1981-1984 Honda ATC110 Service & Repair Manual

IMPORTANT SAFETY NOTICE tl:t.I;I'IliM Indicates a strong possibility oj se l'ere personal injury or loss of life if instructions ore not /o llo14·ed. CAU11ON' IndI cates Q pOSSJb ,fIlY of personal mjury or equIpment damage if InSfruel/OrlS are not follo .... ed. NOTE: Gives helpful i nformation . Detailed descr ipt ions of sta ndard workshop procedures, safety principles and service oper ations are not inclu ded. It IS importan t 10 note t hat th IS manual cont a ins some warnings and cautIons against some specific service methods wh ich could cause PERSO NAL INJURY to service personnel or c ou ld damage a vehicle or render It un sa fe. Please understand that those warnings cou ld not cover all conceivable W3VS in which service, whether or no t r ecommended by Honda might be done or of the poss i bly hazardous consequences of each conceivable way, nor could Honda Investiga te all such ways. Any one using se r .... '~ procedures or t oo l s, whether or not recommended by Honda must satis fy himself thoroughly that neit he r personal saf ety nor vehi cle safety will be jeopardized by the service metho d or tools selected . --- ----

• • ~ HON'DA ~ . ATCll0 H OW TO USE THIS MANUAL Sections 1 and 2 apply to the whole motorcycle , while sections 3 through 16 describe parts of the motorcycle, grouped according to location . CONTENTS GENERAL I NFORMAT ION MA INTENANCE Find the section you want on this page, then turn r--f================= to the table of cantents on page 1 of that section . Most sections s tart with an assembly or system il- lustration and ali the required specifications. torque values, general instructions, tools and troubleshooting for the section. The subsequent pages give detailed procedures. If you don 't know the source of the trouble , see section 17 TROUBLESHOOTING . Refer to the addendums at the back of the manual for 1982 through 1984 service information . Date of Issue: August, 1983 e AmeriCan Honda Motor CO., Inc. 1983 - A~ Rights R ••• rved w 2 '" 2 w FUEL SYSTEM ENGINE REMOVAL /INSTAL LATION CYLINOER HEADNALVES CYLINDER / PISTON CLUTCH/ OIL PUMP STARTER/A. C. GENERATOR SUB·TRANSMISSIDN TRANSMISSION/CRANKSHAFT FRONT WHEEL/BRAKE/STEERING ~~~~~~mw==== <{ J: U ..J <{ REAR FENDER /EXHAUST PIPE IGN ITION SYSTEM U p === ===== ===== a: LIGHTS /SW ITCHES g ~=============================== WIRING DIAGRAM TROUBLESHOOTING 'B2 ADDENDUM '83 ADDENDUM '84 ADDENDUM ~ - - "1i:. _ '

• MOOEl IDENTIFICATION - The trame serial number js stamped on the steering head left side. The carburetor ident ification number is on the carburetor body left side. - ~ HONDA ~ AlellO The engine ser ia l number is stamped on the crankcase lower left sid e. :...--- Date of Issue: Apr il, 1981 t9 HONOA MOTOR CO., L TO. -""- , I • ,

~ H~~?OA 1. GENERAL INFORMATION GENERA L SAFETY 1- 1 SERVICE RULES 1- 1 SPE CIFICATIONS 1- 2 TOROU E VALUES 1-4 TOOLS 1 -5 CAB LE & HARNESS ROUTING 1- 7 GENERAL SAFETY r§';ii!iiliJ cam ! ;it!!i!<' If the engine musl be fIIm/ing 10 do some work, make Slife ,lie area ;s ""II-"emilaled. Nel'l'f run the engine in a closed arm. 171e exhaust contains poisonous carbon monoxide gas. Gasoline is extremely flammable and is t!xplosil'e under cerIa;" conditiolls. Do "0 1 smoke or all ow flames or slJOrkJ in YOllr k'ork area. SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that don't meat HONDA's design specifications may damage the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. 4. Instart new gaskets, O·rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts Of nuts, begin with the larger-diameter Of inner bolt first. Then tighten to the specified torque diagonally in 2-3 steps, unless a particular sequence is specified. 6. Clean parts in non· flammable or high flash point solvent upon disassembly. 7. Lubricate any sliding surfaces before reassembly. 8. After reassembly, check all parts for proper installation and operation. • Date of Issue: April, 1981 © HONDA MOTOR CO., LTD. 3 1-1

