Positioning:
The Honda ATC200ES Big Red was a highly capable and popular three-wheeled ATV, known for its utility and off-road performance. This manual serves as an essential resource for owners and enthusiasts of this specific, single-year model.
Competitors:
Competed against other utility ATVs of its era, offering a balance of power and agility.
Features:
This service manual is a critical tool for maintaining the longevity and performance of the 1984 ATC200ES, offering comprehensive coverage unmatched by generalized repair guides.
Value Proposition:
Provides essential technical information for repairs, maintenance, and troubleshooting, enabling owners to perform work themselves and reduce reliance on external service providers.
Engine:
Complete engine overhaul, including disassembly, inspection, reassembly, and adjustments.
Fuel System:
Carburetor (Mikuni VM series), fuel pump, fuel lines, fuel tank, and related components.
Ignition System:
CDI ignition, magneto, coil, spark plug, wiring diagrams.
Transmission And Drivetrain:
5-speed manual transmission with automatic clutch, primary reduction gear, drive shaft, rear axle, and differential.
Brakes:
Front and rear drum brakes, brake cables, linkages, and hydraulic components (if applicable for certain brake systems).
Suspension:
Front telescopic forks, rear swingarm, shock absorber, and linkage systems.
Electrical System:
Lighting (headlights, taillights), battery, charging system (magneto, rectifier/regulator), starter motor (if equipped), switches, and wiring harness.
Body And Frame:
Frame, fenders, plastic body panels, seat, handlebars, footpegs, and racks.
Drivetrain:
Includes detailed information on the shaft drive system, differential, and related components.
Electrical Components:
Covers starter motor, rectifier, stator, magneto, and all switches.
Maintenance Schedule:
Regularly scheduled maintenance tasks, including oil changes, filter replacements, chain adjustments, and lubrication.
Troubleshooting:
Diagnostic guides for common problems such as no-start, poor performance, electrical issues, and component failures.
Repair Procedures:
Step-by-step instructions for disassembling, repairing, and reassembling all major vehicle components.
Rebuilds:
Complete engine and transmission rebuild procedures.
Torque Specifications:
Detailed torque values for all critical fasteners, ensuring proper assembly and component integrity.
Adjustments:
Procedures for adjusting carburetor settings (idle speed, mixture), valve clearance, and brake linkages.
Removal Installation:
Detailed instructions for removing and installing components and sub-assemblies.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Suitable for DIY enthusiasts and professional mechanics.
Illustrations:
Includes detailed diagrams and illustrations for clarity.
Part Diagrams:
Features explicit part diagrams to aid in identification and assembly.
Diagnostic Codes:
Manual may include procedures for identifying and resolving issues that could be considered 'error codes' through symptom analysis and electrical testing, but not digital OBD-II style codes.
Engine Type:
Four-stroke, air-cooled, OHC
Bore X Stroke:
64.0 mm x 57.7 mm
Power Output:
Approximately 13.0 HP @ 6,000 RPM (Manufacturer's estimate, actual may vary)
Torque Output:
Not explicitly specified in common literature, but significant low-end torque is characteristic.
Fuel Delivery:
Carburetor (Mikuni VM series, e.g., VM26)
Carburetor Specifications:
Main Jet: #105, Pilot Jet: #20, Needle Valve: 2.0, Throttle Valve: 2.5, Air Screw: 1.5 turns out (Typical values, refer to manual for precise specifications)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
2.6 US gallons (approx. 9.8 liters)
Recommended Oil Viscosity:
SAE 10W-30 (Refer to manual for specific temperature ranges and approvals)
Oil Capacity:
1.5 US quarts (approx. 1.4 liters) after oil filter change (check manual for exact capacity)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Air-cooled
Starter Type:
Kickstarter
Valve Clearance Intake:
Refer to manual for specific cold/hot clearance (typically very small, e.g., 0.05-0.10 mm)
Valve Clearance Exhaust:
Refer to manual for specific cold/hot clearance (typically very small, e.g., 0.05-0.10 mm)
Conrod Specifications:
The manual will detail conrod bearing inspection and replacement procedures.
Piston Information:
Manual covers piston inspection, ring replacement, and cylinder bore measurements for wear and ovality.
Type:
5-speed manual with automatic clutch
Clutch Type:
Automatic centrifugal clutch
Final Drive:
Shaft drive with enclosed differential
Reverse Gear:
No reverse gear typically found on this model.
Transmission Oil Type:
API GL-4 SAE 80W-90 Hypoid Gear Oil (check manual for precise specification)
Transmission Oil Capacity:
Refer to manual for specific capacity, typically around 0.4 liters.
Engine Oil Change:
Every 1,000 miles or 6 months, whichever comes first (refer to manual for exact recommendation).
Spark Plug Check:
Inspect at regular intervals, replace as needed (refer to manual for specific interval).
Air Filter Cleaning:
Clean as needed based on operating conditions, typically every few hundred miles or annually.
Chain Lubrication Adjustment:
Lubricate and adjust chain tension regularly, depending on usage.
Valve Clearance Check:
Recommended at specified intervals, typically every few thousand miles or annually.
Engine Oil:
SAE 10W-30 API SE or SF (Refer to manual for precise specifications)
Transmission Oil:
API GL-4 SAE 80W-90 Hypoid Gear Oil (Refer to manual for precise specifications)
Brake Fluid:
DOT 3 or DOT 4 brake fluid (if applicable for hydraulic systems, though likely drum brakes with cables).
Common Problems:
Carburetor issues (clogging, wear), ignition coil failure, wear on automatic clutch components, and general wear and tear due to age.
Preventative Measures:
Regular cleaning of the carburetor, proper fuel storage, and diligent adherence to maintenance schedules can mitigate many common issues.
Oem Parts:
The manual will provide part numbers and diagrams to facilitate the sourcing and replacement of original equipment manufacturer (OEM) parts.
Coolant Type:
Not applicable, this is an air-cooled engine.
Fuse Locations Replacement:
Manual will detail any fuses present in the electrical system and their replacement procedures.
Lubrication Points:
Comprehensive guide to all lubrication points, including cables, linkages, and pivots.
