Pampas56 43 Posted June 2, 2020 I have a small leak on the engine cover gasket on my little Fourtrax and want to change the gasket. I can't find any procedures on the internet, the closest is for a FWD 300. Can anyone point me to a written R&R list for a 91 Fourtrax 200? Or maybe some insights on what to expect when I try to take it apart. I am very good with tools and do most of my own repairs and maintenance. Just a little nervous because this will be my first foray into a motorcycle engine. Thanks Steve Share this post Link to post Share on other sites
_Wilson_™ 6,014 Posted June 2, 2020 can you post us some pics ?? welcome to the forums. Share this post Link to post Share on other sites
Pampas56 43 Posted June 2, 2020 The leak is just to the left of the sprocket about 10 o'clock on the cover. The second picture is of the cover I need to remove. I know the starter is there, but don't know what else is under the cover. 1 Share this post Link to post Share on other sites
_Wilson_™ 6,014 Posted June 2, 2020 I'd go a head and pull the chain, and drive sprocket off ... it's not a big deal ... then get a better look ... however ... i have seen those chains run loose and eat into the housing ... 2 Share this post Link to post Share on other sites
Pampas56 43 Posted June 3, 2020 I've already pulled them once to find the leak. A new chain and sprocket set should be here tomorrow. The leak is on the seam between the case and cover. I just need to know how to get the cover off without incident. Share this post Link to post Share on other sites
_Wilson_™ 6,014 Posted June 3, 2020 can you pen point exactly where the oil leek is ?? behind the sprocket at ten o'clock ? https://www.hondapartsnation.com/oemparts/l/hon/5053dc11f870021c54bdab54/1991-trx200-a-parts Share this post Link to post Share on other sites
Pampas56 43 Posted June 3, 2020 Yes, I have pinpointed EXACTLY where the leak is. That is not the issue. I just need to know how to get the cover off the easiest way with no problems. Steve Share this post Link to post Share on other sites
_Wilson_™ 6,014 Posted June 3, 2020 wish i could be of more help, so .. .. ill step back and let the experts handle this ... it looks like the engine (from what i see) may (QUESTION MARK) may need to be split .... I'd drop shadetree, jeep, or fish a note ... Share this post Link to post Share on other sites
Fishfiles 17,773 Posted June 3, 2020 From where you point to the leak , my guess would be the chain was run loose from not periodically adjusting the chain and ate the case , very common problem , if that turns out to be the problem , there are chain case protectors for some models , which may help it from happening again in the future ---- get a manual , here are a couple of pics of how it is put together 1 Share this post Link to post Share on other sites
Pampas56 43 Posted June 3, 2020 I understand what you are saying but the case and cover are in pristine shape. I am looking at a simple gasket failure. Is there an on-line manual for that old a machine or can you point me to a place to buy a manual? Thanks Steve Share this post Link to post Share on other sites
_Wilson_™ 6,014 Posted June 3, 2020 (edited) https://atvhonda.com/topic/92-service-manual-downloads/ not sure if you model is listed ... Edited June 3, 2020 by _Wilson_™ 1 Share this post Link to post Share on other sites
Fishfiles 17,773 Posted June 3, 2020 I personally would rather a hard copy that a download I copied and pasted your model and year to e-bay and here are two that popped up: Here is a new one , $36 and $8 shipping : https://www.ebay.com/itm/Clymer-ATV21-All-Terrain-Vehicle-Maintence-Manual-Service-Book-Guide/233597499730?fits=Year%3A1991|Model%3AFourTrax+200&epid=12035036311&hash=item36637ef952:g:yPYAAOSwgXVeyb9H Here is a preowned manual for like $13 https://www.ebay.com/itm/HONDA-FOURTRAX-90-Service-Repair-Manual-2000-1999-1998-1997-1996-1995-1994-1993/303576672205?fits=Year%3A1991|Model%3AFourTrax+200&hash=item46ae9467cd:g:cX0AAOSwaJFedqJ0 1 Share this post Link to post Share on other sites
Fishfiles 17,773 Posted June 3, 2020 2 minutes ago, _Wilson_™ said: https://atvhonda.com/topic/92-service-manual-downloads/ not sure if you rmodel is listed ... I tried to look at that link and it don't work for me .... 1 Share this post Link to post Share on other sites
_Wilson_™ 6,014 Posted June 3, 2020 (edited) yeah... it never worked (from day one) for me ether ... but i have the bible shop book... I've always prefered shop papaer shop manuals ... i have one on every machine i own, and most machines my pop owns ... the johndeer books are about 4 inches thic ... lol! you can spend some big $$ for some of those books .. the worst was a book on l model toyota diesel $175 ... for that 81 pickup i owned .... Haynes , and clymer didn't even come close to holding a candle to it ... nether did chilton... Edited June 3, 2020 by _Wilson_™ Share this post Link to post Share on other sites
