1973-1986 Honda ATC 70 Service & Repair Manual

ATe 70, 90, 110, 1855, & 200 Workshop Manual

Contents IrmoductOfy "etion. eMp'" 1 Engi .... clutch .nd IIN.boo Ch .p t, . 2 FUl l .ylt ,m end !ubric";0<1 Cha pt .. 3 Ignirion 'YI'tem Ch.p t e, 4 Fr.me a nd forils Chap'" 5 WhoM.,. brekes and "," 5""'on Acknowledgem,"" About Ihl. m ........ 1 Introduction 10 , ... Hond" ATC 10, 90.nd 1 10 singlet Dimension •• nd weight. Ordering ~r. ~rt. Se ', Uv Ilr.l Ope •• tioN with unit ill trim' EngI".,rV-1rbo. removal Di'mantling - ge<>.'" Cvllndtt. b .... 1 P""I·Torque '''"lml",lon examlnl,'on 100 renov.tion - geMr.1 P.,,,01 IIn ll} ,emOll.I.nd Petrol t.p 'epiKement C.,bu"IIO< Ca<bu,eIlO< Hltings Ai, cle.n., Gene'ltO< - checking output Coil - cMcIr.lng. remov,l .nd repl_ment COntlCt brnlle' Fr ont fo'~' Stllfl,in9 head bearings Fr.me _ • • • mlnl1lon and "nov.tion F'ont whM' RII' IXle a ... mbIy R ... brake R, .. Ij)rOCkli .nd shoct. Ibeorbe, 11;U'" dfive) ,'-" Ughtif\(l .¥S tem - gene,,1 Headl.mp Ch.pt .. 7 AT e 185/ 200 mod.l , SpKil,c. t ion. Rou ti ne m, ln!en,"':' Eng ine Fuel. lubrlc.tlon and e.mull av-IIm. Pige Section , Rout)".. m.;nlen.nce , Quick gl,nCI mlint"n,nee adju. l _n ll .nod u~ci lles , RKOm .... nO.<I lu~nls , Worklng cooditiof\a .nod • ,- , U.min.11on .nd .....:>v ll ion: ,. G •• !t>o_ 20-22 Clutch " Engine rn .. .,mblV4l'!nerll 25,36 Aefill ing unit In I r.m. ,. Rebuilt .nglne " " bn,,,,, '\1l1m Engi".. lulHieatlon 67 - 72 Oil fllte< n O~ j)I,Imp n Conde-n"f _ removel and " replac ament TIming " S~'lting plug. 78-80 84-86 Thr onl. l\tve, 87 . 88 89 9~91 Fln.1 d'iv, dlain 97 - 104 Tyre. 104. 105 105--101 ,OJ T.II I'mp '" ligh ting .wi l d> '" 123 Ignhion .yllem 127 Fflme and lo .h 130 Whee'l. br .... and tl ... Electrical -vall'" '" B- 1' " " " " " " " " " " " " 8. 8. - 83 8'.83 " 107 . 108 108_111 '" '" '" '" '" '" NOle : G ...... al delCriptlon w>d spKificatlonl a .. g .. .., In this O\apte, immediiltely Ifl .. the Nil of eortllntl. F lu fl d ;agno.;l Is g;".., It the MId of the a...p ler. Wi ring d"gllmtl Matric 'nd.1t Engll ,h/Amerlcan t .. mina'OII., - 117. 120 ... 167 . 189 no

- 4 Right- hand view of the 1979 Honda ATe 110 Engine unit of the 1979 Honda ATe 110

Introduction to the Honda ATe 70. 90 and 110 singles The present Hondl .mpire. which IIlned it! I woode" .nedr.1n 1947. flOW occupl .. , v," modem factory. Thelirll molor cyde to be imponed inlO the UK In the ....... 60 ', . the 250 CC twin ·O, .. m·. w .. the Ihin edge of the wedge whldo h'l been lhe J,PI''''" domln.tlon 01 the motorcvcle IndulI ,..,. . Stran", it looked 100. 10 We .llm 'VII . ... Ith J)ftIIIO<i 11 .. 1 treml . ,nd ·..:Iu ... · styling. Sine. Ihlt time Hondl hu g,own 10 ill prlHnllormldable .... ,nod oo-lIlon II Ih. laryesl currenl prod~cerof motor cvcles In the World. Th, flng' of !Old going models now emcomp .... ,nglne, of luch ... ide", di ffering conllgurllion ... ,Ingle cyllnde •. It ......... " sI. cylinder. • nd V-tw in type • . Th' fI"", 01 model, .rellabl. has also Itfllchld beyond pure", roed-golng machi",s . ,nd flOW c.ters for all kind, 01 off-rOId 1POfI. be It 01 • compelitive or 'fun' nalull . The tll""ndou , UPlU'''' of 1n1""U In the v.riou, types of ' din ' riding. _Ie .... ;" lhe Un ited Sill .. . ""If the I"t lew V .. rt. .... ",lIm I VI"", Increuect uri" OOllnll.I. .nd Horm. In common wilt. J",_ .... ,,-. off ... ,n increlslng", comprehena ...... "'" 01 mlchlne, 10 COpe with Ih i. demand . AI In .Itlmll .... 10 lhe vlriou. tradil io,,,' lWO- ... he.1ed mlch l"" . Hondl Introduced the ATC (AH TI .. l ln Cyclel onto Ih. '''f),ndlng off-tOld m .. hl in the US In 191 I. In lllilly. It ..... powered by I 90 cc v, .. ion of lhe mOo" . slngl. "" ..... ed camsh.ft . lou.· Wok. slngll-cVllnde' engine. In 1973 . 1 70 cc .nglned v.rnon . Ih' ATC 10. joined the .xilling mod.1 In o rder to clter lor lhe VO\Inge' _'" group .ttflCled to the unique ,tyllng 01 thl ATC. Th, .mlll.r .ngin.d version w" nol. 110· .......... II pOpUl .... lhe original model ,nd ..... dropped from the .. nge In 1914. It hIt flOW been ,e-lmroducld to lhe US m,"''' II lrom J.nu.,..,. 