ATC 110 engine oil leak and manual clutch questions?

[1stwarrior95]

Hi everybody. Lookin for some answers and came across this site. Looks like a place to enjoy!

79 ATC110;

Question 1,
Anybody ever heard of or seen one of these with a manual clutch? This is a project I'd like to tackle, but thought I'd seek addtional information first.
Here's my theory, I have the 110 and I also have a CT90, (I think), engine that has a manual clutch.
I tried awhile back to crossbread the 2 but the CT90 clutch basket extends out further than the 110 auto clutch version. I couldn't get the side cover on.
Any ideas, suggestions, links, pics, etc would be appreciated.

Question 2,
Our 110 had the chain jump off a year or so ago and cracked the engine case so it leaked oil. I JB welded it and it lasted about a month so I took it apart again and tried to do a better job of JBing and also built a case saver for it this time.
This time it's lasted until now, but once again, it'sstarting to leak. My question is, could I take all the internals out of the 110 case and put them in a ATC90 engine case? Will they interchange? (I ask mostly because I already have a couple 90 engines and 110's are more difficult to find around here.

Sorry so long. :rolleyes:
Thanks in advance everybody.

[deerslayer1407]

When i had a 110 about 5 years ago, chain jumped, and broke the back of the motor, so i took the motor apart, and cleaned everything up good, then i used silicone over the hole, and it sealed it up good for the 2-3 years i had it after that. But maybe i was just lucky that it heald that good. Its just a thought for * if * cant find any other way to fix it.

[Simpo]

hello mate, my ATC90 has a manual clutch...but sorry cant help you - i didnt put it together :wondering but ill take the side cover off tomorrow and take some pics... it might help you :beer

[RedRider_AK]

A manual clutched 110? That's overkill for an engine with so little power, in my opinion.

[Vealmonkey]

Why don't you just put the 90 motor into the 110?

[Somekindofjerk]

With an alluminum block a mig welder that runs 3(volt setting)40(wirefeed speed) and fluxcore can fix your problem, youd be better off though with a tig weld, much more andhecive and small(not as much height to the weld) thats what i would do, and trust me a manual transmision in it wont do any good i tried, however aftermarket sprokets can change your gearing quiet a bit, get a bigger sproket for the engine and youd be set, dont change the back sproket to much work and you risk blowing the engine.

[greenhuman]

The manual clutch parts bolt right up. You have to use the manual clutch spacer behind the clutch. The ATC spacer is thicker. The ATC gearstick shaft has to be cut level with the selecting arm so the manual cover will fit. Don't forget to block the kick starter shaft hole in the manual side cover.
If you transfer all the 10 bottom end parts into the 90 cases, the 110 cylinder won't fit. The hole for the cylinder is smaller in a 90 than a 110.

[1stwarrior95]

Thanks for the replies guys!

I'll try to answer everbodies questions in order.

deerslayer;
I tried the silicone thing before I tried JB weld. I think the problem with both methods is that the crack is right where the engine case joins the outside engine plate?, (not sure what it's called).
I think I'll end up having it welded like Somekindofjerk suggested. :beer

Simpo;
If ya can get some pics of your manual clutch setup that'd be great! Any info helps. My email is tbaker@nemr.net if ya wanna email them instead of posting them.

RedRider_AK;
Ya, you're right about it being overkill. The reason I'd like to have the manual clutch is precisely what you stated...to little power. With a manual clutch if ya happen to run out of power climbing a hill, (or whatever), you can release the clutch and roll backwards without the fear of accidentally touching the throttle and doing a backflip! :lol: (Another reason is it'd be more unique!)
Besides, if I need more power I just ride my Raptor! 6 times 110cc's! :lol: ;)

Vealmonkey;
The manual clutch 90 motor I had was junk. It laid outside for about 10 years! About the only parts that were salvagable was the clutch setup. Also I just rebuilt the 110 engine just before it started to leak oil. Just my luck. :cry: :lol:

Somekindofjerk;
See my response to deerslayer above. /\

greenhuman;

The manual clutch parts bolt right up. You have to use the manual clutch spacer behind the clutch. The ATC spacer is thicker. The ATC gearstick shaft has to be cut level with the selecting arm so the manual cover will fit. Don't forget to block the kick starter shaft hole in the manual side cover.

COOL! Maybe I didn't change the spacer last time. I'll have to check it out again. I did cut the shifter shaft down and welded part of it, (that releases the autoclutch if I remember right).
I think I was gonna just use the kickstarter shaft itself to block the hole. Just cut off the outer end flush with the case.


If you transfer all the 10 bottom end parts into the 90 cases, the 110 cylinder won't fit. The hole for the cylinder is smaller in a 90 than a 110.

Bummer! Although concievably, (spelling?), a person could have the hole in the case machined out then all other parts should fit?

Thanks again guys. I'll see if I can post a pic of the beast later! :beer :Bounce

[RedRider_AK]

If you lose power, you just pull in the clutch and coast down, eh? The centrifugal clutch on the 110 lets you do the same, just let go of the throttle. Or, even better, downshift and keep the shifter down, it'll stay in neutral until you let it back up (works the same way upshifting).

Twould definetely be unique though. And just the thing if you decide to let your son or something race it (ha ha).

[1stwarrior95]

If you lose power, you just pull in the clutch and coast down, eh? The centrifugal clutch on the 110 lets you do the same, just let go of the throttle. Or, even better, downshift and keep the shifter down, it'll stay in neutral until you let it back up (works the same way upshifting).

Twould definetely be unique though. And just the thing if you decide to let your son or something race it (ha ha).

Well, I dunno about the coasting down part, :eek: but with a manual clutch you can instantly release it instead of the couple seconds it takes for the engine to idle down enough for the autoclutch to disengauge. Those couple seconds count for alot sometimes.
Truth be known, I like the unique part the best! :lol: :w00t:

My son does do most of the ridig on it though. Racing...that makes me hurt just thinkin about it!! Hahaha

[1stwarrior95]

Pic of the beast in question. (test).

http://www.imagestation.com/picture/sraid187/pb9db5abde97f39d8630d0f315890f92c/f242b169.jpg

http://www.imagestation.com/picture/sraid187/p2eef0ca26e5a783e7c44214b19892071/f242ae74.jpg

[RedRider_AK]

Well, I dunno about the coasting down part, :eek: but with a manual clutch you can instantly release it instead of the couple seconds it takes for the engine to idle down enough for the autoclutch to disengauge. Those couple seconds count for alot sometimes.
Truth be known, I like the unique part the best! :lol: :w00t:

My son does do most of the ridig on it though. Racing...that makes me hurt just thinkin about it!! Hahaha

Hehe, I can just imagine a little kid tearing up the MX tracks with a non-suspensioned machine... flipping it about 6 times a lap...