Kt196 drive belt

jp88

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So I bought my son a coleman kt196 a couple of years ago. Im good at working on cars but have never really messed with ATVs until now. I had to replace the drive belt a few days ago but today it broke again. I noticed when I took the cover off and pushed the kart forward that one pulley spun because the chain is on the other side of it. I was able to spin the clutch a couple times by hand then it just got really tight and won't spin. I'm assuming that's probably not normal? Also behind the clutch there a little bit of oil at the bottom of the where the clutch is connected to the motor. What do I do?
 

Denny

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Slow down and take some pictures. You’re upset and not making much sense. We need good views of the clutch faces too. I think you may have a dirty or frozen clutch or clutches. We can help you.
 

panchothedog

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I'm with Denny. Your driver ( the one that's on the engine ) is probably all gummed up and not disengageing all the way. It's a pretty common problem and not that difficult to fix. Let's see some pictures, and show us what's turning, and what isn't. Also, welcome to the forum.
 

jp88

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20241014_130029.jpg
 

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jp88

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The top one moved freely by hand a couple of turns but now it wont move. I didnt start the motor. I kind of think I may have put the new belt on wrong but he rode it for 2 days after so that wouldn't make sense.
 

Denny

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Clean the driver on the engine like WTR says. Replace the belt with the proper sized Comet brand belt. Yea, they’re expensive but way worth it. They will outlast any other brand by a large margin. If you used a cheap belt that would explain your problems also. Only use dry graphite to lube the clutch when you clean and rebuild it.
 

panchothedog

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Post #7 and #8 are absolutely correct. Lots of videos to show you how to service
( clean ) your 30 series torque converter driver. At present it is expanded, or closed into the high gear ratio. The center shaft part should be much wider, and will be after you service it. The inner part will contract back into the outer bell.
 

jp88

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I did notice when I look the parts up it automatically shows for a 212cc instead of a 196cc?
 

panchothedog

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I guess it might be easier, but not by much. Plus it doesn't cost a penny to service the driver and you would have to do the same to a new one eventually. The driven clutch doesn't need service anywhere nearly as much. Quality belts will help make the interval between services longer, and themselves last much longer than the cheapies.
 

JimD

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Where is the plastic oil plug on the engine? Looks to be missing in your picture and that could be a BIG problem. I think I can see threads in that hole so that would tell me it is a function hole to add the oil. But then again my wife is always asking if I am blind when looking for something in the shop that someone misplaced.
 
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