Technical Info.
How do I remove the clutch unit so I can replace the Drive Belt?
Our Belt and Clutch Page, will help you with belt replacement and show you how to set up the CVT correctly.
Please Note: As with all CVT transmissions when fitting a new belt, all adjustments must be checked and may require adjustments to clutching units, otherwise it can result in premature belt failure and/or poor performance.
Does your Mammoth jump out of gear and jump back into gear as you drive?
You need a updated Main Gear Set in the transmission. We can rebuild and improve your set. You can also send us your trans and we will repair it for you.
Pricing:
You send us your gear set, we rebuild and improve your gear set. You remove and install it yourself. $100 + Shipping
Used this link, Mammoth Transmission Disassembly Photos to remove the main gear set from you transmission.
Send us your transmission we remove, rebuild your gear set and reinstall it in your transmission for you $175 + Shipping
Call 802 645 9100 or email us for assistance.
Timing Setting: 7' Before TDC
Mammoth Engine Bolt Torque Settings
Engine Manual Download taken from the Suzuki Manual
Kazuma Mammoth 800 Owners Manual Download
Mammoth Engine Disassembly Photos
On some Mammoths the temp gauge reads incorrectly, we have a repair kit for that.
Cooling System Kit
Does your cooling fan run too often?
This kit relocates cooling fan switch and adds a thermostat to cooling system which results in more constant engine temp and better cooling. Kit comes with a new and more accurate cooling fan sensor, wiring, thermostat, gasket, temp gauge recalibration kit and instructions. To purchase go to Upgrades
A important note to all current owners and new owners of Mammoths be sure to use Loctite on the bolts that attach the Brake calipers to the machine, this is a must!
4x4 Cable Adjustment on the front diff, can also be used to adjust the locking rear diff.
Jack up front end so wheels of ground. Move select lever to 4x4 note position of shifting arm on diff, now move selector to 2x4 note position again. Now disconnect cable from lever on diff, move the shifting arm on diff between the two noted position and at the same time turn a wheel by hand, the 4x4 should engage about half way between the two noted positions. If it does not engage in the middle, move the arm so that the 4x4 just starts to engage. Now remove the shifting arm from the diff by removing the circlip from the shifting shaft, be careful not to move the position. Lift off arm and reset so that it is now positioned in the middle of the two noted positions, replace circlip. Recheck engagement as noted early. You may have to do this a few times to get it right. Reconnect cable and move 4x4/2x4 lever to check operation. Finer adjustment can be done by adjusting the cable nuts.
Hard Starting and "cold blooded" issues.
Some but not all Mammoths can be "cold blooded". Below is a modification that seems to help the problem. What I have found is that two different carb models are used, one needs to have the hole in the manifold that is circled in the picture below blocked. Remove the carb from the manifold, block the hole that is circled, with a 5/16 x 1/4 set screw with sealer around it. Refit carb, check and adjust idle mixture and speed. If your Mammoth starts and runs ok when cold you do not need to do this.
Check that your coil wire is not chaffing on the distributor mount, cut open a 3-4" of 1/4 fuel line hose and clip it over the wire to protect it.
Idle Adjustment Screws on Carb
Seat Belt Installation
Do not use the hardware fitted to the seat belts, you will find the mounting hardware in the nut and bolt bag. Mount belt reel first to frame temporary this will allow you to pull out the belt from the reel. Do not remove plastic clip from belt until you have mounted the reel unit. Attach the rest of the belt attachment points as shown.
Does your Mammoth not like to start sometimes it just goes Click, Click? We have a simple fix for that.
Does your dump bed rattle and squeak drive you crazy? We have an anti rattle kit available.
Did you know that there is a design problem with the rear axle bearings that allows water to get in? We have a repair kit to solve that issue.
Go to Upgrades for info and pricing on these kits
Upgrade Kits are available online at Upgrades or call us at 802 645 9100.
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