Table Of Contents - Honda 1980 ATC 185 Shop Manual

Table of Contents

Important Safety Notice2
Contents3
How To Use This Manual3
Model Identification4
General Safety5
Service Rules5
Specifications6
Torque Values Specification8
Tools Specifications10
Cable & Harness Routing11
Maintenance Schedule12
Lubrication14
Service Information15
Troubleshooting15
Engine Oil Level Check16
Engine Oil Change And Oil Filter Screen Clearing16
Oil Filter Rotor Cleaning17
Lubrication Points18
Inspection/Adjustment Specifications19
Air Cleaner21
Spark Plug22
Valve Clearance23
Cam Chain Tension24
Carburetor Idle Speed24
Fuel Line24
Fuel Strainer25
Throttle Operation25
Ignition Timing26
Cylinder Compression26
Drive Chain27
Brake Shoes29
Front Brake29
Rear Brake30
Clutch31
Spark Arrester Cleaning31
Nut, Bolts, Fasteners32
Lighting Equipment32
Tires32
Steering Head Bearings33
Fuel System35
Fuel System Troubleshooting36
Fuel Tank37
Air Cleaner Case38
Crankcase Breather39
Carburetor Removal40
Throttle Valve Disassembly41
Float, Float Valve And Jets41
Carburetor Assembly42
Float Level Adjustment43
Throttle Valve Assembly43
Carburetor Installation43
Pilot Screw Adjustment44
High Altitude Adjustment44
Engine Removal48
Engine Installation51
Cylinder Head/Valves53
Cylinder Head/Valves Specifications54
Camshaft Removal55
Cylinder Head Cover Removal57
Rocker Arm Inspection58
Rocker Arm Shaft Inspection58
Camshaft Bearing Inspection59
Camshaft Bushing Inspection59
Cylinder Head Removal59
Cylinder Head Disassembly60
Cylinder Head Inspection60
Valve Spring Inspection61
Valve/Valve Guide Inspection61
Valve Guide Replacement62
Valve Seat Inspection/Refacing63
Valve Seat Grinding63
Cylinder Head Assembly65
Cylinder Head Installation66
Camshaft Installation69
Pulser Rotor Assembly70
Cylinder/Piston Troubleshooting73
Cylinder Removal74
Cylinder Inspection74
Piston Removal75
Piston/Piston Ring Inspection75
Pistol Ring Installation77
Piston Installation78
Cylinder Installation78
Clutch/Oil Pump80
Clutch/Oil Pump Specification81
Clutch/Oil Pump Troubleshooting82
Right Crankcase Cover Removal83
Clutch Lifter Disassembly83
Clutch Lifter Assembly84
Centrifugal Clutch Removal85
Weight Inspection86
Clutch Drum Inspection87
Clutch Installation88
Manual Clutch Removal91
Clutch Inspection92
Manual Clutch Installation93
Oil Pump Removal95
Oil Pump Disassembly95
Oil Pump Inspection96
Oil Pump Assembly96
Oil Pump Installation97
Gearshift Linkage Disassembly98
Gearshift Linkage Assembly99
Starter/A.c. Generator Troubleshooting103
Recoil Starter Removal104
Recoil Starter Disassembly104
Recoil Starter Assembly106
A.c. Generator Removal108
A.c. Generator Installation109
Recoil Starter Installation111
Transmission/Crankshaft/Kick Starter Specifications113
Transmission/Crankshaft/Kick Starter Troubleshooting113
Crankcase Separation114
Crankshaft Removal115
Crankshaft Inspection115
Crankshaft Bearing Inspection116
Timing Sprocket Installation117
Transmission Disassembly117
Shift Fork/Shift Shaft Inspection117
Transmission Assembly119
Crankcase Assembly120
Front Wheel/Brake/Steering Specifications123
Front Wheel/Brake/Steering Troubleshooting124
Headlight Case Removal125
Headlight Case Installation125
Handlebar Removal126
Handlebar Installation126
Brake Lever Bracket/Throttle Lever Installation127
Throttle Lever Disassembly128
Throttle Lever Assembly129
Front Wheel Removal130
Front Axle Inspection131
Wheel Bearing Inspection131
Brake Drum Inspection131
