Can anyone help, Or heard of SONIK ?

[damobear]

that big belt in the pics above doesnt move easy i am sure

 

[damobear]

sure this engine bit has droped

and is this thing the clutch ?

 

[damobear]

poss where the ATF goes

few more pics

 

[toofarnorth]

That filler is where you put engine oil, your Cart doesn't use atf. Yes that pulley is the clutch, Your cart has a constant velocity transmission, they call it a variator, witch means as the engine is running the belt should always be turning as engine rpm increase centrifugal force causes the clutch in the secondary pulley to engage,power is then transmitted to your gearbox then to the chain then to your wheels. As rpm goes up the pulley attached to your engine squeezes together on the belt making the belt effectively ride on a larger diameter pulley, at the same time it pulls the secondary pulley apart to shrink the diameter that the belt rides in, these two working together give you a variable ratio automatic transmission. If the outer part of clutch won't budge then that means the bearings are seized or the gearbox is broken.

 

[damobear]

when u say outta part ? do u mean that big hub looking bit ? that spins but it seams as if its the part with the belt that moves out towards the hub type thing then makes a nasty noise, after my dinner irll try and film excatley what happens so u can see

 

[damobear]

gonna try and film what is going on now, be great if you can give me some idea of what to do next, am thinking prob gonna be gear box out right ?

 

[damobear]

film

take a look here....

http://www.youtube.com/watch?v=hwApdiiM8MQ

 

[toofarnorth]

Ok I didn't realize that the secondary pulley has a some sort of gear reduction unit behind it. The gear reduction is likely the problem, I think you'll have to take it apart....

I don't want to get your hopes up but I have a thought, one thing you might look into is that engine is used in scooters and atvs so that gear reduction might have a neutral and reverse position that doesn't get used on your buggy because you already have a reverse gear in that gearbox, if that is the case then it's possible that gear reduction has worked its way into neutral. That stud that sticks out of the gear reduction unit on the same side as the output shaft might be a forward/reverse actuator, try twisting, pulling, or pushing on it, you never know you might get lucky.

 

[damobear]

lol what bit sorry ? could u do me one of your class easy to follow instruction thingys when u get chance mate lol, Hope what ur saying is right but to be honest from the day i got the thing what i wanted to fix was the noise and kick it gave when changed gear, the chain etc all happened on the way to the garage lol and everyone thought that once the chain etc was on it would prob have sorted itself out, just no monkey could get the chain even on lol, so i am more than gratefull for all ur help as i feel we have over come quite a few bits and bobs, it just seams as soon as i sort sumin, another thing dies on me lol, dont get why, as it is a 2007 model and only done 300 miles, i just think the kiddy who had it b4 proper didnt care and just treated it like **** really. Been told its the same engine frame etc as the blade xt250 so maybe as i cant find much on parts for my sonik, i maybe able to look up this blade thing also

 

[toofarnorth]

If you take some better pics of the reduction unit I might be able to give you some ideas of how to open it up, you might have to take off the clutch/driven pulley to get at the gears.

 

[damobear]

few more pics mate

hope this helps u help me lol

 

[toofarnorth]

It looks like that reduction unit is forward only no reverse or neutral so no luck there. I'd say you have a pretty good start on taking it apart to see whats broke. You'll probably have to take the clutch/pulley off in order to get at the bolts that hold that part together. You might look into getting a generic/universal 250cc scooter repair manual because I think chinese scooters us that same engine. A scooter shop should be able to get any parts for that engine including the broken bits in the reduction unit.

Good luck!

 

[damobear]

Mate cant get that nut off NO way No how, just cant find anything to hold the drum still so just keeps spining, HELP lol .........................

 

[toofarnorth]

Run a ratchet strap around the drum and tighten it down then run the rest of the strap to something solid on the cart that should keep the drum from spinning, also try hitting your wrench with a hammer in the direction that you want it to turn, it makes kind of a poor mans impact wrench. Or you could use an actual impact wrench lol. That nut might be reverse threads, if any threads stick out you should be able look at them and tell what way the nut needs to go.

 

[damobear]

ive worked out what way it needs to turn so thats good, yea i have an impact wrench, and air tools but still cant hold the drum bit steady, its a bloody nightmare, irll look into the strap idea as that sounds as if it may work, irll find out where i can get one of them strap thingys from,

 

[toofarnorth]

A belt (like the kind you wear) would also work just wind it on the drum so it gets tighter as you try too turn the drum in the direction that will loosen the nut.

 

[damobear]

okey dokey will ry first thing in the morning thanks, pretty sure my prob is in the transfer box thing behind

 

[damobear]

grears in transfer box thingy by clutch

Sorted, got it off, think the bits that are mashed are called the Gear Idle Tranfer and the final drive, Does that make sense ? irll get a pic 4 ya, but there is a huge chunk missing, what could have caused this ? is it sumin eles i need to look into or is it just pony chink parts ? and where wud i get new ones of these ?

 

[toofarnorth]

I think your engine is a copy of a Honda 250cc scooter engine I'd take them down to a honda shop and see if they can match them up for you. If you don't have a local honda shop you could try online, just make sure any parts you order have the exact same measurements and spline/teeth counts. Did the gearbox those came out of have lube in it? You should also inspect the bearings in there because bad bearings will cause chipped teeth like that.

 

[damobear]

cable

got the bits and all sorted now i hope, gonna take her 4 a spin in a sec, just one other thing got the handbrake cable but its 2 long, is there anyway i can adjust the thing, its only about an inch too long any clues ? (the actual cable not the sleave )