence is repeated to progressively shift up
to 3rd, 4th and Sth (top) gear.
CAUTION:
* Do not shift gears without disengaging the clutch
and closing the throttle. The engine and drive train
could be damaged by overspeed and shock.
Do not tow the vehicle or coast for long distances
while the engine is OFF. The transmission will not
be properly lubricated and damage may result.
Shifting pattern
Turning Maneuvers
For better traction in off-road use, the ATC has
been fitted with a rear axle which drives both rear
wheels equally at all times.
When negotiating a turn, the wheel on the outside
of the turn must travel a wider radius, and thus a
greater distance, than the inside wheel. As the rear
axle does not permit a differing rate of wheel rota-
tion, it is not enough to merely steer the ATC into
a turn. The new rider must learn to shift his weight
and control the throttle to allow the rear tires to
negotiate the turn. This is the primary technique
to be mastered in riding the Honda ATC.
Practice turning the ATC at slow, constant speeds.
For your initial riding practice, operate the ATC in
low gear.
Defer higher speeds until you are confident of your
abilities.
Steer in the direction of the turn, and lean your
body to the inside of the turn, while supporting
your weight on the outer footpeg. Use the throttle
to maintain power throughout the turn.
This technique allows the ATC to lean slightly
toward the outside, altering the balance of traction
between the rear wheels sufficiently to allow them
to negotiate the turn.
Once this technique is learned, turning maneuvers
can be performed within a relatively small area.
Support your weight
on outer footpeg.
Lean towards
inside of turn.
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25
Incorrect turning techniques may cause the front
wheel to slide straight ahead when steered without
affecting the ATC's direction of travel. If this should
occur, close the throttle and come to a stop. Then
continue practicing the technique outlined on the
preceding page.
If the front wheel tends to skid in mud or snow,
you may be able to improve control under these
conditions by leaning forward, transferring additional
weight to the front wheel.
If the rear wheels inadvertently skid sideways, correct
your slide by steering in the direction of the skid
if you have room to perform this maneuver safely.
Avoid braking or accelerating until you have direc-
tional control.
To avoid skids while traveling on slippery terrain,
the rider must exercise a high degree of caution.
Controlled skids and spins, when performed safely,
add to the sport the rider can enjoy. However,
as skidding maneuvers are inherently more hazardous
than those performed under full traction, we must
caution the rider to first master the basic techniques
of handling before practicing any skidding maneuver.
26
Surface composition is, of course, a major factor
affecting skidding capability. It is obviously easier
to slide on packed snow than in deep sand. Surfaces
with extremely low or extremely high coefficients
of friction must not be used for skidding maneuvers.
It 1$ dangerous to skid on ice, because you may
lose all directional control, and it is dangerous to
skid on pavement, because you may regain traction
suddenly and unexpectedly, which can cause you
to lose your balance and overturn,
Climbing Hills
Practice climbing on evenly surfaced slopes of less
than 20°. The ATC’s capability in climbing hills or
traversing any specific terrain is dependent upon
rider skill. As you gain experience in handling the
ATC, and learn the hazards to be encountered and
your own limitations, you may then proceed to
ride more challenging terrain. However, you must
first be able to discern and avoid any hill or hazard
that would cause the ATC to overturn.
The riding technique for hill climbing involves trans-
ferring your weight toward the front wheel to keep
it in contact with the ground. This may be done
by leaning forward, or for greater weight trans
ference, by standing on the footpegs and leaning
forward.
Take a running start, in the appropriate gear and
speed for the ascent, and climb at a steady rate of
speed.
* Do not apply power suddenly by opening the
throttle or changing gears while ascending a hill
or the front wheel may rise from the ground.
If the front wheel lifts, rider control will be
lessened and the ATC may overturn backward.
* Hill should not be crested at high speed.
Once over the top of the hill, you may lose control
or be thrown from the ATC.
27
If you should find that you have incorrectly esti-
mated climbing capability and lack the power or
traction to continue the ascent, then turn the ATC
around if space permits, while you still have the
forward speed to do so and descend. Avoid stalling
part way up a hill, as maneuvering will then become
more difficult.
¥ Before attempting a turn on a hillside, the rider
should first. master turning technique on level
ground.
If you do lose all forward speed, and can neither
continue uphill nor maneuver the ATC under its own
power, dismount and physically turn the machine
around. If it cannot be turned and must be backed
down, first shift the transmission into neutral and
very carefully back the ATC down, slowing it by use
of both brakes. However, we strongly recommend
that the rider turn the ATC around rather than back
it downhill.
¥, WARNING
* To avoid overturning, the rider must exercise a
high degree of caution when dismounting or
moving the ATC on a hillside.
