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Honda 86-87 TA200 FATCAT User Manual

Honda 86-87 TA200 FATCAT
206 pages
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8S-B7
:'l"
R200
FA T
CAT

Table of Contents

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Honda 86-87 TA200 FATCAT Specifications

General IconGeneral
Compression Ratio9.0:1
IgnitionCDI
Transmission5-speed
Final DriveChain
Front SuspensionTelescopic fork
Front BrakeDrum
Rear BrakeDrum
Starting SystemElectric Start

Summary

Important Safety Notice

General Safety Precautions

Provides warnings about potential hazards and safety measures to follow during service operations.

How to Use This Manual

Manual Structure Overview

Explains how the manual is organized into sections for efficient use and reference.

General Information

General Safety

Details essential safety precautions for operating and maintaining the vehicle.

Service Rules

Outlines fundamental rules and guidelines for performing maintenance and service procedures.

Specifications

Lists key technical specifications for the vehicle's components and systems.

Tools

Identifies special and common tools required for various service and maintenance tasks.

Lubrication

Troubleshooting

Provides solutions for common problems related to the lubrication system.

Engine Oil

Covers engine oil specifications, recommendations, and checks for proper lubrication.

Maintenance

Maintenance Schedule

Outlines the recommended schedule for regular maintenance tasks and intervals.

Fuel Line

Details procedures for checking and maintaining the fuel line system.

Spark Plug

Provides instructions for inspecting, measuring, and replacing the spark plug.

Brake System

Covers maintenance procedures for the front and rear brake systems.

Fuel System

Troubleshooting

Guides users through diagnosing and resolving common fuel system issues.

Fuel Tank

Details the removal and installation procedures for the fuel tank.

Carburetor Assembly

Explains the process of assembling the carburetor, including float and jet adjustments.

Engine Removal/Installation

Engine Removal

Step-by-step instructions for safely removing the engine from the motorcycle frame.

Engine Installation

Provides guidance on reinstalling the engine into the motorcycle frame correctly.

Cylinder Head/Valves

Troubleshooting

Diagnoses common problems related to the cylinder head and valve train.

Cylinder Head Cover Removal

Details the process for removing the cylinder head cover to access internal components.

Camshaft Removal

Describes the steps required to remove the camshaft from the cylinder head.

Cylinder Head Assembly

Guides through the reassembly process of the cylinder head components.

Cylinder/Piston

Troubleshooting

Helps diagnose issues related to cylinder wear, piston damage, and compression problems.

Cylinder

Covers the removal, inspection, and measurement of the cylinder.

Piston

Details the inspection and measurement of the piston and its rings.

Clutch/Kick Starter/Gearshift Linkage

Troubleshooting

Addresses common problems with the clutch, kick starter, and gearshift linkage.

Right Crankcase Cover Removal

Provides instructions for removing the right crankcase cover.

Centrifugal Clutch

Covers the removal and inspection of the centrifugal clutch components.

Manual Clutch

Details the removal and inspection procedures for the manual clutch.

Alternator/Starter Clutch

Troubleshooting

Helps diagnose issues with the alternator, starter clutch, and related components.

Left Crankcase Cover Removal

Outlines the steps for removing the left crankcase cover.

Stator Replacement

Provides instructions for removing and replacing the alternator stator.

Crankcase/Crankshaft/Transmission

Troubleshooting

Diagnoses common problems related to the crankcase, crankshaft, and transmission.

Crankcase Separation

Details the procedure for separating the crankcase halves for internal access.

Transmission Disassembly

Explains how to disassemble the transmission components.

Front Wheel/Brake/Suspension/Steering

Troubleshooting

Guides through diagnosing and resolving issues with the front wheel, brakes, and suspension.

Handlebar

Covers the removal and installation of the handlebar and related controls.

Front Wheel

Details the removal and inspection procedures for the front wheel assembly.

Tires

Provides instructions for tire removal, installation, and repair.

Front Fork

Explains the disassembly, inspection, and assembly of the front fork components.

Rear Wheel/Brake/Suspension

Troubleshooting

Helps diagnose and resolve common problems with the rear wheel, brake, and suspension.

Rear Wheel

Covers the removal, inspection, and disassembly of the rear wheel.

Rear Brake

Details maintenance procedures for the rear brake system components.

Swingarm

Provides instructions for swingarm removal, inspection, and pivot bushing replacement.

Fenders/Exhaust Muffler

Seat

Covers the removal and installation procedures for the vehicle seat.

Side Covers

Details the removal and installation of the left and right side covers.

Front and Rear Fender

Provides instructions for removing and installing the front and rear fenders.

Exhaust Pipe/Muffler

Covers the removal and installation of the exhaust pipe and muffler system.

Ignition System

Troubleshooting

Helps diagnose and resolve common ignition system problems.

CDI Unit

Details the inspection and performance testing of the CDI unit.

Ignition Coil

Covers the inspection and testing procedures for the ignition coil.

Ignition Timing

Explains how to check the ignition timing using a timing light.

Battery/Charging System

Troubleshooting

Diagnoses common issues related to the battery and charging system performance.

Battery

Covers battery removal, inspection, charging, and installation procedures.

Charging System

Details inspection procedures for charging voltage, regulator/rectifier, and charging coil.

Starter System

Troubleshooting

Helps diagnose common problems related to the starter motor and relay.

Starter Motor

Covers the removal, brush inspection, and commutator inspection of the starter motor.

Starter Relay

Details the testing procedures for the starter relay switch.

Lights/Switches

Troubleshooting

Diagnoses common issues with headlights, taillights, and various switches.

Headlight

Covers headlight bulb replacement and headlight case removal/installation.

Neutral Switch

Details the inspection and testing procedures for the neutral position switch.

Ignition Switch

Covers the inspection, removal, and installation of the ignition switch.

Troubleshooting

Engine Does Not Start or Is Hard To Start

Guides diagnosis for engine starting failures and hard starting conditions.

Engine Lacks Power

Provides troubleshooting steps for diagnosing engine power loss issues.

Poor Performance At Low And Idle Speeds

Helps resolve issues related to poor engine performance at low speeds and idle.

Weak Or No Spark

Troubleshoots ignition system faults causing weak or no spark.

Poor Handling

Addresses problems related to heavy steering, wheel wobble, and vehicle pulling.

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