Honda ATC 90 Shop Manual

Atc 90 1973-1978/ atc 110 1970-1981

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Also See for ATC 90

Owner's manual - 76 pages
Service manual - 33 pages

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Table Of Contents

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Contents
Table of Contents
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Download this manual See also: Service Manual, Owner's Manual

Table of Contents

3
Safety Notice
5
General Service Precautions
6
Special Tools
7
Inspection and Adjustments
7
Engine Inspection
7
Servicing the Air Cleaner Element
8
Brake Adjustment
9
Drive Chain Adjustment
10
Engine Removal
12
Engine Installation
14
Principal Changes to the CT90
15
Chassis
15
Front Wheel Disassembly
15
Front Wheel Inspection and Repair
16
Front Wheel Reassembly
18
Rear Wheel Removal
18
Rear Wheel Inspection and Repair
18
Rear Wheel Installation
19
Drive Mechanism Disassembly
21
Drive Mechanism Inspection and Repair
21
Drive Mechanism Reassembly
25
Steering System Disassembly
27
Steering System Inspection and Repair
27
Steering System Reassembly
30
Brake Disassembly
31
Brake Inspection and Repair
31
Brake Reassembly
33
Frame Body Disassembly
35
Frame Body Inspection and Repair
35
Frame Body Reassembly
37
Major Differences between ATC90 and US90
37
Engine Mounting Bracket
37
Step
38
Exhaust Muffler
39
Drive Mechanism
40
Steering System
42
Steering System Inspection and Reassembly
44
New Mechanisms and Major Modified Points of ATC90K3 from ATC90K2
44
Chain Guide
44
Chain Case Inspection Window
44
Chain Tensioner, Tires
45
Ignition Coil and Condenser Removal, Inspection and Reinstallation
45
Carburetor Fuel Cock
45
Choke Lever
46
Engine
46
Left Crankcase Cover and Rotor
50
Left Crankcase Cover and Rotor Reassembly
51
Piston and Cylinder Disassembly
55
Piston and Cylinder Inspection and Repair
59
Cylinder and Piston Checks
60
Cylinder and Piston Reassembly
64
Cam Chain Tensioner and Cam Chain Construction
64
Cam Chain Tensioner Disassembly
65
Cam Chain Tensioner Inspection
65
Cam Chain Tensioner Reassembly
65
Cam Chain Disassembly
65
Cam Chain Assembly
66
Clutch and Oil Pump Disassembly
68
Oil Pump
68
Gear Shift
68
Clutch and Oil Pump Inspection
70
Clutch and Oil Pump Reassembly
72
Carburetor Assembly & Disassembly
73
Carburetor Inspection
74
Carburetor Reassembly
74
Float Level Adjustment
75
Carburetor Adjustment
76
Tappets
76
Contact Breaker Point Gap and Ignition Timing
77
Ignition Timing Inspection
78
Spark Plug Adjustment
79
Clutch Adjustment
79
Cam Chain
79
Checking the Engine Oil Level
80
Changing the Engine Oil
81
Chassis Exploded View
81
Front Wheel - to Disassemble
83
Front Wheel: Inspection and Repair
83
Cold-Patch Repair
84
Rubber Plug Repair
84
Front Wheel: Reassembly
88
Rear Wheels and Drive Mechanism Exploded View
88
Rear Wheels and Drive Mechanism Removal and Disassembly
92
Rear Wheels and Drive Mechanism Inspection and Repair
92
Rear Wheels and Drive Mechanism Reassembly
96
Installing New Parts to Old Model Motorcycle
96
Rear Wheels Bosses Installation
96
Chain Guide Installation
97
Technical Data and Wiring Diagram
98
Optional Parts
98
Wiring Diagram US90
99
Wiring Diagram ATC90K3
100
Addendum Sheed ATC90 '77 - Wheel Exploded View
101
Wheel Disassembly
101
Wheel Inspection and Repair
103
Wheel Assembly (ATC90 '77)
104
Specifications (ATC90 '77)
106
ATC110 '79 Addendum
107
ATC110 '79 Specifications
108
ATC110 '79 Wiring Diagram
109
ATC110 '79 Cable and Harness Routing
110
ATC110 '79 Torque Tables
111
ATC110 '79 - Tools
112
ATC110 '79 - Service Data
113
ATC110 '79 - Maintenance Schedule
114
ATC110 '79 - Carburetor Inspection and Adjustment
115
ATC110 '79 - Carburetor High Altitude Adjustment
116
ATC110 '79 - Throttle Cable Adjustment
116
Fuel Filter Cleaning
117
ATC110 '79 - Brake Lever/Parking Brake
117
ATC110 '79 - Clutch Exploded View
118
ATC110 '81 - Addendum Sheet
119
ATC110 '81 - Specifications
120
ATC110 '81 - Maintenance Schedule
121
ATC110 '81 - Wiring Diagram
121
ATC110 '81 - Torque Values
122
ATC110 '81 - Cable and Harness Routing
123
ATC110 '81 - Ignition System Diagrams
124
ATC110 '81 - Ignition Coil Inspection and Adjustment
124
ATC110 '81 - AC Generator
124
ATC110 '81 - Lighting Coil, Exciter Coil
124
ATC110 '81 - Pulser Generator
125
ATC110 '81 - Ignition Timing
125
ATC110 '81 - CDI Unit Removal and Inspection
126
ATC110 '81 - Drive Chain (Removal of Endless Drive Chain)
128
ATC110 '81 - Drive Chain Cleaning and Lubrication

Also See for Honda ATC 90

Honda ATC 90 Owner's Manual 76 pages

Honda ATC 70 Service Manual 33 pages

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This manual is also suitable for:

Atc 110