85 klt 110 shift problems

[threewheely]

well from al I have read about these 85 klt 110 kawi's they have a problem with a shift shaft snapping, or stripping. I bought this for 150.00 with a busted shift shaft by the way you can not find them any more. I ordered on from ebay from a 04 kawi bayou 300 for 15.00, and a shifter for the same make, well cut the end of the shift shaft from the 04 welded onto mine, then I cut the splined section off the shifter of the 85, then cut off the splinded block from the 04 shifter, and welded it onto the 85. I have replace the clutch plates on it also, kind of bangs when going into 1st, not sure how to adjust the clutch so I hope someone on here has done it. But the real problem is shifting while it is running, some times it does not want to up shift, or down shift have to play with it. When I had it apart I would turn the shift drum by hand, then you would have to rock the lay shaft to get to click into gear, just figured it was not running. Now I wonder is it the shift drum, or the forks are getting worn. hopefully someone has some thoughts on this, trying to keep this a low budget toy to haul kids around, thank's for any help.

[barnett468]

remove axcess plug on clutch cover.

loosen nut.

adjust so the shift lever has around 3/8" of free play [there will still be slight spring resistance].

if it still banks install oil for wet clutches only.

if still not fixed after 30 minutes of riding then you likely need to disassemble the eng but see how shift works as you watch with cover off. kick the kick starter while doing this so the gears are moving or it might not shift.

[threewheely]

thank's barnett468, I will either get to it today or tomorrow after work will let you know how it work's out. I think my new fly wheel is showing up tomorrow. will do it at the same time. What do you mean install oil for wet clutches only, are you referring to 80w gear saver oil that's what I use in my 2 stroke's. I am using regular 10/30 weight oil now, that's what is recommended. thank's again, steve

[barnett468]

ok i'll be around.

the oil must say "4 stroke oil for use with wet clutch" in your particular case. this oil occasionally frees up sticky clutch plates. its a cheap first option.

[threewheely]

I still did not get to mess with clutch yet will do it Saturday morning. will have to change oil using regular 10w 30 oil automotive. then will adjust it. going to start a new thread on another subject though will come back to this one thank's again barnett468