1918. The US ma"'It ...... Iso the lira' to ,ote.ive the latlll ve .. ion on the ATC lheme . the ATC Dim en s ions and weights Model . .. . .. . ..................... .. . ....... . ............ .. .... ............. . 011.,.11 width ..•...•... . .. •. .• .. ...... • ..•...• . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . Wt\eelb"e ............... ~ ..... • .......... • .. Ory w eig ht ......... • ..... • ..... • .......... •.. 110 . ThIs ..... ,.I .. Nd the".1 the beginning of 1979. end ha• • .! the tim. of writing. lull been "leaNd to the UK m."'eI. The A TC 11 0 il aimil .. In Yinu.' ''' I. respeeu to iUt loreru ....... . Ind b kltended 10 compl.mllflt lhem Ind UIlOO the r.nge . rather thin auperMd. the .. rile. model, . The .ngine In this model Is .n .nlsrged ,.ersion of the .... II -tried single cylinder motor. The ,I ma.t indestructible c.peb!lItl .. of thll engine type Ir' &dmirlb", lUited to the go-In ywhere abiliti .. 01 Ih. ATC machines. It is nol uncommon lor Ih.m 10 co';,. ultlmelv high mileages. oIl1n In lr<luOU' condition. Ind ... lth limi ted servicing. Complem.n tlng lhe IltOng .ngTIII/trlnsmlssion packlg •• Is , robust presNd lleel I"ml . , one-piece HII Ind .. If mudgulrd, unil. Ind the unu.u ,1 1:>0.<1 e.tllme'" ptlctlcll th.ee - wheeled conligu,"lon. The ... he.11 c.rry .normous. soh'" I nlllled . off-,OId tv". !hI1 .... bI. an ATC to tf.,. ..... lmo.l IllY type of obttecle or lIH"fac •. Of _ .. I praclicsl lell u ,,, . lhe dull_.atio IHIgh .nd low "nge l ",'rbo». the ful"'-enclosed ~ chlin. end !hi .". teglcl'''' placed .ior-cle .... r inllk •. Ir. won..., of sped~ notl . The machi ... In ", ..... 1 II 10111", functional . .. belil.l e \/Ihlcle 01 thll tyPl. end I. IUd! b l&nIibly equipped: unnee._ry 9Idoetry doe, not leatu" on ,n ATC. It. In herent .impllcity enlu ....... 01 riding 01/1' difficult 'I .. sln. snd ea" 01 mlinllnance. Tlken U I ... 1\01, . Ihe A TC .ange .torl"nl.l Hond, ', e><tremely 1U0000e .. lul stt.mp l 10 produce an appealing vehicle 10 tide .. 01. 11 ~ groups . ... ho eIIsl" 10 tek, to the 'dirt' ... Ith, rIC,,"ion or 'Iun' machine. At Ih. 11m. time it Is c.p.oble 01 providing chllp .nd tllI,bI. Itlnsoon lor peopI. IUd! It I.rm .... whoM ....... IU.I "'101 CI" be catered lor Idmirlb", by such a devic ... the AM T .... ln CVdI . ATC7 0 ATC90 AT C 110 1300mm 1500 mm 1500 mm (51 .1 In ) (53 .0 In) ( 53 .0 In! 8 00 mm 970 mm 950mm ( 31 .5 In) (3 8 .2 In) (37 .4 In) 78 5mm 890mm 940 mm (3 0. 9 In) (35.0 In) (3 7.0Inl 8 95 mm 101 5 mm 10 15mm (35.2 in ) (4 0.0 In) (4 0 .0 In) 74 kg 103 .5 kg 107 kg (15 3. 1Ib) (228 .2 IbJ (235.9 Ib)

Ordering spare parts When orditri"ll _re pan, lor any Honda. II ill tKfvlaable 10 deal dl.1IC1 with In offlcl'l Honda '1i1t01 wl'lo should btl able to wpply mo.l of the peru. IK atock. PI"" o:.nnot be obtained from Honda direct and III orden mUI' be roul"; vll In apprOVed agent _n If the parU required a .. nol IMoldln 'locI< . Alway. quoll the engine and "'me numbe ... ln full, especially If PIIrtsar. required 10< .arlle. models. The loglne flumbe. 1I.llmped on tM crankCUI on the I,,, · kIIn<!,;de of the mIlCh I ... ; the frame "umbe. ill l,amJ)ltd on lhe left-hend side of tha sleering held lug . UM only glnulnl Honda "P ...... Soma p.onem ports are location o lt ha frame !lumber "'1,llbll thll.re mllde In Jape" and m ..... be pocked In Ilmila. looking PIIcbll"_ These should btl fIVOlded. II they may be of inferlo. quality Or material., and Cln f,llln .. rvlce. Not_thlllll, filII"", of patta,n PlIIU may Inv,lIdl'l any Wll11Inty &{IrHmenl. Some of It.. more expendabl" Pin, tuch I. _rk plUOI. bulbll, IV .... 0111 and g ...... ItC., can btl obtained from ICcellDfY lhops lind molD' feclOB. who hlVI COl ,",.,,!ent opening hours . and CIOn often be lound not I .. from hom •• It I, also pOUibla 10 OOllln parts on a Mall Order bali. !rom • number 01 tpeel,lIltII who itdveniH "'IIu1arly In IhfI moto<cvcla m-.gazin ...