28
* Applying only the rear brake or engaging the
transmission, while rolling backward downhill can
easily cause the ATC to overturn and fall on the
rider.
Descending Hills
It is usually advisable to descend hills with the ATC
pointed directly downhill, avoiding angles that would
cause the vehicle to lean sharply to one side. As
you approach the point of descent, stop and survey
the terrain below. Never ride headlong past your
limit of visibility. When you have picked a safe
path of descent, shift the transmission into low gear
and descend slowly with the throttle closed. Sit
back on the seat, with arms extended and braced
on the handlebars.
When descending sand dunes, we recommend that
the rider intermittently apply both brakes.
Braking effectiveness is, of course, reduced while
descending any incline with a loose surface.
CAUTION:
* Do not lock the brakes or you may lose control.
29
Traversing Slopes
When riding across a slope at right angles to the
incline of the hill, lean your body uphill to maintain
balance and stability. On a loose surface such as sand,
it may become necessary to steer slightly uphill in
order to maintain your course of travel.
* Balance is more precarious while the ATC is tilted
to one side. Avoid traversing slopes where there
is slippery or difficult terrain.
30
Riding Through Water
* Do not ford any stream with fast flowing water.
The tires may float, making it difficult to main-
tain control,
* Do not ride the vehicle through water for extended
periods.
The Honda ATC can ford water to a depth of ap-
proximately 300 mm (12 in,) although the rider must
be careful to avoid getting the spark plug or air
cleaner wet from splashing water.
When crossing streams, choose a course where both
banks have gradual inclines. Proceed at a slow,
steady speed, and take care to avoid submerged
obstacles and slippery rocks.
After riding through water, the brakes may be less
effective than normal. Test the brakes after traveling
through any water, and if necessary, apply the
brakes repeatedly until the heat of friction has
dried them, and the brakes regain their normal
effectiveness.
31
High Altitude Riding
When operating this vehicle at high altitudes the
air-fuel mixture becomes overly rich. Above 6,500
feet (2,000 m) driveability and performance may
be reduced and fuel consumption increased. The
carburetor can be modified to compensate for this
high altitude richness. However, the carburetor must
be returned to standard factory specifications when
lower altitude riding is desired. (See pages 43—44).
32
PARKING
I. Stop the vehicle, shift the transmission into low
and turn the fuel valve and ignition switch OFF.
2. Apply the parking brake by pulling in the clutch
lever and locking it with the lock.
CAUTION:
* To start the engine on a slope, apply the parking
brake, shift into neutral and then operate the kick-
starter pedal.
ONO MAINTENANCE iE RNR
MAINTENANCE SCHEDULE
® The maintenance intervals shown in the following schedule are based upon average riding, conditions.
ATC's subjected to severe use, or ridden in unusually dusty areas, require more frequent servicing.
Perform the Pre-ride Inspection (page 19) at each scheduled maintenance period.
e The U.S. Environmental Protection Agency requires manufacturers to certify that vehicles built after Janua-
ry 1, 1983 will comply with applicable noise emission standards for one year or 3,000 km (1,865 miles)
after the time of sale to the ultimate purchaser, when operated and maintained according to the instruc-
tions provided. Compliance with the terms of the Distributor’s Warranty for the Honda Vehicle Noise Emis-
sion Control System is necessary in order to keep the noise emission control system in effect. (USA only)
[: Inspect and Clean, Adjust, Lubricate or Replace, if INITIAL REGULAR
SERVICE SERVICE
necessary PERIOD PERIOD | Refer to
C: Clean R: Replace L: Lubricate [| page
A: Adjust | (First week of (Every 30
operation) operating days)
ENGINE OIL NOTE(1),(2) R R 36
* ENGINE OIL FILTER SCREEN С С 36
ENGINE OIL FILTER ROTOR C 38
AIR CLEANER ELEMENT NOTE (2) C 46
SPARK PLUG I 45
* | VALVE CLEARANCE I I 40
* | CAM CHAIN TENSIONER A A 56
* CARBURETOR I I 42
* SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PRO-
PER TOOLS AND IS MECHANICALLY QUALIFIED. |
**IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN 33
AUTHORIZED HONDA DEALER.
