1985 ATC 110 Shift Drum Stopper Arm Upgrade

[Badbmwbrad]

Thanks for the excellent work of a member who has scanned and posted Honda Service bulletins for Honda ATC 110. I'm going to repair my 1985 Honda ATC 110 shift drum stopper.

Honda service bulletin #3 for ATC 110 3-wheeler shows an improved transmission shift drum stopper arm and shift drum stopper plate. I'm trying to figure out
which parts at DRATV are the improved parts.

The Honda Service bulletin #3 (dated Nov 1985) lists an improved stopper arm 24430-943-00 and an improved stopper plate 24425-943-000.

DRATV lists Plate, Drum Stopper 68K http://www.dratv.com/pdrst6.html
DRATV lists Shift Drum Stopper (arm) 268N http://www.dratv.com/268n.html


WWW.DRATV.COM lists Shift Drum Stopper (arm) 154C http://www.dratv.com/shdrstallctc.html (which is temporarily out of stock).

The differences I see in DRATV photos are one (older?) version of the stopper plate "star wheel" appears to have truncated tips and another version has pointed tips. Which is the upgraded stopper plate for 1985 ATC 110?

In addition, it's unclear what differences exist on the two stopper arms shown at DRATV.

Has anyone else sorted this out who can advise which are the correct parts to order from DRATV?

[SWIGIN]

How about asking him?

[kb0nly]

I don't honestly know which ones are the updated parts, that is their differences, but i have always ordered parts 68k and 268N and they work great. You don't have to replace the plate though unless yours got gouged up by a broken stopper, or if its badly worn.

I think though the rounded tips is the newer plate because on the 125M's that i have worked on only a few had the pointed tips and they were definitely older and the engine hadn't got a punch mark from it being updated. But thats just speculation on my part i will admit that.

The pointed tips on the plate though would make for harder shifting because the roller wouldn't just roll over the tip, so if yours doesn't have the one with the rounded tips i would replace it and order the new stopper arm. The one thats out of stock i asked him about a while back, he said it was an "older" part that was no longer available. So perhaps that was the original. The other style is widely available.

[Badbmwbrad]

I removed the right-side engine cover, clutch and the primary driven gear. It's obvious the shift drum stopper arm (the stopper plate follower) has broken off but I can't find the broken-off follower end! It should look like a little roller on the stopper arm. It's not inside the right-side engine cover.
Where could it be hiding?

[kb0nly]

Whats the history on this trike? Did you get it in this condition? I don't remember without reading back now. Did it look like the cover had been removed recently? Easy way to tell is if the philips heads of the cover screws were rusty or if they were shiny in spots from tool contact. Someone else might have already opened it up, found the piece but didn't fix it, i had that happen on a few as they probably didnt know how to remove the clutch or have the right tool or just didn't want to get involved with it, etc.

That roller is too big to go through any of the holes on the ones i have done, i haven't seen one yet that it made it into the case but if you have a magnetic pickup tool fish around inside, look through the holes behind that primary gear and see if its in there anywhere.

I had one that i couldnt find it and just figured someone else removed it because i fished around for like an hour and couldn't find anything inside using a really strong magnet on a flexible pickup tool.

[Badbmwbrad]

I purchased this ATC 110 about 14 months ago for $175. It didn't run very well, too many parts were missing and I didn't think that I would care (but it turns out that I love this thing). I recall that it has always down-shifted into false neutrals so it probably already had a broken stopper arm when I bought it.

When I removed the right side engine cover, the Phillips screw heads holding it on were not chewed up at all.

http://hondatrailcts.yuku.com/topic/4890/having-shifting-troubles--new-drum-stopper-install-81-CT110#.UvaONfldV28

The linked thread has a photograph (near the end of the thread) which shows a broken-off shift drum stopper arm. My 1985 ATC 110 has a shift drum stopper arm broken in the same location. The loose part would be the roller and a short section of the broken arm. The engine block's right half has a couple of small openings into the oil sump but I don't think the broken piece of stopper arm could fit into the opening.




Whats the history on this trike? Did you get it in this condition? I don't remember without reading back now. Did it look like the cover had been removed recently? Easy way to tell is if the philips heads of the cover screws were rusty or if they were shiny in spots from tool contact. Someone else might have already opened it up, found the piece but didn't fix it, i had that happen on a few as they probably didnt know how to remove the clutch or have the right tool or just didn't want to get involved with it, etc.

That roller is too big to go through any of the holes on the ones i have done, i haven't seen one yet that it made it into the case but if you have a magnetic pickup tool fish around inside, look through the holes behind that primary gear and see if its in there anywhere.

