Archive for the 'Mammoth 800 Info' Category

Dec 03 2008

Kazuma Mammoth 800 How To: Snorkel Kit

Published by admin under Mammoth 800 Info

New item on the drawing board for the Mammoth 800.  Air Intake Snorkel Kit.  A cool hop up that pipes fresh  air into the Mammoth air breather.  Will prolong the life of the engine by streaming fresh filtered air from outside the engine compartment.  In dusty conditions dust swirls behind the Mammoth’s air stream filling the rear of the machine including the engine compartment.  Engine also performs better with clean cool air piped in.  Pictures and more info to follow……stay tuned.

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Nov 19 2008

Turbo Charged Kazuma Mammoth 800 Engine

Published by admin under Mammoth 800 Info, Mammoth 800 Pix

Turbo Charged Kazuma Mammoth 800 Engine

Yes, that is a 800cc Mammoth Engine all tricked out!  Several off-road vehicle companies are using the same 800cc engine in some of their toys.  Our friend Greg at Henderson Brothers Racing owns this buggy.  He manufacturers and sells the 800cc turbo charger kit that is very popular in the dunes.  Greg has earned the reputation as being the high-performance guru for the 800cc engine.  The very same engine that is in the Kazuma Mammoth 800.   Yes, we have traded some parts and everything used in the buggy engines is the same as used in the Mammoth 800 powerplant.  Greg says the bottom end of this engine is rock solid and that he spins his buggy up to highrpms all day long in the sand.  Hey Greg, where is our turbo kit for the Mammoth?

Rumor is that a 800cc turboed is a wicked ride.

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Nov 18 2008

Kazuma Mammoth 800 Information - CVT Belts

Published by admin under Mammoth 800 Info

Sooner or later you will need one.  It’s the nature of the beast.  All the big names use the popular CVT style of transmission which includes a drive belt.  The earliest roots I can trace to this kind of design goes back to Honda’s scooters and the Honda Odysee and the snowmobiles.  If anyone knows different,  please use the contact page to correct me.

A fellow Kazuma Mammoth 800 Owner asked for assistance with transmission diagnosis.  He explained that his Mammoth would jerk and jump while driving across a bumpy field.

Anyway, the Mammoth transmission and CVT drive system has proven to be just as reliable as all the other big names in the sideXside world.  I had a complete Mammoth transmission on the shelf for over a year before finally selling it a few weeks ago.  Found out that the tranny was destined to be dropped into some kind of test experimental machine and not a Mammoth.  I do not think I will restock a tranny because of the obvious bullet proof design.   The name of the machine that needed a tranny redesign was learned and I was not surprised.  Apparently their transmissions are not holding up.

Eventually you will find yourself crossways over a log, drop a wheel in a hole or some other kind of off-road predicament and you will “smoke the belt”.  The Mammoth engine is known for its tremendous low end torque at the crank shaft.  You feed her some gas and that crankshaft is going to spin that clutch up front one way or another.  Heat is the destroyer of CVT belts.  Low quality belts will shred and turn to fuzz with lots of little fuzzy strings everywhere.  Higher quality belts will get a burnt spot and you will notice a performance decrease especially under load.  The higher quality belts, even with burnt spots will usually get you out of the boondocks and back near civilization where a belt change can be performed.

Familiarize yourself with the belt change procedure and how to remove the belt cover and inspect and clean your front clutch.  Sticky front clutches can be prevented by a simple cleaning and inspection.  A belt change can be performed in the field with minor hand tools and a rubber mallet.  Keep a spare belt on hand at all times.  If you do not have the mechanical know how to perform the belt change or inspection,  then pay a shop to do it.  Normal price for belt change in our area is 75 bucks and that includes a new high quality Parts-Unlimited belt.

After chasing elk, whitetails, coon dogs, rabbit dogs, ducks, wid hogs, javelinas and other off-road escapades for over 40 years, I can vividly remember rescuing my buddies from stuck jeeps, broken down ATVs, out of gas vehicles or other backwoods mishaps.  Your Mammoth is too big a machine to have it 5 miles off the beaten path needing a belt change because you did not service it or replace the original belt with a high quality one.

