How to Remove a Locked Up Go-Cart Clutch

The centrifugal clutch for your go-cart is an important drive train component used to transfer rotational force to the vehicle's drive axle. When the engine reaches a predetermined RPM, centrifugal force will expand the internal friction shoes of the clutch, causing the outer clutch bell and affixed gear sprocket to rotate. Replacing your go-cart's centrifugal clutch may prove necessary if the internal friction shoes become excessively worn, or after sustaining damage that results in a “lock up” condition.

Things You'll Need

• Cinder blocks or jack stands
• SAE ratchet set
• Penetrating spray lubricant
• Allen wrench set
• SAE wrench set
• Wire brush or steel wool
• Replacement clutch
• Keyway with setscrews

Instructions

1. Allow the engine and drive train components to completely cool.

2. Examine the top portion of the engine and locate the spark plug wire. Disconnect the spark plug wire from the spark plug. Be sure to disconnect the spark plug wire by the large L shaped boot to avoid damage to the wire.

3. Elevate the rear end of the go-cart, using a pair of cinder blocks or jack stands positioned underneath the rear axle housing or frame.

4. Examine the drive train components and locate the chain cover, positioned to the side of the engine. Remove the retaining bolts securing the chain cover to the vehicle.

5. Spray the large crankshaft bolt and setscrew holes around the perimeter of the clutch hub with penetrating spray lubricant. This will aid in the removal procedure if the clutch appears to be heavily corroded.

6. Remove the large bolt securing the round shaped clutch from the end of the engine's crankshaft, using an appropriately sized socket. The crankshaft bolt uses a left hand thread pattern; turn the bolt clockwise to loosen it from the crankshaft.

7. Examine the front portion of the clutch hub and remove any setscrews located around the perimeter, using an appropriate size Allen wrench.

8. Loosen the four bolts that secure the engine to the go-cart's engine mount. Use an appropriately sized wrench to hold each bolt head while turning the corresponding nut, located underneath the engine mount, using a socket and ratchet. Loosen the engine mount bolts enough to slide the engine forward or backward.

9. Slide the engine toward the rear axle to provide a sufficient amount of chain slack needed to remove the old clutch. Grasp the clutch hub and housing. Rock and rotate the clutch from side to side, while attempting to pull the clutch off the crankshaft.

10. Remove the old rectangular shaped keyway from the crankshaft. Remove any residual rust or debris from the crankshaft with the aid of a wire brush or piece of steel wool.

11. Place the chain over the gear cogs of the new clutch. Slide the clutch onto the crankshaft. Rotate the clutch hub until the clutch keyway slot lines up with the slot on the crankshaft.

12. Insert the new keyway into the square shaped keyway slots for the clutch and crankshaft. Make sure the front of the clutch hub is completely flush with the end of the crankshaft; install the setscrews into the corresponding setscrew holes located around the perimeter of the clutch hub.

13. Reinstall the crankshaft bolt and washer to the crankshaft. Make sure the chain is properly seated on the clutch and drive axle sprocket. Slide the motor towards the front of the cart to tighten the chain slack.

14. Tighten the mounting bolts after achieving the proper amount of chain slack. Rotate the rear drive axle; make additional adjustments to the chain slack if the tightness of the chain causes the gears to bind, or if the chain is in danger of popping off during normal operation.

15. Replace the chain cover and reconnect the spark plug wire. Remove the cinder blocks or jack stands from under the rear of the go-cart to finish the installation process.

References

• GoKart Supply: Tips