I just bought my son a Falcon 90 and the manual (which is obviously wrong in regards to the oil drain plug) says to replace the engine oil and differential oil prior to use. I opened what I thought was the plug to drain the differential and a spring came out and I did drain a small amount of gear oil. I tried to put some gear oil in the hole in the top of the gear housing and it just drained out the bottome of the gear housing. I 'm afraid to run the quad with out putting more gear oil in. Can some one tell me where to put the gear oil.

 

nexnbaxx,

The plug you pulled was for the timing chain tensioner. You need the bigger plug on the bottom right for the opil drain plug. There is no gearbox oil. The tranny is oiled by the engine oil. No need to change anything else. The plug that you tried to fill on the left side is for the stator. This is not a fill and should not have any fluid in it. The oil fill is on the right side twards the back of the motor. Use 15w40 oil when you change it. It will only take about 1/2 quart. Also you need to locktite anything you can get your hands on. These can be reliable quads but if you dont locktite it will fall apart.

 

That really helps explain alot. Thanks very much for the info.

 

Anytime.

 

Hi Guys I did the same thing with my sons Mini 90 by taking out the wrong drain plug thanks to the manual.
could I have damaged anything by letting that spring almost come out? I lost alot oil and a rod came down above the spring. I just put everything back in and drained the oil from the correct spot and put about a 1/2 quart back in.
But ever since my son has been riding this quad which is only maybe 2 hours it has never idled great. I have followed the manual over and over trying to adjust the carb. But this thing will only run cold with the choke full on when it warms up of course it bogs down. I have two suzuki quads and have never come across this kind of problem.
I bought this from almostfreeatv and have had no luck with service. I really could use help I would like my son to enjoy riding right now he is very discouraged and my only excuse not buying another suzuki is price.

 

Hey Kazumadad,

The same thing happened to me. The spring and rod came out and I just pushed them back in. The quad has been running fine. One thing I wanted to bring to your attention. Last week, my son had been riding the quad for about half hour and got tired, So my wife took it for a spin, about 1 minute after she got on, the throttle stuck wide open and was uncontrollable. Turns out that there is a screw on cap on top of the carburator that came loose. Thank god my son wasn't on when it came off. So now I check that cap evertime he rides it. I have some friends who ride alot, told me that they have heard that happens quite a bit with these Kazuma's. As far as the idle issue, I havnt had any problems yet. Maybe someone else will have the answers. Don't forget to check that cap, serious accident waiting to happen.

 

Thanks I did know about the carb cap it was actually in the manual and a friend of mine actually had that happen to his son bad news he hurt his wrist a little bit and now is afraid to ride.