My duck hunting buddy that needed diagnosis of his Mammoth transmission - , He was running a heavy duty clutch kit with a high quality belt.  We found a burnt spot in the belt and of course the belt is thinner and charcoaled in that spot and would drop down in the rear clutch as it went round and round.   I called him and told him.  He responded ” Oh yeah, I started the Mammoth one day with the choke and fast idle on while it was in gear with the emergency brake on.”  And I thought yes, that will definitely charcoal a big hunk of your belt in one spot.  We replaced his high quality burn spot belt with this one for $28.95 and he is planning to leave soon for his goose hunting spot in Arkansas.  He uses his Mammoth to haul loads of goose decoys across muddy fields and is running ITP Mud-Lites at 27″.  He has made a custom top for his Mammoth which consists of a big wooden box u-clamped to top of roll bar and carries decoys in the top box and the back bed.

Again, when you arrow that huge Mulie deep in the mesquite, sand, rocks and washes, you will remember this Mammoth Tips and Tricks Article and be wishing you would have done a little belt maintenance before you hauled your Mammoth hours down the road to go on that hunting trip and needing it to drag home ole mossyracks and the meat.

I told you so! Carry a spare belt.  The Polaris Dealers I know, include a spare belt as part of the onboard tool kit when purchasing a new Ranger or Razr.

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Nov 12 2008

Kazuma Factory Gets Tough!

Published by admin under Mammoth 800 Info

For immediate release: 

It’s about time Kazuma drops the hatchet on the kitchen-table internet dealers and so called “repair / support” shops. The days are gone when you can secure any kind of PowerSports Dealerships without the capital (funds) to back you up.

A friend of mine just secured a Polaris Dealership. The paperwork was horrendous and you don’t get anywhere unless you order and pay for over $30,000 in opening PARTS INVENTORY along with the big bucks for the Polaris ATV and UTV inventory.

Here is one to ponder—if you are a small engine repair shop and decide that you want to work on Honda ATVs or Yamaha? So you call Honda up and say you are a dealer-shop, and you want discounts on Honda Original Equipment Parts. You think Honda Headquarters or Yamaha Headquarters will sell you discount repair parts?

Why are some of the former Kazuma Dealers crying foul-ball or worse? Because they do not support Kazuma by stocking or selling their ATVs, Dirt Bikes, UTVs and some do not even have a key switch on the shelf. Kazuma has finally lowered the BOOM on them. YES!

Honda, Yamaha, Kawasaki, Suzuki, Polaris, Arctic Cat ALL do not offer discount replacement parts to repair shops. Only the authorized franchise dealers that committed huge amounts of time and money for inventory and franchise fees get any kind of parts discounts. They are the ones in the business to serve the customers needs for the long haul. The way it should be!

Why should the Kazuma Factory operate in a different manner from the big 6?

HATS OFF to Kazuma for finally getting tough on dealer wannabes! It’s been long. long overdue.

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Nov 07 2008

Kazuma ATV Reviews

Published by admin under Mammoth 800 Info

New article found on Kazuma ATV Reviews.  Makes good reading if researching the Kazuma Mammoth 800 also.  Here is the links: Kazuma ATV Reviews and there is another link here Kazuma ATV Reviews PDF File 

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Jun 02 2008

Kazuma Mammoth Information Board

Published by admin under Mammoth 800 Info

The Kazuma Mammoth 800 order list is growing as Kazuma Factory scrambles to meet production. Worldwide demand is soaring as Mammoth Factory orders stream in from Australia, Africa and more.
The United States sales of Kazuma Mammoth 800s sky-rockets as powersports enthusiasts buy them as soon as they are unloaded from incoming shipping containers. Calls and emails are received everyday requesting applications for becoming a new Kazuma Dealer. More new Kazuma Dealers are being signed up and this is great to get this popular Mammoth of a machine distributed and available in more areas for test drives and tire kicking but these newly signed up Kazuma dealers can be a big problem for end users and Kazuma Support. Inexperienced new dealers do not have the customer service skills or resources (money) to handle warranty claims or technical support. This lack of dealer customer service experience and resources results in end users being pushed off on Kazuma Support or the end user is caught in the middle as a new dealer learns the ropes in dealing with the Chinese ATV Industry.

To obtain the best consumer experience when shopping the Chinese ATV or UTV Market, find out how long the dealer has been selling Kazuma products or Chinese products in general. The smart consumer will avoid the newly signed Dealers. Let someone else survive the learning curve time period that all newly signed dealers go through.

