Can't remove Driven pulley - no cleareance, Please Help

[Murf]

I have a model 616B Manco go kart with Comet Driver and Driven pulleys. I bought new ones to replace both. It has a Subaru 169cc engine.

The problem is I cannot get the Driven pulley off the shaft because there is not enough clearance to slide it all the way off.

See pictures below:

This shows how it hits the brake mounting that is welded to the frame so I cannot move it further to get it off the shaft:
https://dl.dropboxusercontent.com/u/30125964/IMG_no_clear.jpg

This shows how far I have the shaft pulled out on the right side and this is as far as I can pull it out:
https://dl.dropboxusercontent.com/u/30125964/IMG_far_as_it_goes.jpg

This shows where the key hits the gear so I think this may be keeping me from getting the shaft to go more to the right:
https://dl.dropboxusercontent.com/u/30125964/IMG_cart_key.jpg

It's like a "catch 22". I know people change these things, but I have never seen a step by step how they get passed this issue. I'm not a mechanic, but I try to fix things that look fairly simple. I thought this was, until I hit this hitch.

Anyone know how to get this off? Any help would be greatly appreciated. Thanks.

 

[Clinton]

Holly huge pictures, Batman!!

 

[OzFab]

Step 1: Remove all the crud from the area
Step 2: Remove the nuts holding the shaft assembly
Step 3: Remove the entire jackshaft assembly
Step 4: Place the assembly in a large vice
Step 5: Remove the driven from the shaft using whatever tools necessary

 

[Murf]

Thanks. I have remove the nut that is on the end of shaft that holds the Driven pulley on. Shouldn't the Driven pulley just slide off the end of the shaft?!? I slid it up to the point it is at now, the problem is it is hitting the frame so I cannot get it any further.

I thinking I'm going to have to remove the 4 motor mounts so I can tilt the motor to the right and hopefully that will give me enough clearance to remove the pulley. In addition, the gear appears to be permanently attached to the shaft where it is at, by what/how - I don't know.

Like I said, the shaft CANNOT be remove and pulled out to the right. Something on the left (the key I think) hits the gear and will not allow the shaft to slide out to the left any further.

 

[B.M.800]

Spray some PB blaster or liquid wrench and let it sit for a while. If you use a hammer, make sure you use a piece of wood. Do not hammer directly on the TC, doing that could bend or break it.

 

[turbozetec]

When you get it off go down to the hardware store and get 2 1in keyways and get rid of the 2in one. Then when you go to install you pull the jack shaft out until just the sprocket is on then you can put the pulley on and put 1 keyway on push the Jack shaft through more and install the last keyway and your done. then when you wan to take it back off just pull the pulley over and take the 1 keyway off and then slide the jack shaft out more pull the pulley out and take the last keyway off and then your out. Your kart looks just like mine Manco vortex and thats how I do it.

 

[Doc Sprocket]

When you get it off go down to the hardware store and get 2 1in keyways and get rid of the 2in one. Then when you go to install you pull the jack shaft out until just the sprocket is on then you can put the pulley on and put 1 keyway on push the Jack shaft through more and install the last keyway and your done. then when you wan to take it back off just pull the pulley over and take the 1 keyway off and then slide the jack shaft out more pull the pulley out and take the last keyway off and then your out. Your kart looks just like mine Manco vortex and thats how I do it.

For clarification- you don't buy "keyways", you buy "key stock". The keyway is the machined slot that the key sits in. Also- you can buy key stock in long lengths (12" often) and just cut to whatever size you need.

 

[Murf]

First, I'd liked to thank all of you for attempting to help me.

Maybe I'm not explaining myself correctly. (I'm and IT guy, engine mechanics is not my thing and something I dread most in life - probably because I don't know the correct procedures for these things).

Yes it is a Manco Vortex. I don't know a "TC" is.

From what I understand, much of the advice that is given to me is what to do AFTER I get the driven pulley off. My problem is actually getting the driven pulley off. Look at the first picture. I cannot get the pulley off the shaft because it hits the frame - I cannot slide the pulley any further to the left (and the shaft any further to the right! That is the dilemma I am trying to figure out. I don't want to take a hammer and just start banging on things because I have no idea what is suppose to give and move and what is suppose to stay put.

I presume it is suppose to slide off the end of the shaft?

Also, the gear - is it suppose to slide left or right on the shaft or is it permanently fixed (by what) where it is at?

Am I correct in thinking I will have to remove the 4 motor mount bolts and tilt the engine on its side so then maybe it will give me the clearance to slide the driven pulley off the shaft?

Sorry, not trying to be a pain. I'm just not getting the advice - most is speaking as if to someone that has plenty of experience with this. Which I do not - I'm a newb.

 

[turbozetec]

Yes the gear will move, just take the 4 bolts loose and move the motor forward to losen the chane then take it off your axel gear then you should have enough play to tilt the motor.

 

[mckutzy]

A TC is a torque converter, a CVT(Continuous Variable Transmission),
Here is site that explaines some things - http://www.mfgsupply.com/gomini/gominiclutch/gominiclutchtorq.html

 

[Murf]

A TC is a torque converter, a CVT(Continuous Variable Transmission),
Here is site that explaines some things - http://www.mfgsupply.com/gomini/gominiclutch/gominiclutchtorq.html

I see. I am familiar with what a CVT is - my Nissan Cube has one. So there is one acronym I actually got!

 

[Murf]

Yes the gear will move, just take the 4 bolts loose and move the motor forward to losen the chane then take it off your axel gear then you should have enough play to tilt the motor.

Sounds like a plan. I'll give that a try when I get a chance.
Thanks!

 

[Murf]

Thanks to all for the advice. I was able to get the old Driven pulley off and the new one on by removing the 4 top motor mount bolts and tilting the motor to the right to get the needed clearance.
Thanks.