2-stroke troubleshooting help for a quad

Yup, I saw the case marking but on the stator the line wasn't as obvious, so I marked it before pulling it. Then I dug up the manual and inspected closer to see where the machine mark was.

The design is not foolproof as indeed all 3 holes line up no matter what. Pretty poor engineering there.

I will take a pic tomorrow. Dinner with in laws tonight prevented me from working on this more, so hopefully tomorrow I continue on this way too long project.

 

Exhibit A, my sharpie marks added so I could remember the position it was in. Case marking is at 9 o'clock.

And exhibit B is the correct alignment. The screw holes line up regardless.

 

That will definitely make a difference. I hate working on something someone else had been working on and couldn't figure out. Something like that can cause you all kinds of frustration until you find it. The one lt80 we had I bought used when the guy rebuilt the carb and couldn't get it to run again. I took the carb off and pulled the bowl everything looked good checked the reed looked fine. I found if I held my hand over the intake it would run but as soon as I moved it would shut off. I knew it was fuel related and replaced everything between the tank and carb no luck. So finally after the umpteenth time of pulling the carb apart I found an oring on top of the main jet that when the main jet was tightened down squished together and all but closed off the orifice. After throwing it away and reassembling everything it fired right up and runs like a top to this day.

 

That thing blowin smoke yet?

 

Can't see any Mark.
How do we know it's correct?

 

Have to hit HW store, couldn't rig a spark plug up for pressure test and didn't have any fittings on hand.

I hear ya, it's wicked hard to see. You can see the mark at 9 o'clock on the case? Go 2 minutes (or is it one minute forty five secs?) CCW, and it is faintly there on the stator to the outside of the screw hole. Furthermore, that's where the manual shows it which is why I knew where to look. Black windings were horizontal top/ white were bottom and the mark is there so I am fairly confident on this.

 

update?

 

Got cookies? I have the new starter gear and key to install. Wife has strep throat and son has stomach bug/ fever.... not a fun weekend here. Couldn't even tinker during nap time, poor guy doesn't yet get the whole "wake up and puke in the bucket/ toilet thing" - lots of laundry let's say...

 

Ouch!
Hope everybody gets better soon, cnice!

 

We have ignition!! Wow, that took a while. Put the carb back on and will re-assemble the rest. Hopefully have the kids tearing up my lawn next weekend

 

So to recap, there wasn't anything actually wrong other than someone took it apart and then put it back together wrong?

 

Seems to be the case.

Nice work cnice_37 !

 

Could be... I have fixed some things along the way, but nothing major really. The key on the starter gear/drive side was definitely toast, but it was so toast that it froze the gear in place.

 

So she is blowin' smoke!! So much, in fact, that the wife yelled at me good for making her laundry smell like 2-stroke exhaust. I kinda like that smell, but to each their own. (no garage, so the quad is in my basement.)

Once I figured out how the throttle assembles correctly into carb body (they should shoot whoever designed this thing) we are revving. One last problem (hopefully) before virgin ride is that the clutch is stuck on all the time, and I think I am missing a spacer piece and possibly the rollers in the variator twisted.

Once again, thanks for the sounding board and the help. Kids were already picking helmets last night but I told them not to jump the gun just yet.

 

I had an LT80 when I was 10. It was the best thing evar! I later figured out that it was an effective parenting tool. When I was bad, key to four wheeler go bye bye! Very effective.

 

Clutch issue turned out to be a re-assembly error. Turns out the old noggin is getting foggy and after looking at the IPL I found my problem.

Maiden voyage was not a 100% success, flywheel started working loose so I shut her down after a good 3 minute ride. I didn't loctite it yet but will torque to spec and put some red loctite on there.

Aside from that, needs some front brake adjustment. The good: it can pull up the front end with me on it (160#) and the top end has to be pushing 30mph. The bad: it's way too fast and strong for my 7yr old 50# daughter. Gonna have to work on that.

Once again, thank you for all the feedback. Never worked on a quad before this, now I think I could dig into most.

 

You shouldn't have to Loctite the flywheel nut to keep it tight. Make sure the crank and flywheel tapers are both clean and dry, then torque the nut to specs...that should hold it...once the flywheel is seated the nut really isn't holding much. If you do Loctite it I would go with blue rather than red...less frustrating to get off again later.
As far as the top speed, there is a throttle limiting screw on the thumb throttle housing...on the front IIRC, just run that in until it runs the speed you want then tighten the locknut down...just don't let the kids see ya do it or they will easily undo it

 

Yard work day and I snapped a fun pic of the crew at work on a brush run.

The LT80 has been lots of fun and hope it will be for a long time to come. The red one is a Razor electric deal, thing moves my 4yr old quite well, it was a freebie!!