Safety fi rst! P,oiHalOll11 mot or mecha n ics •• e I •• toed In ."f . worl" ng P<OCedu'H. How .... , enthusIa st ic yOU ma y be abOut gen , ng on with the iOO 111 ha n<l do la~" the ,ime 10 en,,, f. th. , you . N I. ty i. not put .1 " ... . It ITMHT\ent" . I.c~ of aU en hOn Cln ,,,w '. ,n an .ccident . " C an I.i lu,,, 10 obsefVe C &l18 ,n el,,,,~nlafY p<ft<:lutlOrl •• There ..... ,lIalw8Y1 be new ways 01 having . cc;.;en.s, and 'he loHowlng point. do no . "."rend 10 be a comp,,,han . ;vlliis. 01111 da"oe" ; they ar" Intended rallle. to mB~e yOu aware 01 the ,i5l:. and 10 encourage B safely- consciou, approach 10 ,II work you ca,,,, ou1 on vou, vehIcle. Essen/ial DOs find DONTs DON" It,rt the '''\Iln, w lt hou' first . sc,rt. lnrng lnat lhe tr,nsminion il in neu\f BI DON" IUddenly remove Ihe li l le< c ap lrom I hoi cooling system - cOI/er it wrlh, cloth ,nd r.le ..... lhe pteMUr. grldu.lly first. (If you m,v get scalded by escaping cooIl nl. DON ,. "I,mpl 10 drain oil until you a ....... il h. 1 cooled IWlfleientlv 10 .void 1C.ldi"\l you. DON" 'l\"11!> any pari 01 lhe '''\lin •. ''''''UII (If lil,n C II withoUI lir1l1 .scer"lni"\l Ih81 11;1 ... fficiently cool 10.void burnl"\l you. DON" allOw b"~1 fl ui(! (If anl ilrel u 10 conl'Cl lhe m,ch lne', palnrwork or pl"ti(: r;omponlntS. DON,. Syphon lo .i c liquid5 5ud. a" lU l l. DrRk, Iluid Or antifr . ... by moulh. Or .lIow Ihem 10 "m.ln on YOUr Ikln. DON'T Inhll. dual _ it may boo inju,ious to hnlth I""a A sbutos f1.eadingl . DO N,. allow ,ny spilt 011 or grease 10 "mlln on Ihl IIoor - wtpe It UP "ralght 'way. before someone Ili Pl on It. OON,. u .. iII .tlning _nne,. or other tools which may 1I",.nd CIU .. injury. OON,. ""mp! 10 lilt • he ...... component whic:h mly be booyond your cepability - gel assistance OON,. rush 10 fin,sh • job. or take unverilied shOr'l cula. DO H" .!low childr,n or .nin,.l$ in or .round an un.n.ndMI vehicle. OO H" inll'l' , Iy" 10 I pte!>SUre above Ih. ,ecornmended muimum. ~rt Irom ""1" I"ssi"lllhe Circe"" and wheel ,im. in .. \f.m. C.N. Ih. Iyr. may Dlow o fl 10'cibly. DO an. u" Ih.1 Ih. machine is supponed secure ly al all times, Th i. I. a"".dally Important when t h. mlchi", is blocked UP 10 aid wheel Or lork removal DO ta ke c.r. wh.n .nemPli"ll to s l.ek.n , Ilubborn nul Ot bolt. 11 11 genefilly ben" to pull on 9 ""anne" ral"'r Ih ln pu"', so Ih81 il slippage OCCur. you lall away from t ... m..::l>lne ,"he, th.n on 10 il. DO wear eve prolectlon when u~ power loois IUc h II doWI , SIIndet. bench ",inder at e. 0 0 use a bar'; .. Ctlam on your hands prior 10 underllk ing diny jobs - it wiW ptotec. '/'OUr p in loom infecllon IS w.1! IS m.k l "ll t ... dirt ",., ro "mOl/' Itt"rwa,ds ; bul ma~ ...... you, h.ndI • ren·t left 1I;ppe",. NOli lhal Iong· lerm conllCI with ulld eng i,.,. oil cen be , ...... lth halard . DO keep loon clolhlng leu III. lie IIc l lnd long h,l, w.1I ou l 01 lhe way 01 mc)'o'ing mKhlnleal pans . DO r,mo., ,Ings. wristwaich elt. beior. wo .... ing on 11" .'hlel" - e5jHlcitliv rh. Ilecl,ieal Iyslem. DO . eep you, work .rea tidy - it is only tOO any to lall ova, . rlld .. 1.1t lying .round . DO ultdse caullon when comp,es";nlj sprl"\ls lor .. moval or .... rallallon, En ... re Ihat lh' !tnslon il applied.nd ,,1,,1Id In a con tTOIled min ,.,.,. u,ing su itable loois wh ic h Ofectude lhe pouibiliry 01 till spr-i"lll1<:aping viol.n.ly, DO .n ..... Ih~1 Iny lilting ladle used h as , .. I. _k ing IoId ,ali"\l IldeqUlta 101' Ih' job. DO ge l someone to check pe'iodicellv IIlII , II .. wel l. when --.Ing .Ione on till whle .... DO c .. ry OUI W(lf~ in a 1og~1 seQu.nc, .nd check UtI! ..... rylhi"llls COI'rKtly assembled and li{lhtened .h.rw.rd •. 