I: Inspect and Clean, Adjust, Lubricate or Replace, if INITIAL REGULAR
necessary SERVICE SERVICE Refer to
C: Clean R: Replace L: Lubricate PERIOD PERIOD age
A: Adjust (First week of (Every 30 pag
operation) operating days)
FUEL LINE I: (EVERY YEAR) 39
* FUEL FILTER C:(EVERY YEAR) 39
THROTTLE OPERATION I I 53
DRIVE CHAIN NOTE (2) LL LL 54
| CHAIN SLIDER I I 55
FRONT FORK OIL/AIR R: (EVERY YEAR) 16
* SUSPENSION I _
SWINGARM BEARING [.L LL _
* FRONT/REAR BRAKE PADS NOTE (3) I: (EVERY YEAR) 51
FRONT/REAR BRAKE FLUID 1 [ R: (EVERY YEAR) 49
FRONT/REAR BRAKE SYSTEM I | I | 49
* CLUTCH A A 47
* SPARK ARRESTER C 57
ALL NUTS, BOLTS, FASTENERS I I —
LIGHTING EQUIPMENT [ I —
TIRES i I 14
* STEERING HEAD BEARING A: (EVERY YEAR) —
** | REAR BRAKE PIVOTS [: (EVERY YEAR) —
NOTE: (1) Replace every 30 operating days or every 3 months, whichever comes first.
(2) Service more frequently when riding in dusty areas, sand or snow.
(3) Service more frequently after riding in very wet or muddy conditions.
34
Cy
*
Always turn the engine off before performing
any maintenance operations unless otherwise
stated.
To maintain the safety and reliability of your
HONDA ATC, do not modify it and use only
new genuine HONDA parts or their equivalent
when servicing or repairing.
The use of replacement parts which are not of
equivalent quality may impair the operation of
your ATC,
TOOL KIT
The tool compartment (1) is mounted on the left side
below the rear fender on the rear grip pipe.
The tools provided are sufficient to perform routine
maintenance and simple repairs. Any extensive work
requiring additional tools should be performed by an
authorized Honda motorcycle dealer.
24 mm box end wrench
Screw driver
Grip for screw driver
10 x 12 mm open end wrench
Pliers
Handle bar B
18 x 24 mm box wrench
14 x 17 mm open end wrench
19 mm box wrench
35
ENGINE OIL/OIL FILTER SCREEN
Engine oil should be changed in accordance with
the maintenance schedule. Use motor oils of the
grade and viscosity recommended on page 13.
When changing oil, drain the oil from the crankcase
while the engine is still warm. This will ensure com-
plete and rapid draining.
1. Remove the oil filler cap from the right crankcase
cover.
2. Place an oil drain pan under the crankcase and
remove the oil drain plug (1).
(1) Oil drain plug
36
N
*
OTE:
The oil filter screen (2) and spring (3) will come
out when the drain plug is removed.
. Clean the oil filter screen.
. Check that oil filter screen, sealing rubber and
drain plug O-ring are in good condition.
. With the ignition switch OFF, operate the kick
starter several times to drain any oil which may be
left in the engine.
. Install the oil filter screen, spring and drain plug.
TORQUE: 10 — 20 N-m (1.0—2.0 kg-m, 7-14 ft-lb)
(2) Oil filter screen (3) Spring
7. Fill the crankcase with approximately 1.1 (1.16
US qt) of the recommended oil (page 13).
8. Start the engine and let it idle a few minutes.
9. Stop the engine and check that the oil level is at
the upper mark on the dipstick with the ATC
upright.
Check that there are no oil leaks.
37
OIL FILTER ROTOR 6. Install the other parts in the reverse order of
The oil filter rotor should be cleaned in accordance removal.
with the Maintenance Schedule on page 33. . Adjust the clutch’s free play.
1. Remove the right footpeg (1), kickstarter pedal (2) 8. Fill the crankcase with the recommended oil and
and rear brake pedal (3). check for oil leaks.
. Disconnect the clutch cable (4).
. Remove the right crankcase cover (5).
. Remove the oil filter rotor cover (6) and clean the
oil filter rotor (7).
5. Make sure the rotor cover gasket is in good condi-
tion and reinstall the oil filter rotor cover.
2
BR UN
(1) Footpeg (3) Rear brake pedal (5) Right crankcase cover (7) Oil filter rotor
(2) Kickstarter pedal (4) Clutch cable (6) Oil filter rotor cover
38
FUEL FILTER
The fuel filter is incorporated in the fuel valve. Accu- 3. Reinstall the fuel filter and fuel valve in the reverse
mulation of dirt in the filter will restrict the flow ot order of removal and turn the fuel valve ON.
fuel and therefore, the fuel filter should be serviced Check for leaks.
periodically. 4. Check the fuel line (3) for deterioration, damage
or leakage. Replace if necessary.
1. Drain the fuel from the fuel tank. Disconnect the
fuel line.
* Gasoline is extremely flammable and is explosive
under certain conditions. Perform this operation in
a well ventilated area. Do not smoke or allow
flames or sparks in the area.