GENE RAL INFORMATI ON SP E Ci f iCATIONS IT EM DIMENSIONS Overall length Overall width Overall height Wheelbase Rear tread Seat height Foot peg height Ground clearance Dry weight FRAME Type Aim size Front Rear Front tire size, pressure Rear tire size, pressure Rear brake Fuel capacity Fuel reserve capacity Caster angle Trail length ENGINE Ty". Cylinder arrangement Bore x stroke Displacement Compression ratio Valve train Maximum horse power Maximum torque Oil capacity LUbl'ication system Cylinder compression Intake valve OPENS CLOSES Exhaust valve OPENS CLOSES Valve clearance Intake (Cold) Exhaust Idle speed CARBURETOR Ty". Main jet No. Sloe jet No. Pil ot screw openi ng Float level 1-2 . - 4 1,630 mm (64.2 in) 950mm (37.4 in) 940mm (37.0 in) 1,040 mm (40.9 in) 680mm (26.8 in) 650mm (25.6 in) 260mm (10.2 in) 110 mm ( 4.3 in) 109 kg (240.3Ib) Backbone (Pressed) 6.5 spw x 70T 6.5 spw x 7DT ~ HONDA ~ ATCll0 22 x 11.0-8,0. 15 kglcm 2 12.2 psi) 22 x 11 .0-8,0. 15 kg/em' (2.2 psi) Internal e)(panding shoe 7.2Iiters(1.9 US gal, 1.58 Imp gal) 0.54 liters (0.14 US gal, 0.12 Imp gal) 2 1 ° 5 , 26mrn (1.0 in) Gasoline. air-cooled 4-stroke Single cylinder, 75° inclined from vertical 52 x 49.5 mm (2.047 x 1.947 in) 105.0 cc (6.4 cu in) 8.2: 1 Overhead camshaft chain driven 6.5 BHP/7 ,750 rpm 0.69 kg·m/ 5,OOO rpm (9.26 ft .lb/ 5,5oo rpm) 0.9 liters (0.95 US qt, 0.79 Imp qt) at draining Forced pressure and wet sump 12.5 ± 1.5 kg/cm 2 (177.8 ± 21.3 Ib/in 2 ) 5° ATDC 20° ABDC 25° BBDC at 1 mm lift 5° BTDC 0.07 mm (0.002 in) 0.07 mm (0.002 in) 1,700 rpm Piston valve # 85 #35 1· 1/ 8 turns 10.7 mm (0.43 in) Date of Issue: April, 1981 <0 HONDA MOT OR CO. , LTD.

~ HONDA ~ ATCll0 DRIVE TRAIN crutch Transmission Primary reduction Gear ratio Final reduction Gearshift pattern ELECTRICAL Ignition Ignition timing Alternator Spark plug Spark plug gap Headlight Tai llight Date of Issue: April, 19S1 © HONDA MOTOR CO., LTD. I" 2,d 3,d 4th Initial Full advance Capacity USA model Canada model 5 GENERAL IN FOR MATI ON Wet multi-plate automatic 4·speed constant-mesh 3.722 .!:!!..9!:!. Low 2.538 4.738 1.6 11 3.008 1.190 2.222 0.958 1.789 3.267 Dri ve sprocket 15T, driven sprocket 49T left foot operated return system N-1-2-3-4 CDI 15° BTDC at idle 31 ° BT OC at 4,200 rpm AC generator, 12V 0. 048 k w/ B,OOO rpm DSHA (NGK) DR8HS INGKI 0.6- 0.7 mm (0.024-0 . 028 in) 12V 45W!45W 1.2V 3.4W 1-3

GENERAL INFORMATI ON TORUUE VALUES ENGINE Item Q 'ty Cylinder head nut 4 Camshaft sprocket bolt 2 Cam chain guide roller bolt I Spark advancer bolt I Clutch lock nut 1 AC generator rotor nut 1 Shift drum bolt I FRAME Item Q'ty Steering stem nut 1 Fork top br idge bolt 2 Handlebar lower holder nut 2 Front ax le nut 2 Bra ke drum nut 2 Seat and rear fender 10 Engine hanger bolt 4 Intake pipe and carbure tor 2 Final driven sprocket nut 4 Gearsh i tt bolt 1 Fender and mud guard 11 Rear axl e nut 2 Fo ot peg bolt 4 Chain tensioner lock nut 1 Thread dia. N 'm (mm) 8 18- 20 6 8- 12 6 8- 12 6 8- 12 16 40- 50 14 65- 75 6 8- 12 Thread dia. (mml N·m 22 50- 70 12 50- 70 10 40 - 48 12 50- 70 32 40- 60 6 5- 7 8 19- 25 6 6- 9 10 44- 52 6 7- 12 4 5- 7 14 60- 80 8 19- 25 10 35- 45 ~ HONDA ~ ATCll0 kg-m ft·lb 1.8- 2.0 13- 1("'" 0.8- 1.2 5.8- 8.7 0.8- 1.2 5.8- 8.7 0.8- 1.2 5.8- 8. 7 4.0- 5.0 29- 36 6.5- 7.5 47- 51 0.8- 1.2 5.8- 8.7"" kg-m ft·lb 5. 0-7 .0 36- 51 5. 0-7 .0 36- 51 4.0- 4.8 29- 35 5.0- 7.0 36 - 51 4.0-6 .0 29- 43 0.5- 0.7 3.6-5. 0 1.9-2 .5 14- 18 0.6- 0.9 4.3- 6.5 4.4- 5.2 32- 38 0.7- 1.2 5. 1-8.7 0.5- 0.7 3.6-5 .0 6.0- 8.0 43- 58 1.9- 2.5 14- 18 3.5- 4.5 25- 33 Torque specifications listed above are for the most important tightening points. If a torque specif ication is not listed, use the standards given below. STANDARD TORQ UE VALUES Item TORQUE N·m (kg' m, ft ·lb) Item TORQUE N·m (kg·m, ft·lb) 5 mm bolt, nut 4.5- 6 (0.45- 0.6, 3.3 - 4.3) 5 mm screw 3.5- 5 (0.35-0.5,2.5- 3.6) 6 mm bolt, nut 8- 12 !O.8- 1.2, 5.8- 8.7) 6 mm screw 7- 11 (0.7- 1.1, 5- 8) 8 mm bolt, nut 18- 25 (1.8- 2. 5, 13- 18) 6 mm flange bolt, nut 10- 14 (1 .0- 1.4, 7.2- 10) 10 mm bolt, nut 30- 40 (3 .0- 4.0, 22- 29) 8 mm flange bolt, nut 24 - 30 (2.4- 3.0, 17 - 22) 12 mm bolt, nut 50- GO (5.0--4.0, 36--43) 10 mm flange bolt, nut 30--40 (3.0- 4.0, 22- 29) 1-4 6 Date of Issue: April, 1981 © HONDA MOTOR CO., lTD .