00 r.m,mbe, Ihll your vehicle'5 "" IBl y , lfeelS thll of you,MII • nd Oillerl, II in doubl on any point. gel II)I<;lall" .dvke. IF . In spite 01 lollowl"llIh ... p<ecau . ionl , you ",r, unIOtlun." enough ro injure vou, .. lt . llek medical allentlon IS 100ft II poss lbl, . Asbes/os Ce na m " oc ,oon !AWI .'lng . ... Iing. and ome, j)fod...ct. _ $UCI> as bta~ot l, n;"", . clutch linings. \PIske •• • elC - cont.in astJe.s, o;>S. Eklrf!n'1I ' !Jr. muSt ~ ''''en ,0 "void ;";"1.110,, 01 d U$f from , uch productS Ii"". If if IonlNdoul 10 M.Jrh . If in doubl •• ""me tha, they do com,i" I$t"'$ ' O$ . Fire Rem.mber al ~II limn that pelrol 10.soIin81 is highly flammable. Neve, smoke, or h eve Bn v kind of naked Ilame . round whon wor k, nlj on Ihe v. hlcla. But lhe ri' k doe. nol end thero - a ""a,k c luoed by an electric ... 1 5I\on-ci,eult. by lWO meldl 5urt ... ces conr..::ti"ll eeth O lher . by Clfel.1S u"" of 1 0011, 0< ev.n bv Static . Iec t,icltv bul t! UP in your body under een . in condition • . un igoill pelrol vapour. which in I confined ~e ;5 highty e~ AlwaYI diaconnecl 11" bl""", eertl! (groundl lerminll before worlcing on.ny pa" of lhe lue l or .fec rricel $'/'!Item. ,nd never ...... opiliing luel 0<1 10 I ho I .ngintr Of •• llIusr . II is 'eoommended Ihl1 a fife ,Xli"lluishe. 01 I type ""IIbI, lor luel and dl""tr 'C II li res Is kept h,ndy in llIe garage Of worl<pl.ce al all ""'" . "'ev,. 1", 10 u ringuish a lue! or .1""tr~1 li.ft wilh water. Note : Any 'f!/~renc. 10 II 'lfJfCh' .p"" ... ring In Ihis mllnuIII should always M IM,.n 10 me.n II hll"d'Mld b.ttery· ope,.led I'1II'1CI,ic IlI"'p 0' fl8Shllghl, 1/ cIoes " 01 me.n II we/dinglg llS lorch or blow/amp. Fumes Cerlain lumes are highly 10. ic: and cln quickly c auSi unconsciousness and aven dellh II inhlled 10 any ' ~ 1ant. Petr ol loasolinel VllPOU' com" In to Ihl, t;.II l "9OfY, ... 5 do lhe Vl(lOUrs from c.n"n IOIvents ... ch II 1<ic:hloroelhylene. At.y dr.ining or pouring 01 tudr vollrile nuids Ihould be done in • w. 1I .... nll1aled a .... WIt.n using de.nl"\l nuldl lod """'ntl. reed !he inll",C· lions Clfefullv. Nev.. use mllen.1s from unm ....... ed c:onlliner1l - lhey m8V giv. off poOlOOOUl vapou" . "' ..... r fUn ll1e engine 01 • molOf .... hide in an .ncloud "" a ce such u a 1I1I"gl. bh, ust f um.s contein catbon mon - o. id e which i •• "'emely poiioooou.; it vou need 10 run lhe engine, always do 110 In Iha OPen air Of al l. all hay. ille "It 01 lhe vehicle outalde Ihe workplac • . The battery "',ver CauM • """k . Of allow. naked lighl. nett lh' v.l>lele·, b811ery, It wlll norm.lly be giving off a e. naln lmounl of hydrogen gas . which i, higltlv .. pIosNe. AlwaV$ disc:ortnll<l the ba tt .ry eenh (gfOllfldl I"mintl bel or. wo.-king 0<1 lhe lu'l or lie<::tricel "."stems. If possible. loosen tM liller plugs Of cove' when charging lhe balle<y hom an ' .t "",1 .aun:: •. 0 0 nol chlrge II an .. eessive r ..... Of Ih. ballery ""f bu .. t. Take t;.II" when 1000000ng up.nd when cenyi"llihe ballery. The acid ,1"""Dlvt' . even wlren diluled. is .ery COtTO"" •• nd """"kI nol be allowed 10 cantlCI Ihe ...... s or ..... In . II you IVIr need 10 p'ePll" elec"oI vta yourself. alw" •• dd lhe add slowlv 10 Ih. Wlte<, Ind n8v,r Ih' o lher WlY round. PrOtliCI I gainSI ""Ie"' .. bv wearing rubber glov .. and 9OIIIIfI •. MaIm; electricity and e/actrica/ equipment When U1i"ll In tlect,ic pOwer tool. inJpeClion lig hl lie . .I ways ansu" t "" 1M .pplia nce i. COfre<::tly connecled 10 i ll plug and that whete ...,.:e,U<')'. it i. p<OpI!fIy a"'lred (grounded) . Do not use IUCh IjI9I~ncas in damp condition. and . again. beware 01 c,..,i"ll a $perk or .pplying UCIIIIYfl hoMl ,n the vlCrnlly 01 tu&l or luel vapou'. Also "" ..... Ihlt rtre l ..... iInc .......... lhe ' ...... nl "'Iional SIIlety I'llInd""Is. - -, . . Ignition HT vo/illge A seve" elecl,ic IIhock t;.IIn ..... 1\ lrom louchlng centin parts 01 the ignition Iv"em . tudr IS Ih, HT lead,. wheo. Ih. engine i. ,unning Or being c,an ked. particull rly If componen l• ." damp Or the Insulation i. d. f "" li ..... Whe .. an electronic ignition System I, lilted, Ihe HT voltag' is much higher and cou ld p'ove fatal .