2. Remove the fuel valve (1) by loosening the mount-
ing nut and remove the fuel filter (2). Wash it in
clean non-flammable or high flash point solvent.
* Never use gasoline or low flash point solvents for
cleaning the fuel filter. A fire or explosion could
result.
(1) Fuel valve (3) Fuel line
(2) Fuel filter
39
VALVES
Valve clearance should be maintained at 0.08 mm
(0.003 in). Excessive clearance will cause noise
and eventual loss of power. Insufficient clearance will
cause loss of power and could cause valve damage.
NOTE:
* Check and adjust valve clearance while the engine
is cold. The clearance will change as the temper-
ature rises.
I. Remove the timing mark cover and valve adjusting
caps.
2. Using the recoil starter, rotate the generator rotor
counterclockwise until the T mark (2) on the
generator rotor lines up with the timing index
mark (1) on the left crankcase. In this position,
the piston may either be on the compression or
the exhaust stroke. The adjustment must be made
when the piston is on top of the compression
stroke when both the intake and exhaust valves
are closed. This can be determined by moving the
rocker arms by hand. If they are free, it is an in-
dication that the valves are closed and that the
piston is on the compression stroke. If they are
tight and the valves are open, rotate the generator
40
rotor 360° (one complete revolution) and realign
the T mark to the timing index mark.
3. Check the clearance of both valves by inserting
a 0.08 mm (0.003 in.) gauge between the ad-
justing screw and valve stem.
/ i; (ZEN a
67
(1) Index mark (2) T mark
. If adjustment is necessary, loosen the adjusting
screw lock nut (5) and turn the adjusting screw (4)
so that there is a slight resistance when the gauge
is inserted.
. After adjustment, tighten the lock nut while
holding the adjusting screw to prevent it from
turning.
. Recheck the clearance to make sure that it has
not changed.
. Reinstall the timing mark cover and valve adjusting
caps.
(3) Feeler gauge
(4) Adjusting screw
(5) Lock nut
41
CARBURETOR
The engine must be warm for accurate idle adjust-
ment. Ten minutes of stop-and-go riding is sufficient. If idle speed changes after adjusting the fuel mix-
NOTE: ture, readjust the throttle stop screw.
* Do not attempt to compensate for faults in other
systems by carburetor adjustment. See your au-
thorized Honda dealer for regularly scheduled
carburetor adjustments.
To adjust the carburetor:
|. Warm up the engine.
2. Adjust idle speed with the throttle stop screw (1)
IDLE SPEED: 1,300 + 100 rpm
3. Adjust the fuel mixture by turning the pilot screw
(2) clockwise until you hear the engine miss or
decrease in speed, then counterclockwise until the
engine again misses or decreases in speed. Center
the pilot screw exactly between these two extreme
positions.
Usually the correct setting (between extremes of
rich and lean) will be found to be 2-1/4 tums open
from a fully closed position.
(1) Throttle stop screw (2) Pilot screw
42
HIGH ALTITUDE
When operating the ATC at high altitude the air-fuel
mixture becomes overly rich.
Above 6,500 feet (2,000m) driveability and per-
formance may be reduced and fuel consumption
increased.
A high altitude jet is available for carburetor modi-
fication to compensate for this high altitude rich-
ness. Although installation and adjustment procedures
are offered here, unless you are mechanically pro-
ficient and have the necessary tools, we strongly
urge that the carburetor modifications, installation
and adjustment procedures given here be performed
by your authorized Honda dealer.
CAUTION:
* Sustained operation at lower altitudes below 5,000
feet (1,500 m) with the high altitude jet installed
may cause engine overheating and damage.
Altitude Main jet Pilot screw
Below
6,500 feet No. 108 Factory preset
Above ,
5,000 feet No. 102 1/2 screw in
Installation:
1. Turn the fuel valve OFF.
2. Place the carburetor drain tube into a suitable con-
tainer. Turn the carburetor drain screw counter-
clockwise.
* Gasoline is extremely flammable and is explosive
under certain conditions. Perform this operation
in a well ventilated area. Do not smoke or allow
flames or sparks in the area.
3. Remove the drain bolt.
“5
(1) Main jet
43
. Remove the standard main jet (No. 108) (1) and
install the high altitude main jet (No. 102). Re-
install the float chamber.
. Make sure the drain screw is turned fully clockwise
and turn the fuel valve ON.
6. Start the engine. Adjust the idle speed and fuel
mixture.
Removal:
1. Follow installation steps 1-3.
2.
3.
Reinstall the original No. 108 main jet.
Tighten and torque the carburetor drain bolt.
Adjust the idle speed with the throttle stop screw;
adjust the fuel mixture with the pilot screw (page
41).
