Gear reduction issues.

#1
Im running this gear reduction set up on a stock doodle bug after much reading about the old PMI kits that were very popular. I bought comparable parts kn BMI and assembled it. Works great to haul an adult around on a 99CC motor.
BUT the clutch engages at idle. At 1st I thought it was a worn clutch. Replaced it. Ran great for a while. Now its engaging at idle again.
Anyone else experience and solve this?
 

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#2
Have you looked into how to lubricate the bushing in your clutch? Put a couple drops of motor oil between the sprocket and the snap ring next to the engine and let us know what happens.
 
#3
Thanks Ill give that a try spark wizard!

Dave, I looked at the TAVs when I installed the gear reduction. I even bought one. At the time I couldnt find one for 1/2" crank shaft. I bought a sleeve but it didnt work with the key way.
Maybe ill have to revisit that.
 
#4
I suspect your PTO (crankshaft Power Take Off) is 5/8 and not 1/2. I may be wrong, but 1/2 inch PTO are few and far between. You might find a TAV for a 5/8 PTO, but the 5/8 to 3/4 spacers work pretty well.
@Jim Donovan is the guy to speak with about a quality Max Torque clutch.
 

Jim Donovan

Well-Known Member
#5
Scott -- I am also thinking you have a 5/8" crankshaft and not a 1/2" but YOU have to verify that for sure. Lets figure out if the china clutch is your problem. Take it apart and look at the spring. If it stays in a circular shape it is been anneal and is now worthless. That is the heart of the clutch--the spring. If it stays straight as an arrow then there is NOTHING wrong with it but if it stays arced then it has been annealed and is useless. Music wire can only take 250 degrees F while stainless steel can take 550 degrees F. We only use stainless because run away go karts are lawyers delight. The next thing you want to find out on the engine is at what rpm does it idle so then you have the correct spring in the clutch. Historically old Briggs engine idled at 1,500 to 1,600 but in 1999 they quit selling engines to the kart manufacturers and they started using Tecumseh which idled at 2,000 so now ALL clutches made by us, Comet and Noram were coming in at 2,200 to 2,300. Honda still idle low around 1,200 so you were wasting a 1,000 rpm before anything happen on the clutch if it was mounted on a Honda but since Honda was so expensive no one used them on fun karts just the rental karts had them and most of them had a built-in-wet clutch.

How often and when do you lube the bushing in the clutch? How are you lubing it?
 

Jim Donovan

Well-Known Member
#6
Dave - what draws me back to this site daily is to read about the projects people like yourself get into and build. I enjoy reading about what people do and try and bring back to life old engines and old mini-bikes and go karts. It is great to see people still tinker with stuff and figure out ways to get things to work. Modern karting doesn't have that which is why I enjoy going to the vintage races and seeing the old West Bend, McCulloch, Power Products, Homelite, come back to life and race around the track. There are some great old karts still running from the 50's, 60's and 70's.
Every September I try and head to Webster City, Iowa to see the original Doodle Bug (1st mini-bike built in 1942 for the war effort by the founder of Max-Torque--George Fields. The handle bar was a 30 caliber machine gun and the unit with gun had to way less than 90 pounds so it could be strapped to the chest of a paratrooper.
 
#8
Guys! I cant believe the detailed and educated responses I have received here. the amount of knowledge and participation in this group blows my mind. thank you all for your input. Im looking forward to getting back in the garage and putting all this new found knowledge to use taking apart that clutch.

Jim - I had never lubed the clutch bushing before spark wizard recommended it on saturday. I followed his instructions and dropped some motor oil behind the snap ring but that did not repair the issue. long weekend in Canada coming up. Im planning to remove and disassemble the clutch to see whats going on a learn them inside & Out

Thanks again - Scott
 

Jim Donovan

Well-Known Member
#10
The story of George Fields history on the first miniature scooter (original mini-bike) dates back to a newspaper article in the Cleveland News dated June 5th, 1942 with a picture of George and his wife riding on this motor scooter. That was back when newspapers were 4 cents. Great article.
 
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