1985 Honda ATC110 ATV Factory Shop Manual (P/N 6194304)

Honda's factory shop manual for the 1985 ATC110 three-wheeler, P/N 6194304 (cover marking SM A30508407), was issued in July 1984. This file includes the October 1986 revision of clutch assembly page 8-10.

Text Search and Bookmarked Workshop Sections

Search and wiring detail: OCR text search is available, although recognition errors can affect matches. Embedded bookmarks open the contents, all 17 sections and the wiring diagram. Small wire-color codes and switch-table labels benefit from zooming.

One printable English PDF contains 195 pages total, including the cover, safety notice, contents page and six memo pages.

Engine Rebuilds, Dual-Range Drive and CDI Diagnosis

The following selected topics preview the contents rather than reproduce the full contents list. Other procedures include spark-arrester cleaning and throttle-lever disassembly.

• Engine repair: Engine removal and installation, cylinder-head disassembly, valve-guide replacement, seat refacing, piston inspection and camshaft timing.

• Clutch and lubrication: Automatic-clutch overhaul, centrifugal oil-filter cleaning, oil-pump inspection and gearshift-linkage service.

• Transmission and crankshaft: Crankcase separation, crankshaft replacement, shift-fork inspection and high/low sub-transmission disassembly, inspection and reassembly.

• Fuel system: PB20A carburetor overhaul, float-level inspection, pilot-screw adjustment and high-altitude jetting instructions.

• Wheels, brakes and steering: Front hub and steering-bearing replacement, rear axle service, drum-brake inspection and drive-chain/sprocket work.

• Electrical diagnosis: CDI terminal tests, alternator exciter- and lighting-coil checks, pulse-generator replacement, wiring diagrams and switch-continuity charts.

This manual suits mechanically proficient owners and technicians with appropriate tools; standard workshop procedures are assumed rather than taught.

Engine, Clutch and Crankcase Work

Step-by-step repair instructions cover cylinder-head teardown and reassembly, valve-seat work and piston-ring installation. Inspection tables distinguish standard dimensions from service limits for camshaft journals, rocker arms, cylinders and transmission components.

Repair planning: The engine-removal section identifies transmission and crankshaft service as the work requiring engine removal. The clutch, oil pump and gearshift linkage can be serviced with the engine in the frame.

The revised clutch exploded view identifies plates A through D and the short and long springs used in the assembly. Sub-transmission coverage extends to bushing measurements and idler-gear needle-bearing replacement, with driver 07945-9430000 identified for the bearing work.

Section-specific specifications, torque tables and inspection procedures let you verify factory tolerances and trace faults at the workbench. Valve-clearance illustrations, the oil-viscosity chart and lubrication diagrams support maintenance checks.

Carburetor Setup and Electrical Fault Finding

Carburetor service: Float-valve and jet inspections accompany the float-level views and adjustment procedures. The manual warns that tightening the pilot screw against its seat damages the seat. High-altitude jetting instructions also explain the risk of engine overheating and damage when that setting is used at lower elevations.

CDI testing: Terminal identification and resistance charts are paired with compatible tester requirements, including the Sanwa 07308-0020000 and Kowa KS-AHM-32-003. An unsuitable tester may give false readings; the manual's specified equipment matters when interpreting the CDI chart.

Troubleshooting charts connect hard starting, power loss and poor low- or high-speed running to fuel, compression and ignition checks. Cable/harness routing drawings and the ignition schematic support electrical fault tracing alongside the full wiring diagram.

Chassis Service and Recoil-Starter Precautions

Chassis procedures cover steering-race replacement, rear axle bearing-holder service, brake-shoe and drum inspection, and final-driven-sprocket removal. Rear fender and exhaust-pipe removal and installation are illustrated as well.

Drive-chain guidance addresses the O-ring chain and premature wear caused by pairing a new chain with worn sprockets. Recoil-starter instructions warn that the spring can pop out of its housing during disassembly. Always verify torque values and safety specifications in the manual before completing chassis or powertrain work.

A Preview of Compression, Valve and Carburetor Data

Engine checks: The compression-test section specifies 1,250 ± 150 kPa (177.8 ± 21.3 psi) with the engine warmed up. Intake and exhaust valve clearances are 0.07 mm (0.003 in) with the engine cold.

Carburetor reference: PB20A specifications include the standard #82 main jet and a 10.7 mm (0.43 in) float level with the float valve seated. Component-specific tightening specifications also cover the spark plug and cylinder-head cover nuts.