NOTE:
* Adjust the idle speed and fuel mixture at low alti-
44
tude to ensure proper low altitude operation.
SPARK PLUG
NGK: DR8ES-L
ND:
X24ESR-U
CHAMPION: RA6YC
CAUTION:
* The use of spark plugs of incorrect size or heat
[2
range can cause serious engine damage.
. Clean any dirt from around the spark plug base.
. Disconnect the spark plug cap and remove the
plug with the wrench provided in the tool kit.
. Visually inspect the spark plug electrodes for
wear. The center electrode should have square
edges and the side electrode should not be eroded.
If the electrodes and insulator tip appear unusually
fouled or burned, we suggest that you contact an
authorized Honda dealer to determine the cause of
this condition. Discard the spark plug if there is
apparent wear or if the insulator is cracked or
chipped.
. Make sure that the spark plug gap is 0.6—0.7 mm
(0.024—0.028 in) using a wire-type feeler gauge.
If adjustment is necessary, bend the side electrode
(1) carefully.
. With the plug washer attached, thread the spark
plug in by hand to prevent cross-threading.
. Tighten a new spark plug % turn with a spark plug
wrench to compress the washer. If you are reusing
a plug, it should only take 1/8—1/4 turn after the
plug seats.
CAUTION:
* The spark plug must be securely tightened. An
improperly tightened plug can become very hot
and possibly damage the engine.
0.6—0.7mm
(0.024—0.028in)
(1) Side electrode
45
AIR CLEANER 4. Wash the air cleaner element (5) in clean non-flam-
The air cleaner element accumulates dust and must be mable or high flash point solvent. Allow it to dry
cleaned periodically. If the ATC200X is ridden in thoroughly.
unusually dusty areas, the element must be cleaned
at more frequent intervals than specified in the * Never use gasoline or low flash point solvents for
MAINTENANCE SCHEDULE. cleaning the air cleaner element. A five or explo-
1. Remove the seat/rear fender by sliding the lever sion could result.
(1).
2. Remove the air cleaner cover (2) by removing the 5. Soak the filter element in clean gear oil (SAE 80—
SAE 90) until saturated, then squeeze out the ex-
cess oil.
6. Reassemble by reversing the disassembly sequence.
four clips (3).
3. Remove a screw attaching the air cleaner element
holder (4) and remove air cleaner element (5).
(1) Lever (2) Air cleaner cover (4) Air cleaner element (5) Air cleaner element
(3) Clips holder
46
CLUTCH
Clutch adjustment may be required if the ATC stalls 2. If the adjuster is threaded out near its limit or the
when shifting into gear or tends to creep; or if the correct free play cannot be obtained using the
clutch slips, causing acceleration to lag behind engine cable adjuster (2), a major adjustment must be
speed. | made. Loosen the lock nut (3) and turn in the
Normal clutch lever free play is 10-20 mm (3/8-3/4 adjuster (2) completely (B). Tighten the lock nut
in) at the lever (1). (3).
Minor adjustments can be made with the clutch cable
adjuster (2) at the lever (1).
1. Loosen the lock nut (3) and turn the clutch cable
adjuster (2). Tighten the lock nut (3) and check
the adjustment.
(1) Clutch lever (2) Clutch cable adjuster (A) Decrease free play
(3) Lock nut (B) Increase free play
47
- 3. At the lower end of the cable, loosen the lock nut
(4). Turn the adjusting nut (5) to obtain the
specified free play at the clutch lever. Tighten the
lock nut (4) and check the adjustment.
4. Start the engine, pull in the clutch lever and shift
into gear. Make sure the engine does not stall, and
the ATC does not creep. Gradually release the
clutch lever and open the throttle. The ATC should
start smoothly and accelerate gradually.
NOTE:
* If proper adjustment cannot be obtained or the
clutch does not work correctly, the cable or
clutch friction discs may be worn. Refer to the
official Honda shop manual or see your authorized
Honda dealer.
Other Checks:
Check the clutch cable for kinks or signs of wear that
could cause sticking or failure. Lubricate the clutch
cable with a commercially available cable lubricant to
prevent premature wear and corrosion.
(4) Adjusting nut (A) Decrease free play
(5) Lock nut (B) Increase free play
48
BRAKES
Both front and rear brakes are hydraulic disc types.
As the brake pads wear, brake fluid level drops,
automatically compensating for wear.
There are no adjustments to perform, but fluid level
and pad wear must be inspected periodically. The
system must be inspected frequently to ensure there
are no fluid leaks.
