LT-4WDinNY

Yep, the sump screen above the drain plug is on the Right center case. What about if the gasket hangs well on the 2 alignment dowels, and I can line the rest of the cover bolts through the holes; not using ANY thing but the gasket and the pressure from the properly torques case cover bolts? 🙂 And, I know to tighten in a order similar to wheel lugs.... PS.... I do have this. I figured I didn't need gasket "maker" so I did pick this up.... https://shop.advanceautoparts.com/p/permatex-super-high-tack-gasket-sealant-1.75-oz.-80060/7160060-P?searchTerm=Permetex+gasket I assume "Tack" just helps hold the gasket while assembling? Thanks again Bruce

Thanks for replying! Yeah... I am assuming the damage that is there occurred when the previous owner put the oil filter in backwards. That caused the major breakdown where they then took it to the dealer to rebuild it. I am assuming that the dealer tore it down and redid the top end and new piston, etc maybe hand tested the starter clutch and it passed; put it all back together and then realized it was bad... recoil pulling the gears and the electric starter. Heck, maybe didn't know it was damaged or they told the owner and he said not to go back in. Never know now. Always has been a bear to pull start with the recoil, but I used the electric start majority of the time but want it better for the kids. Also... I got the new starter clutch and flywheel installed torqued to their correct ft-lbs and Loc-Tite as the Suzuki manual says. I cleaned off the old side cover gasket. I have a new gasket... is that all that is needed to seal, or do you recommend a gasket tack compound there too? The Suzuki manual just says to install gasket and reinstall the cover. On disassembly, it looks like there was some RTV along the bottom sides of the gasket... where the oil is constantly sitting. What are your recommendation? Bruce

I got the side cover off, learned how to put the subtransmission back together. I took the nut off the crank. Grabbed the new flywheel puller. Put the small piece on to protect the crank shaft end, and the flywheel fell off on its own??? So that was weird. I then looked and tested the starter one way clutch. It wasn't in pieces like I had seen on others on YouTube. It only turns in the one correct direction as indicated by the arrow. However, it looks like maybe it is slipping under load? Is that possible? I know that it was very difficult to pull start since I bought it back in 2001. The guy I bought from had the receipts on a recent engine rebuild by our local Suzuki dealer in the $1200 range because they put the oil filter in backwards. Anyhow, I am trying to make it easier for my kids to ride. I think I verified that the starter clutch was bad by removing the electric starter, then it would pull start normal... I took pictures of the one way clutch and the CALTRIC replacement parts I bought off Amazon. Looking closer, appears to be heavy wear on the metal pieces in the clutch and scratches on the starter gear surface that goes inside the clutch. I am going to replace the OEM parts with the CALTRIC brand parts off Amazon. However, I found some other discerning things behind the flywheel. Looks like the center case has cracks, and one broken off tab with the other 2 worn? Also it looks like some scraping inside the case bottom right... assume from when the post broke off. The post was NOT in the case, so probably occurred prior to the Suzuki Dealer rebuild. Also some discoloring on the crankshaft and back of starter clutch. Again, putting in the CALTRIC brand replacements for the starter clutch and starter gear as a set. Thanks! Bruce

View File 1984-86 Honda ATC200S Shop Manual Honda Shop Manual for ATC200S for 84-86 Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV  

View File 1985 Honda ATC110 Setup Instructions These are the setup instructions for dealer to "uncrate" and get put together for sale. Has some helpful pictures and specs to reference beyond the service manual. Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV  

View File 1980-83 Honda ATC185/185S/200/200S Service Manual 80-83 Honda Service Manuals for ATC185/185S/200/200S Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV  

View File 1982-87 Honda ATC Big Red Service Bulletins Internal Honda Service Bullitens for the ATC200E, 200ES and 250ES. Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV  

View File 1985-86 Honda ATC250R Service Manual "Water Cooled" 85-86 Honda ATC250R Service Manual Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV  

View File 1985-87 Honda ATC250ES Big Red Service Manual Honda Service Manual for the 95-87 ATC250ES Big Red Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV  

View File 1981-84 Honda ATC250R Service Manual "Air Cooled" Honda ATC250R Service Manual 81-84. Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV  

View File Honda ATC Recoil Info Information on determining correct Recoils for different year and model Honda ATCs Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV  

View File 85 Honda ATC110 Misc Tool Service Parts Info Neat info in my manual, listing special tools and any recalls. Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV  

View File 1985 Honda ATC110 Service Manual 1985 Honda ATC110 Service Manual. Should be very similar for 83 or 84 ATC110 models. Seems like Honda "started over" on Service Manuals in 85. Submitter LT-4WDinNY Submitted 12/21/2021 Category Honda ATV