• Routine Maintenance Ref er fa Chapter 7 f or information related /0 the AT C Inttoduct;.." Periodic rout.". ",,,intenanee ;. " <;"'I1I ;nUOOI proc,,'" INI1 tommencu immedial ..... 1he machine i. used . Due to the \yJMI 01 vehicle !h l the ATC is. lind becau ... no adorn.' .... 0< trip milu9" mel"r i. lillO<1 . rouline main ten8r>C<1 muSt be ""n",d ou1 ()n " calendar month bul, ,,,Iher Ihan a mil e "ge f acOfdlKl bUI '. M,lnten,n ce lhouJd be reg.meG •• an insurar • .:. pOlicy , 10 hoolp keep the machine in the peak of condition and 10 eMU.e long. trouble-I'ee ...... ke . 11 has the eddil~1 benefit 01 giving elrly warning 01 any l,ul15 thai mlY ~"'" and will act IS , regular 5II fe ly chtlck. 10 the obvious IIdval1!age 01 bolh ,ide, and maChln .. 8 Ii~e . Th e various ""Inumlne" Inb a' . desc ribe<j uflde. their 'eSPeCtive ulendio. heading •. AcCOfT'llMnyi"ll di'gr,ms "r, PlO\Iided. wi'>e •• Moe .... ..,. . 11 should be femembe..w that t he ;",,,,,,,,1 betwee n lhe various maintanance 'ash se"," only 8$" guKle . As lhe machine 11"'" older or I. used under part;culartv adverse condit>onl, it would be &<!vinble to ,educe the period between eac h che<: k. For "" ... 01 .e lerenee neh service "",".ation il r:iesc.ibe<j in detail u nder the .el .... 'nt heading . HO'o'o ..... ar. if funhe. I/""".al inlorml1ion is .equi,ed. it can be Iound within the m ..... al uode< the pe.llnent MCt>on heading in the .. I",ant Chapl .. . No $ileCiel loojl afa requi .. d 1 o. thi! normal 'oo tine malnlenanc e task•. Tha tool. conta i ned in tha too lkit sup pl ied with every new machine are limited. bill will sullke II t he owne, withel 10 carry 001 only minor mtinlenanCI tl"'t . In order 10 make routine maimananee taskl .. e ..... a. pouible . howa ...... . good selection 01 gena.al wa.hhop looj, it invelu.ble . Included in the kil must be • 'Ing<! of metric .ing or com - bination spann .... a IIIIeCtion 01 cmlShe ad sc.,wd,i", •• and B1 least on. pai, of ci'clip ~iers. Addi l Oonaliv . owing to lhe .xueme tightness 01 molt casing SCfttWI on Jape ...... machi""s .• n I mpac' $C •• _ ....... '''II''the. wi th • choice or I.,g' and Imall c;mss/Iead $Crew bits . it .bsoiulltv indi,penuble. Thi, il PIIniculertv so" "" engina h ... nol be.n di.m,nlled .0".,. laaving Iha laCIOI'/ . Wh .n buying tOOII . il i. won h _nding • II Ul e more Ihan the minimum 10 enlUf. t haI good oualitv lools a .. obrained . Some of the cheaper '0015 e.e 100 IOfl or Ilimsy 10 do an ade - QUite job. II it infurialing 10 havllO IIOp pan w ..... II.ougll' job bleauM • openne< t>at SpI .... ed 09'n or broken .• nd a .. ~ace· mel'll muM be foond . 1 Checking Ihe engine/gearbox oil level Unsc".w lhe fi lle' ~ug whkh is ,iIUBUld to tha .ea, of lhe rig hl _ hand c,an ke' H h 'l l. It wil l b, noted Ill al Ihe Olug lneorpom les I 185 /2 00 models. dip.tic k which shou ld be wiped otl using a clean. lint·f' .... rag Place t he plug back in pOsilOon. but do notlCtew Ill'Iome: allow it to ' ... ' in P04'ltion on the edge oIlhft ori f ic • . Remove I he plug and note 11>11 lev. ' 01 lhe oil on the dipstick. which should be between lhe twa I ... ", mark •. " neeeSIBf'/'. lOP up uSing SAE I rNV/40 Ingin. oil. Note tlll1 If lhe machine hit been ridden flcenliv . il should be allowed to l1and for a few minutes 10 .lIow tho o il clinging 10 I he internal eu rf aces 10 d,.in down inlO lhe ",mp. 2 Tyrepressures Always d1eclt the ty .. pressure' wilh • gauge .1111 is known 10 be aceu.al •. 0 .... 10 the a" remely low pre,sute" wllieh I hese Ivre. ape.al. , It ma ~ nol be pOlli bl . to obl.ln • pr essure reading when u.ong " gauge . II I •. I'Iowevet. P04',ibl. to check lha l the 'V'" Ire ool1'ecltv Infl"J1e d by m ... u,ing I he cI .cumle",nc. 01 each with a tape .me"ure. The 1'/" p .. "ures should .Iw ..... be ct>ec:ked wl>en 1M tVfelare coId.l.a . be f ora I h, machine has been .idden. The ty'" becoma warm during uH , causing lhe wenure 10 IncreaH and SO give a false r.ading. f or norm,l usaI/" . Ihe Me. on the ATC model' should be In fl.lld 10 l he .ecommended WelSU'" in l he table below ATC 70 Froffla"d fUr A TC 90 and "0 Frofflami rear 0.2 kg/em'1 2 _8 psil O. '5 kg/cm' 12.2 pJi) The muimum _"mended prltSUftt 10< I he ty .... i. 0 .2 klJi'crn' (2.8 psll. and Iha minimum It; 0.12 kw'cm' (1_71>.il. To menure t he In ll. lion. If en ai, pr. ssure gaul/" is u nB vail · able or unable 10 cope wilh SUCh small amounll 01 wassu" . use 'he tape mea",re melhod . W •• p Iha tape me""'" ,round lhe Ci.cum" "ane, of t he Iyf" 011.' thl "ead bloch . and note 1M reading where Ihe 1_ ends meel.ach olhe<. When IIIe ATC 90 and 110 modtrlo' tV ... a .. r;otTec ll ... In ll lted 10 0. 