Front Wheel Disassembly132
Tire Removal133
Tire Repair(With Cold Patch)134
Tire Repair(With Rubber Plug)135
Tire Assembly135
Front Wheel Assembly137
Front Brake Lining Inspection138
Brake Panel Disassembly139
Brake Panel Assembly139
Fork Top Bridge Removal140
Front Fork Removal140
Steering Stem Installation141
Top Bridge Installation142
Rear Wheel/Brake/Drive Mechanism Specifications145
Rear Wheel/Brake/Drive Mechanism Troubleshooting146
Rear Wheel Removal147
Rear Tire Disassembly/Assembly147
Rear Wheel Installation147
Rear Axle Removal148
Final Driven Sprocket Inspection150
Axle Inspection151
Rear Wheel Bearing Holder Removal151
Brake Lining Inspection152
Rear Brake Drum Inspection152
Rear Brake Disassembly152
Rear Wheel Bearing Holder Disassembly153
Rear Wheel Bearing Inspection153
Rear Wheel Bearing Holder Assembly154
Final Driven Flange Assembly155
Rear Axle Installation156
Rear Fender Removal159
Rear Fender Installation159
Exhaust Pipe Removal160
Exhaust Pipe Installation160
Ignition System Troubleshooting163
Ignition System Specifications163
Ignition Coil Removal164
Ignition Coil Inspection164
Generator164
Lighting/Exciter Coil164
Cdi Unit Removal165
Cdi Unit Inspection165
Pulser Generator166
Ignition System Ignition Timing166
Lights/Switches Troubleshooting167
Lights/Switches Specifications167
Headlight Disassembly168
Headlight Assembly168
Taillight Disassembly168
Taillight Assembly168
Light/Dimmer Switch169
Engine Stop Switch169
Wiring Diagram171
Clutch Technical Features173
Full Troubleshooting175
Engine Does Not Start Or Is Hard To Start175
Engine Lacks Power176
Poor Performance At Low And Idle Speeds177
Poor Performance At High Speeds178
Poor Handling178
81 Addendum: Contents179
General Information Specifications Atc185S180
Atc200 Specification181
Torque Values183
Cable And Harness Routing184
Regular Maintenance Schedule185
Inspection/Adjustment186
Air Cleaner And Case186
Clutch Inspection/Adjustment187
Crankcase Breather Inspection/Adjustment187
Front Wheel/Brake/Steering188
Fork Bridge Installation189
Rear Wheel/Brake/Drive190
Lighting Switch192
1982 Addendum: Contents195
1982 Addendum General Information Specifications196
1982 Addendum Torque Values196
1982 Addendum Maintenance Schedule197
1982 Addendum Cable And Harness Routing198
1982 Addendum Lubrication199
1982 Addendum Oil Recommendation199
1982 Addendum Inspection/Adjustment199
1982 Addendum Air Cleaner And Case199
1982 Addendum: High Altitude Adjustment201
1982 Addendum: Front Wheel/Brake/Steering202
1982 Addendum: Front Wheel Removal203
1982 Addendum: Front Wheel Installation203
1982 Addendum: Rear Wheel/Brake/Drive Mechanism204
Rear Wheel(Atc200)205
Rear Brake(Atc200)205
Brake Drum Cover Removal205
Drive Mechanism (Atc200)207
1982 Addendum: Wiring Diagram208
1982 Addendum: Recoil Starter Disassembly209
1982 Addendum: Recoil Starter Inspection211
1982 Addendum: Decompression System Inspection211
1983 Addendum: Contents215
1983 Addendum: General Information Specifications216
1983 Addendum: Cable And Harness Routing218
1983 Addendum: Maintenance Schedule219
1983 Addendum: Lubrication220
1983 Addendum: Oil Recommendation220
1983 Addendum: Air Cleaner And Case Inspection/Adjustment220
1983 Addendum: High Altitude Adjustment221
1983 Addendum: Front Wheel/Suspension Removal222
1983 Addendum: Front Wheel/Suspension Installation222
1983 Addendum: Drive Chain And Sealed Brake(Atc185S)226
1983 Addendum: Wiring Diagram227