~ HON'DA ~ Ale110 TOOLS SP ECIAL Description Clutch outer holder Valve !J.lide reamer Ball race remover 41 mm lock nut wrench Valve guide driver Valve guide adjuster Tire disassembling 1001 set l ever Weight COMMON Description Float level gauge Pin spanner lock nut wrench 20 x 24 mm lode nut wrench 30 x 32 mm Extension bar Universal holder Flywheel puller Valve guide remover 5.5 mm Valve spring compressor Vallie adjusting wrench B x 9 mm Driver pilot 17 mm Bearing driver outer 37)( 40 mm Driver pilot 35 mm Bearing driver outer 62)( 68 mm Bearing driver inner 25 mm Driver handle inner C Driver handle outer A Valve guide cutter Pilot 5.5 mm Driver outer 42 )( 47 mm Driver inner 20 mm Date of Issue : April, 1981 © HONDA MOTOR CO., lTD. Tool No. 07923-0340000 07984-0980000 07944-1150001 07916-9180000 07942-1180100 07908-GB40000 07772-0010000 07772-0010100 07772-0010200 T ool No. 0740 1-0010000 07702-0010000 07716-0020100 07716-0020400 07716-0020500 07725-0030000 07733-00 10000 07742-00 10100 07757-00 10000 07708-0030100 , 07746-0040400 077 46-001 0200 077 46-0040800 07746-0010500 077 46-0030200 077 46 -00301 00 07749-00 10000 07742-0030100 07742-0030200 07746-00 10300 077 46 -0040500 7 GENERAL INFOR MATION Interchangeability M9360-277-9 1774 (Available in USA only) Commercially available 41 mm wrench I M987X-J50-XXX (Available in USA only) Interchangea bil ity M936 1-4 12-099788 (Available in USA on ly) 07916-3710000 or 07916-6390001 I Commercially available in USA 07725-00 10101 07933-0010000 07942-3290100 07957-3290001 Commerciallyabailable in USA 1 07946-3000100 1 07946- 07947-6340400 3600000 or 07946- 9180100 I 07945-3710200 or 07945-5000000 07949-61 10000 or 07949-2860000 or 07949-3000000 Ref. Page 7-4 5-9 11-17 12-14 5-9 2-7 11-10 Ref. Page 3-9 11 - 16,1 1- 18 7-4 11-16 7- 4,11-16,11-18 2-13,8-7 2-13,8-6 5-9 5-7,5-13 2-7 11-4 11-4,11-17 12-10 12-10 11-5 11- 14 , 11 - 17,12-10 " 1-5

GENERAL INFORMATION CABLE & HARNESS ROUTING (1) BRAKE CABLE (2) ENGINE STOP SWITCH WI RES (3) THROTTLE CABLE (4) CLAMP (5) WIRE HARNESS (6) SEAT LOCK LEVER (7) WIRE HARNESS (8) WIRE HARNESS GROUND WIRE (9) IGNITION CO il flO) AC GENERATOR WIRE (11) COl UNIT 1-6 >-____ ___ ~·~xu·u,·~~ ~ ~~ __ _ 8 rA!J\ HONDA ~ ATCll0 4 [- .~ Dale of Issue : April , 1981 if) HONDA MOTOR CO. , LTD.

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1981-1984 Honda ATC110 Service & Repair Manual

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