newbie needs help with clutch

[Jay7]

Hey all i just bought this homemade kart and could really use some help setting it up. It's got a 6.5 hp 4-stroke engine, 5.3-6 tires, and what i think is a Hilliard extreme duty clutch with a 12 tooth sprocket that drives a 72 (apx) live axel. I have no experience with these things though and my big problem seems to be with the clutch. its kind of working but i think the chain is way to tight (it has practically no movement) but there seems to be no easy way to adjust it, the engine is mounted in single holes so i plan to redrill them for proper chain tension. the clutch has problems disengaging (probably not properly lubed either) and doesn't seem to completely engage, i was able to drive it a few hundred feet and the clutch was smoking. When i look at Hilliard's install instructions the clutch is actually flipped around with the sprocket on the inside but mine is on the outside...was it installed backwards?!?

 

[Jay7]

these are pictures from hilliard's install instructions...

 

[devino246]

I dont think it really matters. Mabe they had it that way because of the alignment on that specific kart.

 

[Russ2251]

the clutch is actually flipped around with the sprocket on the inside but mine is on the outside...was it installed backwards?!?

It is bi-directional.

 

[anderkart]

Yeah It looks like your chain is way too tight and binding up.
Does your rear axle roll freely with the chain this tight?

Your motor mount should have slotted holes so you can slide the engine forward/back an 1-1/2" or so and adjust your chain to have like a 1/2" or 3/4" of free play so its just tight enough to stay on, but loose enough so it rolls freely while spinning the axle.

Some models of clutches can be mounted in your choice of the drive gear inboard or outboard. Your clutch is fine mounted outboard, just make sure to lube its bushing/bearing every hour or so of riding. Your gear ratio seems like it should be fine with your rear tires.

 

[Blazkowiez]

Anderkart is correct, you will have slotted holes as chain stretches through the lifespan.

Clutches can be mounted inboard or outboard

I will say this, install a bellypan in your kart, we don't want someone's leg slipping and getting very very hurt.

 

[Kenny_McCormic]

Go buy a half link for a quick fix.

 

[Jay7]

thanks for all the suggestions. i'm going to deal with the chain thing monday but i'm pretty sure the mounts are single holes so could be a bit of a pain. as for lubing the clutch do I need to be taking the cover off, which would mean the chain as well, every time or what? and hilliard's site just says any lightweight non-synthetic oil...i'm thinking 10/40, same as i have in the engine, is there something beter?
I'll definitely be looking into fabing a bellypan (i guess thats the floor next, and some kind of chain/gear guards any suggestions for that? also planing to add rear-suspension and more roll-cage/frame enforcements.

 

[fowler]

just fab a chain guard from sheet metal or ply wood
it should be good with suspension
i see the tow ball NICE

 

[anderkart]

as for lubing the clutch do I need to be taking the cover off, which would mean the chain as well, every time or what?

Its not a bad Idea to remove your clutch once in a while for inspection but without removing the clutch: you can just drip 3 or 4 drops of any quality motor oil down into the narrow gap between your clutches drive gear and the side of your engine every hour or so of riding. (the clutches bushing is right at that very end of the clutch right under the gear) Then roll the kart back and forth a bit to slowly spin the clutch drum and let the oil work its way down into the bushing. Don't over oil or the excess will work all the way through the bushing and then sling out onto your clutch shoes and drum making the clutch slip.

 

[Jay7]

so i was able to drill new holes for the engine (there were small slots but it was already at the edge) and the chain rolls nicely now. i noticed im missing a bolt to hold the clutch on the crankshaft, anyone know the size of that? nothing i have around will fit. Unfortunately i broke the starter rope, and when i took it off to try and fix it managed to break the recoil spring

 

[Blazkowiez]

Typically its 5/16 fine thread (24) by whatever length you need it to be, with a lock washer, and a sturdy flat washer.