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-   -   kazuma 110cc shifting problems (http://forums.atvconnection.com/chinese-quads-ask-expert/315319-kazuma-110cc-shifting-problems.html)

jay shawn 07-11-2009 10:22 PM

kazuma 110cc shifting problems
 
ok i have a kazuma 110cc quad i bought used and put new magneto on it and started right up. ok now the 1st and 2nd gear does not work they are acting like they are in neutral but 3rd and reverse work with no problem what could the problem be need new clutch?? dont know any help will be apreciated thanks!!

mywifesquad 07-13-2009 08:01 AM

Welcome to the forum jay shawn ! :)

Does this engine have reverse as a down shift? and the 3 forward gears as a upshift? If so does it actually feel like it shifts into 1st and 2nd? or go straight into 3rd? If it moves in 3rd and reverse the clutch is more than likely ok..

jay shawn 07-13-2009 07:44 PM

its weird the gears are 321nr the 3rd gear is working and reverse so im thinking the gears are bad

kbirdjr 07-13-2009 11:23 PM

I have a similar problem with a Hi-Bird 110. My wife used it all day yesterday (over 100 degrees) pulling a lawn cart around the yard with a few hundred pounds of dirt in it at a time. After about 8 hours of intermitant use it just acts like it is in neutral. I can feel it shift into gear but then it will not pull. It does this in both forward and reverse. I am guessing clutch but don't know what kind it is or where to find it. The engine is a 1P52FMH. Can anyone tell me where to start? Thanks in advance.

mywifesquad 07-14-2009 07:00 AM

jay shawn, It would be pretty tough to destroy 2 gears, and not hear any nasty noises when you shift. Id guess a shifting fork got bent and it doesnt allow the gears to engage. Unfortunately the cases need to be split to take a look.

mywifesquad 07-14-2009 07:04 AM

Welcome to the forum kbirdjr! :)

Im not sure if you wore out your clutch completely or it just got worn out enough to slip. On the right side of the engine(when your sitting on the quad) there is a screw/nut/washer combo sticking out of the cases. Loosen the nut and back it off a turn or so...do this while holding the screw with a screw driver. Then tighten the screw so it bottoms out, but doesnt bind on the nut....after it bottoms out turn the screw out 1/8 to 1/4 of a turn and tighten the nut(while holding the screw in place). This is the proper adjustment of the auto clutch....if this doesnt fix the problem you will need new clutch plates..

kbirdjr 07-14-2009 01:10 PM

Thanks, I will try that this evening. If that doesn't work, what kind of clutch does it have and where do I find parts?

jay shawn 07-14-2009 05:25 PM

you can get a new clutch from ebay like 40 bucks i finally found a new motor for mine and runs like a champ thanks

kbirdjr 07-15-2009 05:00 PM

Quote:

Originally Posted by mywifesquad (Post 2819825)
Welcome to the forum kbirdjr! :)

Im not sure if you wore out your clutch completely or it just got worn out enough to slip. On the right side of the engine(when your sitting on the quad) there is a screw/nut/washer combo sticking out of the cases. Loosen the nut and back it off a turn or so...do this while holding the screw with a screw driver. Then tighten the screw so it bottoms out, but doesnt bind on the nut....after it bottoms out turn the screw out 1/8 to 1/4 of a turn and tighten the nut(while holding the screw in place). This is the proper adjustment of the auto clutch....if this doesnt fix the problem you will need new clutch plates..