15 kmlcm' (2.2 p si). I he m ax imum lyre circum f,.ence will he aop,o. imataly 17 4 2 mm (68.S Inl. The correcl ci r cu m fe rence for ATC 70 model, i, 1290 - 1320 mm (50.0 - 52 .0 in) . Th, .eason Ih. a"",Oriim' lion i, due 10 th, actu.1 circumfa.ene. "'''fing slight'" due 10 _"ing down 01 me I"ad blocks and s"ltclling 0111>1 .... 1>IMf. When pufTllllng up lhe tyfa' il i, .ecommended I h.\ • tfadition'l f OOl pump be used ."h" than Ihe high pre5lure ga.age-type lir lin .... No. onlv i. il no l pracli ca ble 10 Insert Im, ll amoonl. of ,i •• nd man!lo' Ihe amounts going in. bill IIIe<I is a large possibility lha l Ihe ty .... will ... "". o:t.mage from OIIer-inft"iQn . The rei' ty ... musl both be Inft~led 10 l he lime <leg ... . This is important 10 Ihe stability of Iha mac hines. If·! ha Iy.es a .. fUn at d iff"ant orenu'" . the resull.nl dl tl" an ca in

Routine meintenance 9 Circumference wil l cause the macllines 10 lean 10 one side and adversely affactlhe lIandll~ and gener~1 siabi ll ty , It is Imponant 10 maintain correCI tvra pressures if muimum ope"ling efficiency is 10 be malnlained . Underinll8ted tvres may adversely effect manouvrability and cause wheel damage . ~rtlculany when lumpl~ Ille maChine. or riding II over very bumpy or roc ~ y lerrain. Overinflal ed tvre. may rub ag81n5t Ille underside of Ihe m""guards. causing dam age to lhe plaslic .urface. and crealing a binding force whH:h would Impllir eSSe of forward motion. 3 Control cabl e lubricetion Apply B few drops 01 mOlor 011 to lhe uposed inner po"lon of each conlrol cable . This will prevent drying- up 01 tile cable . belween the more Ihorough lubricalion that should be carr i ed oul during Ihe 30 Operaling days "",Ice. ./ - ---- --:::::::.'-' - -_ .... _ ___ oiI_ -,,,,- Fig, RMI . Co ntr ol cable lub,ication 4 Rear chain lubrication In order that Ihe lile 01 the rear ch,in be ,xl ended as much U possible, 'ellul .. lub,ication and adjustmant i. essenl ial. Inlermed ia te lUbrication should lake place at th e weekly se",ice inl8",al with th e chain in situ. Applicelion of One of Ih e proprielary chain g re ases contained In an ae,osol can is Ideal. Oroinary aniline oil c ll n be used. Ihough owing 10 Ih e Speed with which il is flung off Ihe rotalinll chain. its effectivene ss is limited. The benefit of Ihe full enciosu,e chainca se , as fined to Ihe ATC ,ange 01 mode l s, is apparent here. Unlike traditional off· road machines w it h their fiM I drive chains pe,manent~ a """ .... d to Iha .. vages 01 mud. water . s and . e tc, the fully anclosed ATC chain le ads 8 comperatively sheltered life . Th is bena fi t also helps th e machine Operator, because the inle"'als between chain "",icing, and replace ments . may we ll be leng- thened . On the ATC models In inspection ho le is Cui In Ihe chaincsse . "lihe' al the 'Ur top or in the Ma . Use these to lacilitate chain lubricalion. Ensur. thaltha rubber seatinll bungs are refilled in the hole5 alt. , lubrication. 5 Safety check Give the machine a close visual inspection. checking for loose nula end fillings. frayed conlrol c,bles etc. Ch e ck the tyres for damage . es.pe<:ially soIininli on Ihe sidewaliis. damage to Ihe area belween lhe Iread b~kl. and culS Or nicks In Ihe larlle un!reeded a reu on Ihe chevron-patlern ty,"". AelT\{)'; e .ny stones or Other objects caught belween tile treads. Check I hat the lillhls funclion correctly. If any bulbs have 10 be renewed . make sure lhet they have the ume 'Olinll a5 the orillinals. E.... 'Y 30 O9<I'.tinli days CarlY ou t the Operations listed under the weekly heading. Ihen perform the lollowing' 1 Changing the engine/transmission oil The enlline oi l capacity is betwe en 0.6 litres a nd 1.0 litre (1.69/1 .4 1 US/Imp plnt-2 . 