Many newly signed dealers fail to stock replacement or warranty parts relying on the factory to handle this difficult issue resulting in misundertandings and more. Savvy consumers will avoid this and take the time to located an established stocking parts dealer before purchasing that new unit.

Negative articles or postings are usually initiated by angry inexperienced dealers because of a warranty claim being partially or completely denied. You may contact us for any questions or concerns. Send us a message by using our contact page.

Recommended Kazuma Parts Source is

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May 15 2008

How To Fix Engine Miss in Kazuma Mammoth 800

Published by highrpmracer under Mammoth 800 Info

Does your Mammoth 800 sputter, try to start and just dies out again. We check for fuel problem first, and will hand feed the carb with either starting fluid or cup of gas. If it still runs bad and won’t take the hand feeding of fuel, then it is time to blame the electrical system. Do you have 12 volts at the coil? If it won’t run at all, probably should check voltage or test light probe first at the coil or even pull the coil wire from the distributor cap and place against engine to watch for spark while you crank the engine. Anyway, we have found that the little CDI or electronic ignition control inside of the distributor will die completely and there will be NO spark or the little devil will drop spark to 1 cylinder and cause very rough running if it will run at all. Replace the ignition module or distributor and presto—my mammoth runs again. For no voltage issues at the coil—usually bad ignition switch. We have seen them crank up and run until you let off the key and the engine dies immediately—-this is bad key switch.

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May 15 2008

How To Fix Over Heating Kazuma Mammoth 800

Published by highrpmracer under Mammoth 800 Info

I started to write this Kazuma Mammoth 800 over heating fix or solution many weeks ago. I have been taking technical support requests for over 5 years on some if not all of the Kazuma ATV products. I have probably fielded or answered over 500 calls or emails on the issue of Kazuma water-cooled engines over heating (the Kazuma gator or dingo 250s water cooled). Here is what I have learned over the years:

  1. Never rely on a gauge that does not have actual temperature readings. I mean NEVER.
  2. Replace or ADD another known good quality temperature gauge.
  3. Once you do the above two items—no more over heating issues!
  4. My Kazuma Mammoth has a dash-mounted digital readout computerized gauge cluster with temp sensor installed in the top radiator hose.
  5. The top radiator hose is hot coolant water being returned straight from the engine and into the radiator for cooling.
  6. My digital read outs are at 175 degrees when fan comes on and fan off at 165 degrees exactly.
  7. I have hit 190 maximum temperature at WOT pulling 1/2 mile steep hill loaded bed 500lbs.
  8. My computerized gauge stores the maximum values—push a button to see what highest temp, speed or RPM ever hit.

In closing—the myths surrounding adding a thermostat. Save your time, effort and money unless you just need to sleep better knowing your Mammoth 800 has a thermostat installed by you. I do not understand why someone wants to increase the temperature of their engine by installing a 190 thermostat and messing with the fan settings etc. If mine is fan on at 175 and fan off at 165 and engine temp never climbs above 190 degrees then, why mess with something that is NOT broke and NOT over heating. Buy a good quality temperature gauge instead. The farmers I grew up with were removing thermostats all the time when I was a kid and not installing thermostats???

The other myth that an engine will overheat because the coolant is not staying in the engine long enough because there is no thermostat installed to restrict coolant flow—–On paper or discussion that theory sounds good. But, its just a theory—show me the proof. Send me those test results.

One last thing, when I asked the owners of the Kazuma Gator 250s or the Dingo 250s about how they knew their water-cooled ATV was overheating they stated: “Because it burns my leg when I ride while wearing shorts and riding in the sand”. I told those ATV owners about #1 and #2 above and I never heard back from them.

A few Mammoth owners have called with the same. I just love asking , “How do you know its overheating or what temperature does the engine go to?”. They answer—”the fan runs and the needle is close or in the red”. AND again I tell them about #1 and #2 above and have never heard from them again. I guess that fixed their Mammoth over heating issues???

MORE–There is a resistor wire fix that plugs into your temperature gauge harness that will move your needle back into the normal operating range.  Use our contact page for more info.

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Apr 08 2008

I got your back, actually your belt.

