My son was riding his 'Zuki 80 when the rear wheels suddenly locked up, and skidded to a stop. The rear axle can spin with the slight slack of the chain, so that's not it. The drive sprocket is locked tight. The engine runs fine. Any ideas as I prepare for repair. Clutch melted down, a thrown belt jammed in there, bearings fried or what??? Just looking for ideas on what to expect. Any personal experiences?

Thanks

 

Welcome to the ATV Connection forums. [img]i/expressions/face-icon-small-smile.gif[/img]
As you expect, removing the clutch cover will tell alot. I've not seen a broke belt but surely it could happen.
It's rare but it sounds like a gear may have broke in the gearbox. If so, I should have a tranny or 2 laying around.
FYI: to make clutch cover removal easy, cut the footpegs in 1/2 (under the motor and be careful not to cut the starter wire). This allows the left footpeg to come off and out of the way. For installation, you put a piece of aluminum/steel/etc where you cut to join them back together.

 

Once the cover is off, what do I look for? While I'm pretty handy, and have the tools, I have no experience with the internals of the 80. Is it something I can do, or do I need a degree from MIT [img]i/expressions/face-icon-small-smile.gif[/img] (which I don't have!). Any recommended disassembly procedure? Tricks of the trade?

Thanks for your response.

Charlie

 

Anybody got ideas? Going to start the disassembly this weekend.

 

Once the cover is off, Give it a look. Then you will need a impact wrench to remove the front and rear clutchs.
Front: remove,clean,and check the rollers for flat spots. If flat spots are present, you will need new rollers.
Rear:Check the bearings (stick your finger in the bearing and turn. If it isn't smooth, the bearing (s) need replaced. Sand the contact pads lightly to remove the glaze.
Gearbox: try to turn the rear shaft. If it does not turn, there is a gear problem.
FYI: when taking the clutch cover off, you have to take the bolt off at the 3 O'clock position on the lil cover.