11 /1.7S US!lmp pint). The precise Quantitv depending on th e model. The standard IIrade of oil Is SAE t QlN40. Placa the machine on la veiliround . preferably raised up and secured in a slabl. posit io n. to facilitate re moval of the dra in ol UIi . Run the I!f1gine /0, a few mi nutes 10 warm up Ihe o il 50 thai it wil l ' un out easier. Place a conta iner under the enlline and remove the drain plu g. which is siluated on the undorsido of the engine. When all the oil has drained, re~l ace and ti ghten ih e drain plug. ensuring Ihat the sul in g washer is in good condi- lion. Re fill the engine with oil of the corre ci viscosily. checking the level as described In lhe weekly check. Note that th e oil should be chanlled al inte rv a ls of 30 operati~ days 0' 3 months wllichever comes r. rft . Also note that under differenl 8mb;"nt circumstances . a different grade of oil is re commended. If Ihe e~lne i. run fo' any length of lime In hOtter Or colder ambie nt temperatures, th e oil viscosily will need 10 be changed to r ellin m.~imum effec t ive lubricali on of the eng ine. Th e accompanying lable shows Ihe recommended oil vi&COSilie s 10 use wh en the machine i5 Operaled under the temperatur es staled. Application General use General U5e Inot below - lO · C 1 15 ° F) 8e low O·C 132 ° F) 8etween - 10· and IS·C 1 15 · and SOO F) Abovll lS oC ISO OF) Recommended oil vi'cOSity SAE IOW/ 400, SAE 2aw/ SO SAE lQIN SAE 200r 20W SAE 3QIN

,. Routine ma i nt enance 2 Sparking plug clfl8ning and re-seUing Rem""" (h. sp.rldng plug end clean it using a wi,e brush . Addi tionally, dun th .. elec trode f aces u.ing fine emery peper or • fine fi le. R" -HI th" points gap 10 betw .... n 0.6 mm and 0.7 mm (0.02 4 - 0.02 8 Inl and check it i, COffeel by using II .. el,r glluge of the OOfTeC! thickn" ••. Bend th' 001". "'&elrod" on"'. do not bend th" cenual "'&elrod, beeauM Ihil will dem.ge th . ce ramic in5ulalor. aefore filling the plUII . sm." the th,eed. wit h. II raplllted g r nse: tills w ill .id future femo\lB I. Refit In.. "".ncing plug end push on th" plug cap. 00 not over-tighten I he spaflting plu\I as this can CIt""" Ihe th,,,,,d 10 mip in Ihe C'f'li~r he.d. II d,m agoe I, appe,,,"t 0<'1 any perl of th" plug. or if ,it h "r of I"'" e l ectrodes Ife IuIdly worn, repl.ce t he plug wilh I ""w item. It i. 0011., 10 "new this 'ela tively c!>e ap but vit.lltem now. then to .eg r et nol having oone 00 at & li te , stage. The standan:! sp arking plug for the ATe 70 model is an NGK C7KS or an NO U-22 FS. The '18ndard ""ark plug filled to the ATC 90 I, In NGK OSHS or an NO X24 FS; and 00 the ATC , 10 model. only an NGK . of types OSHA 0' DSKS . i, recommended. 3 ChtJCking and adjusting the contact breaker points/ignition timing AT C 70 model on lv The ill"itioo timing Is dete,mlned by when the contact breaker points open . Tha Itywhnl Operales Ihe coolacl breaker ar>d Ihe h ....1 of lhe conlacl arm will wea', altering the ignition timing. The recoil Ili n er and anach&d cove' on the le ll_hand side of lhe enOlne should be removed, To facilil al e easio, viewing of the con ta cl brn k ar poin", through the apertures In Ihe flywheel, the recoil stane, pulley may be de lJlched; it fa retained by fou' bolts, When the Ii"., marked 'F' on lhe flywheel line. up wilh t he mark on the c' ankshaft shaft. Ihe contac t breaker ahould Jull start to open. II edjuslment is nec_a",.. the flo ed conlact Cln be moved by slaC kening the clamping SC,ew Ind using. sc,e wd river in t il. slO! provided. Aeliohl en Ihe clamping screw an d chec k Ihe adJust menl aga in . to enSu.e thaI II hu nO! all ered . When Ihe Ignition liming II correct. ,0181 '1 lhe f1ywhnl to de te'mine t he position at which Ihe conlaCI b.eak er points a'e /ully Open. Whllfl fully open Ihe conl8ct b reake' gap should be between 0.3 mm and 0.4 mm (0.01 2 and 0,01 6 in). 1/ lhe gap is oolSlde the spec ified .ange, the COntact b ... e~e, paint. need .enewing, as described in Chapter 3 Secllon 5, Aefit the recoil .tlrta. putley (if ,emoved), Ihe 'ecoll sl8n e, and engine aide COVe,. Contacl breaker gap il menured wilh /eeler gauge IATC 110 shown) ATC 90 and 110 models only The ig nition timing is de termined by when the cof'llact bru ke. points open. The camshelt operate. Ihe contaCI b'eaker and lhe h....1 01 the conlact arm will wear . all"rlng the ion ilion lim;ng. Remove the le/l·hand s ide ""gine CO ver and I h" rscoil starter which is fitted within the cover, If deemed neeuse",. . remove IIII! Ih ,e e $OCuring boilS end ,emov e Ihe rolor moonled sterter pulley, Thil will allow easle' v",wing of the liming mar ks insc, ibed on Ihe rolor. Also r"move Ihe points cove, on the 1,, /1 - h an d side of the cvllnd<tr head . 