LT-4WDinNY

19 hours ago, Mech said:

As you were.. I checked in a manual and the oil restrictor is in the other side case.

Loctite master gasket is still the stuff to use though..  It doesn't harden till you clamp the parts together, which means you don't have to hurry.. another of it's advantages. It's brilliant stuff. Silicon is terrible stuff.. except perhaps.. oh I don't know.. fitting windows into a caravan say !

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

I guess I will upload them at the "official" manual page....  Bruce

OK... these I scanned myself from a Honda dealer binder I bought off ebay years ago. I searched for a 83 manual for a 110 and could not find a Honda manual online anywhere.  Enjoy!  

See https://www.quadcrazy.com/profile/32340-lt-4wdinny/content/?type=downloads_file

Bruce

Here is a list of the Frame Vin Numbers.... Should be on the left rear frame down pipe from the rear rack to the bottom frame.  I assume they are valid for Europe models too...   You need that letter in front of the last series of digits.  I believe there is an engine vin number too.

Bruce

I have been using www.BikeBandit.com for OEM parts lately.  You can shop for aftermarket parts on sites such as www.DennisKirk.com or Rocky Mountain ATV.  Of course, ebay and Amazon have parts too, but might not be the quality... you get what you pay for at times!

Bruce 

On 8/19/2021 at 8:58 PM, Sycoholic said:

I have the Maier ones on mine. They're not too bad. Factory looks cleaner though. Good luck finding them affordable though.

I think some others have used OEM ones to make molds and are popping them out.  Check www.3wheelerworld.com in the New Parts for sale area....

Bruce

Very Cool!  My Big Red is pretty original with a ton of Hondaline items.... HL guard, Work Light, Speedo, Rear "Trucker" Mud Flaps and even a Honda of Canada block heater!  Non Hondaline assessories are CMP foot guard/skid plate and a Cycle Country snow plow.   Where did you get those side mudflaps on the back?  Honda made those side trim pieces that are nearly always MIA! 

Bruce

On 9/21/2021 at 1:30 PM, briantutt said:

Hello All,

I picked up a 1984 ATC 200S.  Needs some work but pretty clean if you ignore the fender and seat.  Anyone know where to download a Service/Repair manual for this?

Thanks,

Brian

Maier still makes aftermarket fenders for those if I recall.  CosmicQuads makes some great seat covers too.  Another place to check is Hi-Flite ... they made them in the day and were still making them the last time I needed a seat cover... but that was in 2005 for my 82R.  I got the desert seat from Hi-Flite.  Very comfy!

4 hours ago, Paul4x4 said:

Nice to hear I'm not alone!

 

ATC's are my biggest love too for some reason. I have three in my collection at the moment, an 84 200ES (in restoration), an 83 200E and their baby 83 ATC70. I'm also restoring a 350X for a friend and have also his 84 200E in storage. I would love to own an older 110 and a 250SX too, if I ever manage to find those! (I live in Europe, so it's not easy to find 3 wheelers here...)

 

Just got my first 4WD quad, and that is a 1990(I think...) Suzuki LT-4WD. Got a great deal on it, and I think its 4WD system is better than on any Honda!

Cool,  We had an 82 and then a 83 Big Red new when I was a kid.  I still remember seeing the line up of ATC's in the showroom in our local Honda dealer.  I have some cool promo items from 83 too... Honda playing cards, and some jig-saw puzzles too!

Yes, I have an 87 and an 89 LT-4WD as I stated.  If it is a 90, they changed the carb that year to the diaphragm type instead of the CV slide carb.  The VIN number is on the rear frame down pipe.  You should be able to determine the model year from that.  Funny thing.... the NY title for my 89 states it is a 1991.  So I bought parts for the carb and learned my lesson, as the VIN came back as a 1989, and as I said, the carbs and exhaust changed in 1990!   It definitely is a unique 4x4 system with the Hi-Lo and Super Low and the Differential Lock too.

6 hours ago, Ajmboy said:

Welcome to QUADCRAZY! That's quite a collection you have there. 

We do have an ATC forum if you are interested in reading some older topics: https://www.quadcrazy.com/atvforum/11-atc-3-wheeler-forum/

Thanks man... I will check it out!  I also have a bunch of 3 wheeler related PDFs of service manuals, owners manuals, parts manuals, setup instructions, etc to add....

I have a few Manuals you do not have.  I personally scanned the 1985 ATC110 manual to PDF from my own Honda binder.  When I get to where I can upload and download, I will get it to you and see what other ones I can add.

Bruce