NOTE:
* If the brake lever or pedal travel become excessive
and the brake pads are not worn beyond the re-
commended limit (page 51), there is probably air
in the brake system and it must be bled. See your
authorized Honda dealer for this service.
Y, WARNING
* Brake fluid may cause irritation. Avoid contact
with skin or eyes. In case of contact, flush thor-
oughly with water and call a doctor if your eyes
were exposed.
Front Brake Fluid Level:
Remove the screws, reservoir cap and diaphragm.
Whenever the level is near the lower level mark (2),
fill the reservoir with DOT 3 BRAKE FLUID from
a sealed container, up to the upper level mark (1).
Reinstall the diaphragm and reservoir cap. Tighten
the screws securely.
CAUTION:
* When adding brake fluid, be sure the reservoir is
horizontal before the cap is removed or brake
fluid may spill out.
(FRONT) (1) Upper level mark
(2) Lower level mark
49
CAUTION:
+
Use only DOT 3 brake fluid from a sealed con-
tainer.
Handle brake fluid with care because it can dam-
age paint.
Never allow contaminants (dirt, water, etc.) to
enter the brake fluid reservoir.
Rear Brake Fluid Level:
Remove the screws, reservoir cap and diaphragm.
Whenever the level is near the lower level mark (4) on
the rear reservoir, fill the reservoir with DOT 3
BRAKE FLUID from a sealed container up to’ the
upper level mark (3). Reinstall the diaphragm and
tighten the reservoir cap securely.
CAUTION:
*
Use only DOT 3 brake fluid from a sealed con-
tainer.
Handle brake fluid with care because it can dam-
age paint.
Never allow contaminants (dirt, water, etc.) to
enter the brake fluid reservoir.
50
| L
© = UPPER
a
J
2
|
^^
(REAR) (3) Upper level mark
(4) Lower level mark
Brake Pads:
Brake pad wear will depend upon the severity of
usage and riding conditions. The pads will wear faster
in wet or muddy conditions. Inspect the pads visually
during all regular service intervals to determine the
pad wear. If either pad wears to the wear indicator
(1), both pads must be replaced. See your author-
ized Honda dealer for this service.
(1) Wear indicator (2) Brake disc
Other Checks:
Make sure there are no fluid leaks. Check for deterio-
ration or cracks in the hose and fittings.
The rear brake pedal pivot must be inspected accord-
ing to the Maintenance Schedule.
See your authorized Honda dealer for this service.
“e if
a PE 38
| - nd
Г) +
=
‚ rrr J
all
i | i
i
E
mall
(1) Wear indicator (2) Brake disc
51
Parking brake
Parking brake adjustment may be required if the
parking brake does not hold properly. 4. Push down the parking brake pin (6) and squeeze
the clutch lever until firm resistance is felt. Meas-
ure the distance the clutch lever has moved, the
distance should be 31-39 mm (1.2—1.5 in).
5. To adjust the distance, loosen the lock nut (4)
and turn the adjuster (5).
. Recheck the distance of the parking brake arm
(3) free play.
Parking Brake Adjustment
1. Loosen the lock nut (1) on the rear caliper.
2. Screw the adjusting bolt (2) in until you feel resist-
ance without applying the clutch/parking brake
lever, and tighten the lock nut (1). 6
3. Measure the distance the parking brake arm (3).
The arm free play should be 3.,5—4.5mm (0.14—
0.18 in) at the tip of the parking brake arm.
J1-39mm | —
| (1.2 =1.5im
(1) Lock nut (4) Lock nut (6) Parking brake pin
(2) Adjusting bolt (5) Adjusting nut
(3) Parking brake arm
52
THROTTLE CABLE
Inspect throttle cable condition and operation. The
cable must not bind or impair smooth operation of
the throttle lever in any steering position. Replace
the cable if it has become worn or kinked. Lubricate
the cable with a commercially available cable lubri-
cant to prevent premature wear and corrosion.
Free play, measured from the forward edge of the
throttle lever (1) should be maintained at 3-8 mm
(0.12—0.31 in). The cable adjuster (3) is located near
the throttle lever. Loosen the lock nut (2) and turn
the adjuster to obtain the correct free play.
"a
o r
>. 3- EmmM
* (0172-0.3fin)
(1) Throttle lever (2) Lock nut (A) Decrease free play
(3) Cable adjuster (B) Increase free play
53
DRIVE CHAIN
The drive chain (1) will wear with use and requires
periodic adjustment in accordance with the mainte-
nance schedule.
NOTE:
* Check, adjust or lubricate the chain with the en-
gine off.
Chain slack should be checked by measuring the
amount of chain slack midway between the sprockets.
