Coleman T-196. jack shaft junk

[Powersrp]

I ve replaced the jack shaft chains and sprockets a couple times, kart prob has 30 hrs on it, drivers are 8 and 10 yrold girls.. has anybody tried moving the drive sprocket over and directly under the clutch drive, this jack shaft has to go, its non adjustable and lasts about 5 hrs then starts banging from loose chain.
Any ideas would be great
Thanks

 

[Kartorbust]

Switch it out for a 30 series to avoid issues. https://www.gopowersports.com/coleman-ct200-series-torque-converter-kit/

 

[Powersrp]

theres nothing wrong with the clutch or torque converter, a chain goes from torque converter sprocket to a non adjustable jack shaft sprocket, then to another sprocket. then to drive sprocket. way too much bs, and its non adjustable.

 

[Kartorbust]

Non adjustable as in chain tension or gear ratios?

 

[Powersrp]

torque converter sprocket chain to jack shaft sprocket has no adjustment,, last about 5 hours then jumping and banging anytime throttle is applied. i wana get rid of the jackshaft and move drive sprocket directly under torque converter, i might have to have a 4” spacer made up

 

[Kartorbust]

Sounds like poor sprocket and chain alignment. Get a straight edge and verify that the sprockets are properly aligned.

 

[Powersrp]

I beleive i did, but will check in the spring, after a few hours the new chain starts banging on take off, or when the girls get back in the throttle

 

[Mrben522]

That part of the KT 196 design is notorious for failing. The chain loosens up with use and there's literally no possible way to adjust tension on it. Ditching that jackshaft is a great idea if you've got the skills and tools to get it done, you may need to do some math on the gear ratios though to make sure you don't loose too much speed or power. Good luck!

 

[mckutzy]

Lets see some pics of this problem on you bike... im not quite getting it???

 

[Mrben522]

KT196 torque converter chain tightening

I bought my kid a basically new Coleman KT196 (only 3 rides) and noticed when you give it throttle quickly, a noise and clank emitted. I suspected chain slippage and confirmed it as the chain from the torque converter to a shaft connecting the driven chain was extremely loose. This newer model...

www.diygokarts.com

KT196 cannot adjust torque converter chain and no master link

Hi all, I have a coleman kt196 and it came with a torque converter, the problem is the chain that attaches to the torque converter is loose and there is no way to adjust it. There is a way to adjust the chain that goes to the axel, but but not the chain that goes to the gear that turns that...

www.diygokarts.com

Here's a few threads of other people having this exact same problem and a few possible solutions

 

[nk49]

Having a similar issue with the chain breaking. The sprocket on the axel seems to be shifted slightly away from the drive sprocket above. Is there a way to adjust the sprocket hub on the axel left or right? I see the bolt which I presume is holding it in place. I’m not able to get to the kart to take a photo or try moving it until later in the week. Can anyone confirm it’s able to be adjusted?

 

[Denny]

As I’m not totally familiar with that kart I’m gonna need a few pictures.

 

[OneBadZL1]

I am dealing with the same issue and can't figure out how the shafts came out of alignment. Here is a picture of the jackshaft and the axle sprocket and the alignment is off by about 1/2". Just enough to cause the chain to snap. The jackshaft is welded and the axle sprocket doesn't appear to move at all either. I thought of putting a washer behind the sprocket to move it over but I can't seem to get the sprocket to separate with the bolts removed. Seems like there is a keyway blocking it and I can't figure it out.

 

[OneBadZL1]

So I figured out a solution. I took off the jackshaft sprocket and placed a washer behind it and that moved it over to align it with the axle sprocket. The kids rode for 3 hours with no issues so far!

 

[panchothedog]

Throw away the stock jack shaft CRAP and purchase the unit Kartorbust
showed you in post # 2 and your problem will be solved. It has its own jack shaft and is self contained. You bolt it to the engine and that is all. You open
a thread asking for help and you get advice from experienced builders, my self included. Do you want to fix your kids kart, or do you want to argue with people trying to help you.

 

[OneBadZL1]

I hope that reply wasn't directed at me. I just had the same issue and posted up my solution that didn't cost another $200 and is working just fine.

 

[madprofessor]

No chain tensioner for the secondary chain? I couldn't buy one for my rig either, because they don't make them for one-of-a-kind rigs.
I just imagine what I would have if I could have anything I want. Then I find a way to build it. Here's a good example of that, a chain tensioner for my very long secondary chain, and one for the chain-drive steering setup.....................

 

[panchothedog]

OneBadZL1. My comment was for the original OP in post # one. That is why I mentioned the advice given in post # 2. Very happy to hear that you have got your kart running. The whole purpose of post # 2 and my remarks is to inform
Powersrp who asked for help is that it is not necessary to run a two chain
set up when running a torque converter. In fact it is quite beneficial not to run
two chains as far as eliminating complexity and potential problems. The easiest way to do this is by using a unit like that illustrated in post # 2. They are self contained, VERY reliable, and hardly ever need adjusting. They are also available from many sources for about $65 to $75. Installing it on the kart would eliminate the PARTS that seem to be giving owners of this vehicle so much trouble.

 

[theonehossshay]

Had the same issue of non-adjustable 1st chain slipping. Cut off the upper shaft, welded it to a hinged plate with a tensioner similar to the existing tensioner for the 2nd chain. Before and after photos attached.

 

[Denny]

All you should have to do is shim the upper shaft it looks like to tighten the upper chain.