I looked at it and could not find the adjustment screw you described. Did I mention that it is a semi-automatic transmission? I don't know if that makes a difference, but there is no hand clutch, just let off the gas then shift with foot. Should it be visable or do I need to remove a cover? I haven't torn into it
very much but it looks like it might just be easier to romove the entire engine from the ATV so I can access everything. I was searching last night and I found this site Kazuma ATV Parts - Falcon 110cc Engine Parts - Kazuma Falcon 110cc Engine Complete - $399.95 - KazumaPartsOnline.com that engine looks exactly like what I have.

mywifesquad 07-15-2009 06:37 PM

Quote:

Originally Posted by kbirdjr (Post 2820749)
I looked at it and could not find the adjustment screw you described. Did I mention that it is a semi-automatic transmission? I don't know if that makes a difference, but there is no hand clutch, just let off the gas then shift with foot. Should it be visable or do I need to remove a cover? I haven't torn into it
very much but it looks like it might just be easier to romove the entire engine from the ATV so I can access everything. I was searching last night and I found this site Kazuma ATV Parts - Falcon 110cc Engine Parts - Kazuma Falcon 110cc Engine Complete - $399.95 - KazumaPartsOnline.com that engine looks exactly like what I have.

It should be under that cover on the right side...

jay shawn 07-15-2009 08:22 PM

take the four bolts off that cover that says kazuma and its under there

kbirdjr 07-15-2009 11:02 PM

OK, I found the adjustment screw described but that didn't help any so I drained the oil and pulled the right side off of the engine. There was quite a bit of clutch material in there so i am guessing it needs to rebuilt or replaced. My next question is how do I remove the clutch. I removed the 8 screws that are visable but I couldn't figure out how to remove the clutch. It seems to be pressed on, is there a special tool to remove it? Also, this thing only has about 7 hours on it so I haven't changed the oil yet. What kind of oil should I use when I finally get it back together?
Are there any repair/maintenance manuals for these things?

Thanks again for all the help guys.

mywifesquad 07-17-2009 07:30 AM

Can you post me a pic of your clutch? You would think that all these little Honda copy engines would use the same clutch...not so lucky..Some are held together with a clip and some with bolts/screws. I suggest getting both new fiber plates and solid plates, or maybe even buy a whole new clutch. Not sure if they sell individual plates.

I run Valvoline 10w-40 in all my Chinese and Honda air cooled toys.. Using the stock oil more than likely contributed to the fried clutch..

Repair manuals are few and far between..Ive got a generic small Honda repair manual that I use for reference but nothing is exact..

kbirdjr 07-17-2009 08:18 AM

I finally realized that there was a nut in the center of the clutch holding it on. I had to cut down a socket just leaving two fingers sticking out a little to go inside the notches in the nut. I think I can handle the rest of process, I am going to replace the entire clutch so now it is just a matter of puting it all back together. I will post some pictures of the clutch and the socket incase anyone else runs into this problem.

mywifesquad 07-17-2009 09:01 AM

Glad to hear you got it figured out... Looking forward to the pics of the job process..It will certainly help someone in the future here. :)

RawTourque 07-18-2009 08:10 PM

5 Attachment(s)
I am doing the same exact repair and came across the same strange nut. I had already thought of same "socket" fabrication but am not sure if it is reverse thread. Bad thing is someone has done this same repair to this thing once before...even zip tied the old clutch plates to the handlebars when they sold it to me. Whoever it was sure boggered up that nut...just my luck. However, before realizing the nut was there, I managed to bust the "star fish" shaped plate on the face of the gear behind the clutch...bull in a china shop my wife says. Whatever! Where do I get this plate and which way do I turn the "ticking time bomb" of a nut in the center of the clutch? Please help, email me if you need to: JBLEE1975@YAHOO.COM See pics attached of the plate and clutch. Thanks

kbirdjr 07-20-2009 03:34 PM

The nut is standard thread, just hard to get to. I was fortunate enough to find a place locally that has alot of parts for these things. I was going to replace the entire clutch but they didn't have the right one so I wound up saving some money and just bought the three friction plates. It was an easier rebuild than I thought it would be, the hardest part is geting the clutch off. As for the parts you need, I also found a website that seems to have about everything you could need. www.kazumapartsonline.com I will try to post some pics this evening of what mine looked like. If you run into any other problems just ask. Good luck.

Woods Signs 09-23-2012 05:40 PM

Different problem
 
I have a 110 Kazuma that starts and runs great. My son was riding it today, it locks up and starts running backward, ALL the gears are reverse gears now. HOW and why did that happen?


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