The amount of slack should be 25-35 mm (0.98—
1.38 in). To adjust slack, and loosen the swing arm
pivot nut (2). Loosen the drive chain adjuster
lock nuts (3). Turn both right and left adjuster nuts
equally to increase or decrease chain slack until it
is within specification.
LA f
E»
25=35mm ea
te ых
‚ №0.99*-438 г) ОА 7, ол
(1) Drive chain
54
NOTE:
* If drive chain slack is excessive when the swing
arm pivot bolt is moved to the limit of adjustment,
the drive chain is worn and must be replaced.
Tighten the swing arm pivot nut (2).
TORQUE: 70-110 N-m (7.0—11.0 kg-m,
| 51-80 ft-lb)
Tighten the adjuster lock nuts.
Lubrication and cleaning: |
Lubricate every 30 days of riding or sooner if chain
appears dry. The O-rings in this chain can be damaged
by steam cleaning, high pressure washers, and certain
solvents.
Clean the chain with kerosene. Wipe dry and lubricate
only with SAE 80 or 90 gear oil. Commercial chain
lubricants may contain solvents which could damage
the rubber O-rings.
h AG
) ©
Y N
E
y; 58 UE h a”
i ña ME
-
ar
=
fmm на.
> ZA
"E"
=
(2) Swing arm pivot nut
(3) Lock nut
(4) Adjusting nut
Drive Chain Slider
Check the drive chain slider at the intervals specified
in the Maintenance Schedule. Replace the slider if the
depth of the groove exceeds 3.0 mm (0.12 in).
(1) Chain slider
55
CAM CHAIN
|. Start the engine and let it idle. NOTE:
2. Remove the rubber cap (1) and loosen the tension- * Do not loosen the 6 mm bolt (3) while adjusting.
er adjusting bolt (2).
When it is loosened, the cam chain tensioner will
automatically position itself to provide the correct
cam chain tension.
3. Retighten the tensioner adjusting bolt and install
the rubber cap.
(1) Rubber cap (2) Tensioner adjusting bolt (3) 6mm bolt
(A) Loosen to adjust
56 (B) Tighten
SPARK ARRESTER
The exhaust system must be periodically purged
of accumulated carbon.
To remove carbon:
1. Remove the spark arrester bolts (1) and muffler
plate (2).
* The exhaust system becomes VERY HOT even
after short periods of engine operation.
To avoid fire hazards, DO NOT perform this
maintenance in the vicinity of flammable mate-
rials.
2. Start the engine, and purge accumulated carbon
from the system by momentarily revving up the
engine several times.
3. Stop the engine and allow the exhaust pipe to
cool.
4. Reinstall the muffler plate.
CAUTION:
* The two mounting screws (3) must be installed
in the spark arrester body at all times for the spark
arrester to be effective.
À
(1) Spark arrester bolts (3) Screws
(2) Muffler plate
57
NNN NNN NNN NN NNN NNN NNN STOR AG Eine
To prepare the ATC for storage:
1.
Completely clean all parts of the ATC. If the ATC
has been exposed to sea air or salt water, wash it
down with fresh water and wipe dry.
. Drain the fuel tank and carburetors. Spray the in-
side of the tank with an aerosol rust-inhibiting oil.
Reinstall the fuel cap on the tank.
Turn the fuel valve to RES and remove the carbu-
retor drain screw; drain gasoline into an approved
container. Reinstall the drain screw.
X
3.
4.
Gasoline is flammable and is explosive under cer-
tain conditions. Do not smoke or allow flames or
sparks near the equipment while draining fuel.
Inflate the tires to their normal pressure and place
the ATC on blocks to raise the tires off the
ground.
Cover the ATC and store in a place which is free
of humidity and dust.
58
(1) Carburetor drain bolt
Removal from Storage
1.
Uncover and clean the ATC. Change the engine oil
if more than 4 months have passed since the start
of storage.
. Drain any excess aerosol rust-inhibiting oil from
the fuel tank. Fill the fuel tank with fresh gasoline.
. Perform all Pre-ride Inspection checks (page 19).
Test ride the ATC at low speeds in a safe riding
area away from traffic.
~
aN TRANS PO R ТГ] №; iii: iu: ui
|. Turn the fuel valve OFF.
2. Remove the drain screw from the carburetor and
drain the gasoline into a suitable container.
* Never transport the machine on its side or with the
front wheel straight up unless all fuel has been
drained.
3. Reinstall the drain screws.
NOTE:
* Be sure the drain screw is tightened.
* If wheel removal is required when transporting,
follow the procedures on the following pages.
59
Front Wheel Removal
1.
4.
5.
Place a support block under the engine to raise the
front wheel off the ground.
2. Remove the four wheel hub nuts (1).
3.