Pampas56 43 Posted June 3, 2020 Thank you. The site has the pertinent info and I was able to send it to my tablet. I agree that a hard copy is preferable to a digital copy. After I fix these problems I will explore the options for printing the manual to a three ring binder and saving the digital info to a thumb drive or SD card. I am on my way to fixing the quad. I will TRY to update when I finish. THANK YOU VERY MUCH Steve 3 Share this post Link to post Share on other sites
Pampas56 43 Posted June 3, 2020 OK. I found the problem. Someone repaired this break and did not do a very good job. I was cleaning with alcohol and the piece just fell out. I am going to try to fill it with JB Weld. Hopefully I can get a reasonable surface to seal this up. Steve 1 Share this post Link to post Share on other sites
Fishfiles 17,773 Posted June 3, 2020 JBWeld is good , MinuteMend to me is better ---remember to keep the chain adjusted and don't run it loose , if a case protector is available for that model , I would invest in one , maybe the fix was ok and it got hit again and knocked it loose 1 Share this post Link to post Share on other sites
shadetree 5,501 Posted June 4, 2020 i have never had good luck with jb weld on oil leaks. i know you wont like my answer ?, but if it were mine, i would just replace that side case with a better one, but good luck trying to locate one that isn't already busted in the same spot !. 1 Share this post Link to post Share on other sites
_Wilson_™ 6,014 Posted June 4, 2020 thanks for the update ..... I'm not against patching ..(never had much luck with it myself) well..... let me put that another way ( as a last resort) ... I'd try and find a good replacement , but as shade said finding parts for those old girls are d--n near impossible !! you might post in the wanted thread .. https://atvhonda.com/forum/20-for-sale-trade-wanted/ Share this post Link to post Share on other sites
Fishfiles 17,773 Posted June 4, 2020 I would try and MinuteMend it Share this post Link to post Share on other sites
Pampas56 43 Posted June 4, 2020 I am hoping it lasts at least tonight. We use it in the pits at the racetrack. If so, I can look for parts or try ?Minutemend. I shaved it down as close as I could and put some Hi-Temp RTV sealant on there to fill in what I could. Also layed a bead on the outside of the seam. Now it's just wait for things to set and if it holds running to get the mail, I will load it up and off to the races. I am not sure that I would have the confidence to split the case and replace the broken half. If it comes to it, I have a friend who TIGs aluminum and he could probably build it up enough for me to dremel the case back into shape. Wish me luck Steve Share this post Link to post Share on other sites
Pampas56 43 Posted June 5, 2020 I am researching the last resort option of replacing the left crankcase half. The items I find on E-Bay are all mid-late80s engines. What is compatible to the 91 TRX200 engine? Share this post Link to post Share on other sites
Fishfiles 17,773 Posted June 5, 2020 49 minutes ago, Pampas56 said: I am researching the last resort option of replacing the left crankcase half. The items I find on E-Bay are all mid-late80s engines. What is compatible to the 91 TRX200 engine? go to partzilla , put in your model , find the part you need , click on that part number and it will take you to the interchange , you'll see it is trx200 and the years that interchange , copy and paste that part number and stick onebay , google and amazon , if something comes up , look at the atv they say interchange with that part Share this post Link to post Share on other sites
Fishfiles 17,773 Posted June 5, 2020 This Honda 11200-HB3-840 CRANKCASE, L. fits the following models and components: Honda ATV 1993 TRX200D A - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1993 TRX200D AN - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1995 TRX200D AN - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1994 TRX200D AN - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1992 TRX200D A - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1991 TRX200D AN - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1990 TRX200 A - FOURTRAX 200 CRANKCASE Honda ATV 1991 TRX200D A - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1994 TRX200D A - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1995 TRX200D A - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1997 TRX200D A - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1991 TRX200 A - FOURTRAX 200 CRANKCASE Honda ATV 1991 TRX200 AN - FOURTRAX 200 CRANKCASE Honda ATV 1997 TRX200D AN - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1996 TRX200D AN - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1996 TRX200D A - FOURTRAX 200 TYPE II CRANKCASE Honda ATV 1988 TRX200SX A - FOURTRAX 200SX CRANKCASE Honda ATV 1992 TRX200D AN - FOURTRAX 200 TYPE II CRANKCASE Share this post Link to post Share on other sites
Fishfiles 17,773 Posted June 5, 2020 Hey , I am not endorsing using Partzilla above , the part is no longer available any ways as OEM , I to use Partzilla for their parts break down , their parts break downs are better than Rocky Mountain to me , I had about enough of Partzilla myself with shipping delays after my last order 1 Share this post Link to post Share on other sites
