1977 Honda 90us ATC clutch will not disengage, adjusted still jumps and will not release when holding shifter down or up. Clutch basket was loose on shaft removed cleaned and installed torqued to spec. I have no end play now, wont disengage. Any help would be great thanks.

 

Not sure just how the ATC works but as you mention "holding shifter up or down" I assume it is a combined shifter and clutch lever like the TRX90 four wheeler. Fairly sure this is like almost all manual gearbox ATVs. Have you set the adjuster? Slacken nut, turn screw one turn clockwise (do not force) then turn back anti-clockwise until resistance is felt, then back off about 1/6th of a turn. Tighten nut.

 

yes i have. I have had a few apart, but always found clutch hub nut always loose with it causing end play buddies would not want to buy spanner, i purchased this one a few months back ran but smoked, vavle seal petrified lol. put a 1mm over piston& rings disassembled complete engine, cleaned checked all specs. all in tolerance. torqued all fasteners to specs. I was wondering if anyone else has had this problem the only change was no end play after torqued. i might be to OCD about it. I am a master expert factory trained H-D tech, Kawasaki trained tech. john Deere tech. journeyman ford tech also.. So now i am mic-ing the spares from parts engines i have collected, about .020 thou. difference in the three i have. Small if i remember correctly is .455 thou. Longest is .475. Im going to install that one and adjust. If you have any other suggestions i would be willing to give it a shot. thanks for your input,as any would be great. the part i am measuring is the through oil part, thats what they call it

 

yes it is shifter and clutch semi auotomatic . forgot to address that sorry. i have done that adjustment a couple dozen times.. i cleaned everything very well but i also purchased honda oil and soaked plates just in-case the material was that type. So I am just getting a little to the point of exausting my little knowledge on this one. I hate to just throw parts at it, as i would like some reasoning before doing so. Been a tech to long lol..

 

The clutch mechanism is almost identical to Kawasaki KLF220 /300 so whatever applies to that should work on a Honda 90. Let us know what the problem turns out to be.