1991 Honda Trx200D Type 2.

[Chase Cook]

Hi I have a 1991 Honda trx200d type 2 ATV and need to know how to adjust the valves on there. The valve adjustments are on the side of the head and looked up videos in there is no videos at all on how to adjust them. I'm taking the head back off to adjust the timing because it's making good spark and getting gas but it's not firing, trying to start but I'm thinking it's because of the adjustments are way out of  line. And I didn't take a picture of how they were before I took the head off.

[Frank Angerano]

Hey chase, adjusting the timing ? The timing should be set in one spot only so check that your at TDC and your marks on the sprocket are good.   Once that's done then the timing is set and should not be moved.  After its all lined up the valves can be adjusted by loosening up the valve stem adjusters with a 10mm wrench. You basically stick the feeler gauge (size as per manual)  in between the valve and rocker arm and slowly tighten the adjuster until that feeler gauge slides out with a little bit of resistance. Then you tighten the 10mm nut good and try to stick the feeler gauge back in, It should go in with a slight push.  After that you should be set.  

Keep in mind that intake and exhaust valves are different sizes on the feeler gauges.  

All adjustments should be made in the TDC position.   

[Chase Cook]

Ok thanks

Also the timing looked a little off because I forgot to put the timing chain guide back in.

[Frank Angerano]

Oh ok, just wanted to make sure as there is really no adjustment for the timing.   Either its on or its off.  Did you find the proper size feeler gauge for the valve adjustment?

[Chase Cook]

On this ATV you can't put a feeler gauge on it. I looked it up ony owners manual.

18324314-Honda_Trx200_Trx200d_Service_Manual_Repair_1990-1997_Trx_200_200d.pdf

[Frank Angerano]

Does the valve cover come off exposing the top end ?

Exposing the valve springs and rockers ?

[Chase Cook]

Yes it does expose the valve springs but not the rockers. The rockers are hooked up separate them selves. I'll take pictures of it later

[Frank Angerano]

From the images you posted it looks to me that the valve cover or top end cover is held down with some bolts?  Have you tried to remove them? 
I marked them in red. 

[Chase Cook]

Yes that's just the valve cover. Then underneath the valve cover is the rocker arm cover I would say.

[Frank Angerano]

Thew way it looks to me is if you pull that valve cover you will be able to adjust valves.  Only one way to find out so pull the cover and lets see. Snap a few pics after its off. 

[Chase Cook]

I will later. I'm going to work right now and won't be back until the morning.I did take them all off though but I forgot to take pictures of it. I need new piston rings because it's low on compression. So I just ordered a whole new top end kit. $70

[Frank Angerano]

Good idea and then you can adjust everything properly. Study the manual while your at work if you can.   

[Chase Cook]

Thanks

[Frank Angerano]

No problem. Keep us posted and be sure to take and post progress photos.  

[Chase Cook]

No problem I will 👍.

[Chase Cook]

I'm back from work and I slept for a while I worked night shift. But here's the pics I was going to send. And the rocker arms are connected separately and they just go one top of the head to adjust the valves.

[Frank Angerano]

Ok good pics. I see now, the valve adjustment is done by the bolts on the aide of the head and that should be listed in the manual.  Have you located that by any chance ?

[Frank Angerano]

I don't think its adjusted with feeler gauges.  

[Chase Cook]

yes I located I'll send a pic of the owners manual how to adjust it.

[Frank Angerano]

That's great info. Now looking at the age of the engine I would set the valves at spec and a hair more due to wear. But run it first and listen for any tapping.
What do you think ? 

[Chase Cook]

Okay I'll let you know when I get my piston kit in the mail. Hopefully it's here by the end of the week.

[Frank Angerano]

Yep no problem, one thing i want to mention. The gaskets that you got, are they quality gaskets? I just want you to be aware that the cheaper brands will come back to bite you in the as*. 

[Chase Cook]

They should be. there from tusk.

[Frank Angerano]

Ok. Just wanted to make sure. 
We have seen a few unhappy campers with blown head gaskets etc.  

[Chase Cook]

I'll update you when I get it running.

[Frank Angerano]

Yes sir. Lots of pre start grease on all moving parts.  Cam, rockers etc.  Crank the engine with out the spark plug in  to pump oil to the the head for a few seconds prior to starting.
I'm sure  you know this but i wanted to put it out there. 

[Chase Cook]

1991 Honda trx200d type 2 ATV.

Now I have almost all my parts in. Still have stuff on its way, the rear hubs,  rims and tires, fuel petcock, (Another) battery, front wheel bearings, front brake pads, fuel line, muffler, coil, and miniature dash. And a plastics paint job.

Only problem is now is to that I bought a brand new top end kit. OEM 65mm piston kit, and it was a pain in the as* to put through the cylinder sleeve for some reason and now it barely wants to turn over, because I might of forced the Piston and Rings in it. But I still don't know why it was so hard to put them in? And was wondering if I need to get a new cylinder sleeve/ hole head for it or not. Or take it somewhere to get the cylinder sleeve bored out a millimeter or two so it spins more freely?

Edited April 12, 2020 by Chase Cook
Needed to put in the ATV name and year

[Frank Angerano]

The rings have to go in a certain way.  There is a small roll pin that sits in the piston, the gap of the rings is supposed to meet at that point.  Did you notice that?  Is the piston the right cc? 

[Chase Cook]

Yes it's the right CC.

Also I replaced pistons and at least six of the vehicles I had over the last few years and never had this problem

[Frank Angerano]

It could be that the cylinder head is smaller then it should be. Maybe a smaller cylinder was put on after a top end went bu previous owner? Buy a micrometer and check the old and new piston.   This should not happen, have you verified the existing cylinder is 65mm? Something is not adding up.   
Were the rings put in correctly?