Remove the two bolts (2) securing the front brake
caliper (3).
Loosen the axle holder nuts (4) and remove the
axle (5).
Remove the axle collar (6) and front wheel.
Installation
1. Install the axle holder with UP mark (7) facing up-
(1) Wheel hub nuts
wards. Install the holder nuts (4). Do not tighten
them at this time.
(2) Bolts
(3) Front brake caliper
60
(4) Axle holder nuts
(5) Axle
. Install the front wheel and collar (6) and insert
the front axle (5).
. Tighten the axle to 70—110N-m (7 — 11 kg-m,
51-80 ft-lb) torque.
. Tighten the axle holder nuts (4) to 10—14 N-m
(1.0—1.4 kg-m, 7.2— 10 ft-lb) torque.
. Install the front brake caliper (2) and tighten it
to 20-30 N-m (2.0-3.0 kgm,
torque.
14 —22 ft)
. Install the wheel hub nuts (1) and tighten them to
30 — 40N-m (3.0 — 4.0 kg-m, 22 — 29 ft-1g).
(6) Axle collar
(7) UP mark
* When the front axle is reinstalled, be careful that
the grease seal is not cut or damaged.
* Be certain that the holding nuts and axle are
tightened. If they are not, the wheel may come
loose during operation.
* If a torque wrench was not used for installation,
see your authorized Honda dealer as soon as
possible to verify proper assembly.
61
Rear Wheel Removal
|. Place a support block under the vehicle and raise Installation:
the rear wheels off the ground. Reinstall the rear wheel and tighten the wheel nuts
2. Loosen the wheel nuts (1) with a 14 mm socket (1) in a crisscross, torquing them to 30-40 N-m
; wrench. he wheel (3.0—4.0 kg.m, 22—29 ft-1b).
. Remove the wheel.
* If a torque wrench was not used for installation,
see your authorized Honda dealer as soon as pos-
sible to verify proper assembly.
(1) Wheel nuts
62
NS NOISE EMISSION CONTROL SYSTEM(USA ONLY ) SSSSSSSS
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following
acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes
of maintenance, repair, or replacement, of any device of element of design incorporated into any new vehicle
for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use: or
(2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by
any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing the muffler, bafflers, header pipes or any other component which con-
ducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle; or parts of the exhaust or intake system, with parts other
than those specified by the manufacturer.
63
NNN S PECIFIC A TION SS SSI
DIMENSIONS CHASSIS AND SUSPENSION
Overall length 1,850 mm (72.8 in) Caster angle 22°
Overall width 1,050 mm (41.3 in) Trail length 35 mm (1.38 in)
Overall height 1,040 mm (40.9 in) Tire size
Wheel base 1,210 mm (47.6 in) Front 23.5x 8-11
Rear 22 x 11.0—8
WEIGHT
POWER TRANSMISSION
Dry weight 128.0 kg (282.2 1b)
Primary reduction 3.333
CAPACITIES Final reduction 3.333
Gear ratio, 1st 2.769
Engine oil 1.2 liter (1.27 US qt) 2nd 1.941
Fuel tank 9.7 liter (2.56 US gal) 3rd 1.450
Fuel reserve capacity 1.4 liter (0.37 US gal) 4th 1.130
Passenger capacity Operator only Sth 0.923
ENGINE
Bore and stroke 65 x 57,8 mm
(2.56 x 2.28 in)
Compression ratio 96:1
Displacement 191.8 ec (11.70 cu in)
Spark plug gap 0.6-0.7mm
(0.024 —0.028 in)
NNN WT RING DIAGRAM aii a
IGNITION COIL
SPARK PLUG
TAIL LIGHT
12V5W
16
G=]
Y
ENGINE e LIGHT SWITCH |
' EADLI
H GHT A.C. GENERATOR
| 12V60/60 W
METER | —
( OPTIONAL PARTS) ENG
_12v3.4W
SWITCH CONTINUITY
Bl BLACK Broo BROWN
passes Y иене
LIGHT SWITCH ENGINE SWITCH Y ELLOW 0 ORANGE
С | 1G: E G —— GREEN Ц LIGHT GREEN
| OFF OO Ro. RED Poe PINK
Woo WHITE Gr GRAY
| RUN
| coor В | G
00302 —965— 0100
65
NNN NNN NNN QO P TION AL PARTS SINO NN
To install the optional parts, follow the instruments furnished with the parts.
Fender stabilizer Speedometer
66
Headlight guard
Headlight lens grille
67
Rubber step (For use with snowmobile boots)
68
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2965621 #1008606F
QOX32-965-6210 AFF E4L PRINTED IN JAPAN
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