Published by admin under Mammoth 800 Info

I was doing some networking recently (exchanging ideas with another high volume mammoth dealer). The subject of belts arose. He picked my brain, testing me to see what I knew that he didn’t yet. So, I gave it right back to him and picked his brain. I kinda owed him some of my kewl mammoth tricks because of a few favors he had thrown my way lately. Anyway, I gained some technical data on some belts and stuff. So I ordered up some new belts for testing in my research and development mammoth shop. Bottom Line - I came away with a high quality replacement belt for the stock clutch set up. I had been concentrating on the HD clutch kits lately and have that pretty well covered for now. Not everyone is going to buy or install a HD clutch and therefore a great need is going to arise for a high quality replacement CVT belt. After 5 months, I have found it. The belt is a double cog style with the aramid core. You would not believe what ATV this belt actually is intended for. Anyway, I gained quite a bit of satisfaction knowing that I got your belt covered. Eventually you will need one. It’s the nature of the beast. Go ask any new Polaris Razr owner what spare parts he has on hand for his new 12K ride. Will the rain ever quit here? Expecting another 4-5 inches possible. I swear the Shawnee National Forest is about to become the Shawnee National RAIN Forest!

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Mar 26 2008

MotorHeads 4 Ever

Published by admin under Mammoth 800 Info

A fellow Mammoth 800 owner recently asked about “Service Advice”. I took a day to reflect on my years of messing with all kinds of different engines. I get really irked or pissed when someone brings a machine to the shop whether its an ATV or whatever and the oil is black and nasty. One of my phobias-I pull dipsticks first off and inspect the oil condition on the stick. I spent years in the remanufactured engine business. My father travelled the country calling on several very large accounts such as NAPA, American Parts, and many more large auto parts corporations and he was handling their remanufactured engine line-ups. I grew up with a man that changed his oil quite regularly. My roots can be traced to a Studebaker Dealership located in East St Louis in 1926.

East St Louis 1926

My DNA has been programmed to change oil in engines. Therefore, most important step with any engine is giving it some clean, high quality engine oil to spin that crank in, bathe those cylinder walls in and protect those cam lobes when under load and HighRPMs.

My Mammoth is parked about 4 feet from the utility room door which contains the wood stove. Firewood is in the back of the Mammoth and I am feeding a fire to keep my toes warm tonight. I just changed the oil this past Sunday while banging around in my shop. I used 3 quarts of Valvoline SYNpower Full Synthetic 20w50 and a fresh K&N Gold Oil Filter. I like the K&N because of the large nut welded on the end of the filter that I can actually put a box-end wrench on it. I greased the u-joints and fittings also. I checked my air filter for signs of any dust leaking past the air-filter. I also changed my fuel filter. The kewl fuel filter to use on the Mammoth is one from the Suzuki Samurai, 86 model. If you have a new machine, I would recommend that you change the front diff, rear diff, and gear box oil. I use Bel-Ray Gear-Saver 80w90. It is red colored gear oil and when it no longer looks red, I will change it again. I inspected my CV boots on the front axles. My original boots are “purrfect”. Everybody said I would be changing them………….mine have been through swamps, brush piles, rock climbs, sand dunes and more. Not a hole or split to be found in those rubber spinning protective boots. My last recommendation is to remove the belt covers and inspect the belt and spray some “Brake-Kleen” on the primary clutch to clean it. Kazuma Factory assembles the primary with grease on the threads which can heat up, get sticky and cause performance problems. I removed a primary and secondary today to install a HD clutch kit for a customer, you need NO special tools to remove both clutches. My special tool is a rubber mallet or hammer. I need to make a video of this for ya’all. If you can’t service or clean the clutch (it is very simple actually), then have some one qualified to service your clutch BEFORE an important hunting trip or a ride deep into the wilderness. Another tip—–get a spare tire and wheel to carry with you and someway to jack-er up and change that flat when deep in the wilderness gumbo chasing wild hogs or wild coon-dogs. My Mamoth has an onboard air-compressor mounted under the hood. The kind you can plug into the power port. I did change my spark plugs to high quality NGKs also. I ride pretty wide open most of the time. Them old Studebakers were pretty fast weren’t they??
My favorite riding spot is under 8 feet of river flood water from the recent record rains in my area. I can’t wait to go muddin when the water recedes—-My Mammoth will be ready to go. Ride safe and have fun!

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