I had one that i couldnt find it and just figured someone else removed it because i fished around for like an hour and couldn't find anything inside using a really strong magnet on a flexible pickup tool.

[kb0nly]

Yep, as i said in my other post i suspect it was previously removed because i haven't ever seen one go into the case. If you take a stopper arm, and i have done this, and try all those holes with the roller end of it you can't fit it through any of the openings. The ones i have pulled out were usually in the bottom of the right cover or behind the main gear.

Person who was last in there must have done a good job and not buggered up the screws. I end up replacing them most of the time with hex head metric bolts.

[Badbmwbrad]

Thanks for relating your experience trying to find a drum stopper roller lost behind the right engine cover. I posted my experience at the Honda Trail 90 forum and was advised to inspect behind the oil filter screen. Perhaps the Trail 90 engine block right-half has larger openings into the oil sump?

I removed the oil filter screen yesterday and checked it for debris (none found) but I didn't check behind (below?) it with a magnet so I'll try that next.


Yep, as i said in my other post i suspect it was previously removed because i haven't ever seen one go into the case. If you take a stopper arm, and i have done this, and try all those holes with the roller end of it you can't fit it through any of the openings. The ones i have pulled out were usually in the bottom of the right cover or behind the main gear.

Person who was last in there must have done a good job and not buggered up the screws. I end up replacing them most of the time with hex head metric bolts.

[Badbmwbrad]

My replacement stopper arm arrived at the local dealer. I still have not found the old stopper's roller wheel and need to search below the oil strainer.


What kind of magnetic pick-up tool did you use to sweep out the crank case?

[kb0nly]

Its one of those long magnetic pick up tools, a flexible one that looks like a long wound spring, with a strong rare earth magnet on the end. Its rated to pick up like ten pounds, so a small piece or nut or bolt is not an issue!

I just got mine at the local hardware store for $8

[Badbmwbrad]

My wife searched local auto parts stores, Sears, Harbor Freight - no luck. I may have to sacrifice a telescopic mag pickup tool for the cause...

[kb0nly]

Harbor Freight has them for sure, i just saw the flexible magnetic pickup tool in their last flyer i got for like $8.99

[Badbmwbrad]

I found this http://www.harborfreight.com/flexible-magnetic-pickup-tool-94614.html
but I'm not sure it will fit beneath the oil strainer...

V8 tools has a magnetic pickup tool called Mighty Worm shown near the bottom of the linked page - http://www.v8tools.com/special.html#3822

I have the replacement drum stopper arm from Honda and plant to install it tomorrow. I'll probably end up bending my small, pen-sized telescopic mag pick-up tool and try to fish out the busted off end of the stopper arm from the crankcase bottom. Given the condition of my ATC 110 when I bought it, I'm not optimistic that someone spent the time to open up the right engine cover and removed the lost part.

[kb0nly]

The mighty worm looks a lot like the one i have. I wanna say i got it from True Value Hardware, but it might have been my local hardware store with Napa in the back. Either way, whatever you can make work should do it.

If you find it i would be surprised, but its possible its in there. I have never seen one get inside the case so this should be interesting!

[Badbmwbrad]

Thanks for your help. Today I replaced the drum stopper arm. The ATC transmission shifts correctly with no false neutrals.

I pulled out the oil strainer and used my telescopic magnetic pickup tool to search inside the crankcase. Its magnet didn't recover any lost parts. It did pick up a few little chunks of metal. It wasn't able to enter the engine crankcase through any of the available passages.

I'm not sure what lies beneath the oil screen and there was a puddle of oil in there because I didn't remove the oil drain plug. I couldn't really see how the casting is formed below the oil strainer or how big the opening is.

My driveway is a large figure-8 with two islands. It is totally covered with glare ice from the rain the other day. 5" of fresh heavy wet snow fell today so I raced my ATC around the driveway after dark. The rear wheels throw up a big rooster tail of snow. The ATC slides sideways in the corners and I had a lot of fun.

[whitetail hunter]

I just replaced the arm on my sons 125m and could not find the roller either. removed the oil screen and flushed and swabbed all passages, nothing found. glad your trike is up and running.

[kb0nly]

I just replaced the arm on my sons 125m and could not find the roller either. removed the oil screen and flushed and swabbed all passages, nothing found. glad your trike is up and running.

I wonder where they all disappear to?? LOL

Was your Son's known history? Is there any chance someone else already removed it? I have only found the roller tip in one that i repaired, but i cant say without doubt that nobody else was in there before me.