8efore chec ki ng the ~nitlon liming . the conlect braske. II"P should be checked . RO l81e the engine unlil Ihe cont..:1 break"r i. in lIS /ul'v open posilion. Check the II"P to ..... if it is between 0_3 and 0 .4 mm (0 .0 12 and 0.016 Inch l. To otdjusllhe gap, slacken lhe Iwo scr"wSlhal hold the cof'llacl breaker assembly, and using I .",,11 screwdr;"er In .he slot t)fO'oIided ease Ihe u""mb'v 10 Ihe correCI posilioo. T'ghten Ihe screws end .echeck lhe gat) 10 en'u,e Ihat the usemblV hn nol moved. The ignition liming is co.rect whllfl t he conl act b, uke, points 8r" abolll 10 separele whan Ihe ' F' line scribed on lit" flywheel '010' coi ncldu exaclly with t ha mark on Ihe cove' . The back-pl at e holding lite complele cootact brUke, assemb'v is sloned . to permit I limited range of adjustment. 1/ Ihe two cros.head r"l aining screws are slac k"ned 8 Hn le, Ihe pla le can be turned until lhe points Commence to separate , and Ihen locked In this position by tightening Ihe SC"'WI. A/ter chec king tha liming 'Olale the engine and chec k again before replacing the COVe "" The aceu'acv 01 the ignllion liming is crillcel In term. of both engine performance and pelro l con· sumplion. Even e "",ell e.ro. in setti"1l can heve a .nat ic nble effecl on bolh. On every MCOnd O. Ih ird occasion thPl Ihe painl' are adjusled lit" 1,,11 wi ck of Ihe COnlICt Ix ea k er cam should be lul>,icPled, A few drops of light machine oil. should be put on Ihe wi<.:k to ,educe w ear on lhe heel af the conlacl a,m . Do not over oil, 1/ oil finds i lS wav on lIIe Ihe conlaCI br"a ke ' points il will act 81 an i,,"ulno, and prev"nt eleclrical cont a ct from bei"ll made . Refillhe conlacl bru ke , COV1!. on lhe cvlind"r head and the llaMG' pullev If It was remOVed. and the tee oil lturter and enoine lift- hand side cover. 4 Checking and adiusting v(1lve clearances It is import anl Ihel the ",,,,eel valve clearance is maintained to ensure Ihs proper ape,alion 0/ Ihe valve assemblies. A small amount of f... e pla y i. dasigned inlo each .elve train to al lo w for a""ansion 01 the vanoul anoine com- ponents. 1/ the sening devia la. g"'atly from Ihal specified. a ma rked d ,op In performance wHi be evldsnl . In the clse of the dearance becominO 100 oreat. II wi!1 be foond Ihal valve ope.a - tion will be noi..,. , and performance will d.OP o ff as I ,esult of Ihe valves not opening fully . If on 1he olher hand, Ihe dearance is tOO smlll, 1h" valves mly 001 close com plete'v. This will no t on'v cause l oss of comp'e .. ion. but will also cause the axhaus1 valve 10 bum OUI very quickly . In extrema case., tile valva he ad may strike the pi.lon c.own. caUSi ng e>len live damltge to Ihe e"lline. The valve clearanCe! muS1 be checked wilen t h" enoins " ca ld In ordar 10 08t a co'rec t clearance measu'ement. A small amount af dismantling is ,equired be/ore I"" valve clea.ance can be ChlCk.,d, Aemove Ihe left. hand side engine COVfl' and the recoil starter . R"move the 51arte' pulley to /ecilitete easier v;"wing 0/ the timing marks on the flywh ....1 generator ( ATC 70 only) and lhe rolOr, A emove also Ih" two large lappel COV erl, To check the valve clea.ances. tum Ihe flywheel/roto' until Ihe line marked wilh e T i. al igned with Ihe ml,k on Ihe engine caslng/Slator. The pislon will now be altOP dead Centre (TOC) on eillter lhe compre$sion 0' uhaust slro ke. Checking the valve clearance must be made on Ihe compression s troke when the valves are closed end bolh .oehr arms a re I. ee to 'oc k. If . lhere /a re, Ihe pislon i. an Ihe exhau5tllrol<e, a complel" lum 0/ lhe flywheel/rolo, II requi ,e d, ta brinO Ihe piston to the com- p",ssion slrol<e. It wil l probably be foond that when IlI'nlno Ihe

1973-1986 Honda ATC 70 Service & Repair Manual

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