shift problems

[rockfishhiker]

I've got a Carbide 7150 with the gy6 internal shift engine that I picked up as a project. When the engine is not running the FNR shift works fine. Once I start the engine and put it in gear, it's hard to get it out of gear unless I tap the accelerator a few to times rev the engine and let it idle down. Is this a clutch problem or is something loose with the shift fork that I need to address?

 

[itsid]

sounds like the CVT isn't disengaging properly.

open up the belt cover and when the engine is idling see if the belt sees some tension or is trying to move the driven (rearmost) pulley

'sid

 

[Joe-405]

What he said. Or too high of a idle can cause it also.

 

[rockfishhiker]

shift

I've got the idle set pretty low. I don't see whee there is any adjustment to the CVT in my service manual other than to grease the movable drive plate which may be the problem so I'm thinking either the belt is not sliding all the way down at idle due to sticking plates or the clutch is not disengaging when the idle drops. I'll jack it up, pull the cover and see what's happening and post the prognosis. Thanks.

 

[itsid]

NEVER GREASE any of the sheaves!!
the belt must not get in contact with any type of lubricant.. EVER!

the shafts, yes, the weights inside the variator.. sure.. drylube will be welcome there... (DRYLUBE! not grease though)
sheaves, nope.. don't even think about it.. you'll need a new belt and a thorough cleansing session to fix that afterwards.

'sid

 

[Joe-405]

Post a pic of it when you get the cover off if you can. It will help also. And keep us updated.

 

[rockfishhiker]

I pulled the CVT cover and the outer clutch disk is hard to turn. Tap it with a rubber mallet a few times and it spins freely. Once I start the engine and run up to speed the clutch engages but when I let off the gas and back to idle it's still stuck. Again if I tap the cover with a mallet while it's spinning it comes to a stop and spins freely. I think the clutch springs are rusted or shot. Also when jacked up the shift mechanism seems very sloppy when shifting. Lots of clunking but I think that's due to the clutch not disengaging.

---------- Post added at 01:52 PM ---------- Previous post was at 01:38 PM ----------

Here's what happens when the back wheels are off the ground:
Engine off: Reverse-locked, I can't move the wheels, Neutral-wheels free rotate, Forward-wheels move forward or backward with some effort
Engine running: Reverse-wheels turn in reverse, Neutral-wheels don't turn, Forward-wheels run forward
Should the gears be locked up in reverse like that when engine is off and in reverse?

 

[rockfishhiker]

I pulled the driven clutch plate and the inside had lots of corrosion. Thee was no gasket on the cover and the kart was sitting unused for a long time before I bought it . The clutch springs are not retracting completely. I think that's the source of most of my problems. I ordered a replacement driven clutch assembly and will post results once it's installed.

Update: The driven clutch replacement solved all the shift problem. I still think I may have one or two teeth out of the reverse gear because it still locks up occasionally in reverse but at this point I just want to get some use out of it. The new clutch springs are definitely less powerful than the old ones. I've got to give it a lot more throttle to get it moving. I may attempt to rebuild the old clutch with a cleaning and new springs now that its off.