Problems while in second

[Neon1990]

hey guys today my z160Ho has developed a bit of a problem.
when i put it in second its on and off the power like the clutch is slipping then grabbing really quick.
it almost feels like the engine is being starved of fuel or running like crap but it only happens in second which made me think it is a gearbox/ clutch issue
what do youse think?

 

[sean01]

well its easy to tell if its a gearbox issue or a fuel issue..

when it feels like its cutting out does it rev up like yr raping the clutch and jerk a bit but yet you can slowly accelerate without it happening? if so then its a gearbox issue..
second gear dogs are dead.. will require splitting the engine to repair..

theres a few threads on here lately regarding gearbox issues. have a look thru them to see other recommendations as to inspecting and checking things out.

 

[Neon1990]

from what your saying i think 2nd is rooted cause if i hold the throttle constant it jerks around and when i'm up it in 2nd it revs up like its slipping but i haven't heard any crunching making me think it was the clutch.

i'll pull it apart tomorrow and have a look. should i be looking at the shift drum like suggested in the other threads.

 

[Neon1990]

p.s. which side of the engine do i take off? sorry i'm new to this
also the chain flicked off the other day from being to loose if that makes any difference

 

[sean01]

chain can make a similar problem if too loose, but usually it will be worse in 1st and slowly get better thru the gears.. the chain can jump on the rear sprocket..

and usually if a chain comes off once then you can pretty much say its stuffed.. the stretch and bend when they get caught up..

right hand side of the engine is what you take apart but dont even attempt it if ya havent got the correct tools..

oh and the gearbox issue rarely gives a crunching sound..

 

[Neon1990]

yeah its only doing it in second
the chain came off while doing a burn out so wasn't to bad i didn't even notice till i went to take off again lol.
i've got a fair selection of tools so i should be right unless you need some special things

 

[DHZ_XR8cing]

Check to make sure your swing arm,rear wheel and engine mounts are tight. It don't really explain why it only does it in 2nd gear but could be something to check.

 

[sean01]

yeah its only doing it in second
the chain came off while doing a burn out so wasn't to bad i didn't even notice till i went to take off again lol.
i've got a fair selection of tools so i should be right unless you need some special things

you need a special tool to take the clutch off mate.. and while you have it apart take the time to sus out the clutch, if you can wriggle the large gear on the back of the basket then its toasted too.. its not part of your 2nd gear problem tho..

 

[Neon1990]

ok i might hold off on taking it apart then. its only a couple of weeks old so i don't think the clutch would be rooted yet

 

[sean01]

only couple weeks old, see if the company you bought it from will help out. they dont have to but most do to keep the peace lol

 

[Neon1990]

sorry forgot to mention its a DHZ dpro160 so i got it from DHZ. its probably more like a month old but i work away so its only been used for a couple of weeks. i'll send em an email can't hurt to ask

 

[Neon1990]

quick question do you absolutely pull the head and all that off when you split the case or is there a way round it?
also bit of an update i've been emailing DHZ and they think it might be the shift drum causing the problem. guess i'll find out when i open it up

 

[DHZ_XR8cing]

Ill bet my left one the clutch basket nut is lose and/or the swing arm bolt is not tight.
Check the engine mount bolts are FT.

 

[Neon1990]

yeah i'll check the clutch first but the swing arm is tight and the mount bolt are FT.

 

[DHZ_XR8cing]

hold your fingers on the top of your chain and your thumb on the bottom and pull it tight. see if the engine or swing arm move at all.

 

[sean01]

there is a work around for the top end but it requires pulling the barrel stud out of the case side your pulling off.. IMO its easier to pull the top end off..

 

[Neon1990]

hold your fingers on the top of your chain and your thumb on the bottom and pull it tight. see if the engine or swing arm move at all.

yeah ok i will give that a try

there is a work around for the top end but it requires pulling the barrel stud out of the case side your pulling off.. IMO its easier to pull the top end off..

OK i'll just pull the hole thing apart if a need to

thanks for the quick replys guys

 

[The_GDFP]

Shift drum end play is my guess. Lets it move around. Bummer is, you likely tweaked the shift for and/or gear dogs by continuing to ride it.

 

[sean01]

yep. then when assembling it check how much play is in the shift drum when you have the bolt tight above the front sprocket.. to much play and this is the result.. shim it or lightly machine the end down where the bolt goes thru.. not too tight tho..

 

[Neon1990]

I measured the shift drum end play as accurately as i could and its about 0.4-0.5mm. what should it be?