Rear End Clunk When Starting Off

9dawgs · 12-12-2011, 08:59 AM

Hey Guys, I have a 1996 GXT 804 with the 295cc Robin's engine and stock rear end. It has a 4" Jakes lift and off road tires but other than that it's completely stock. It's started to develop a clunk in the rear end that's concerning me. It seems to slip for a second before actually engaging when I press on the gas in forward. Is there anything I need to be looking at to maybe tighten up. I just changed the 30w oil in the rearend but it was doing this before that oil change.

I'm new to this so a reply with maybe some pictures pointing at what I need to check would be awesome. Any help would be appreciated. Thanks in advance.

pnshvl68 · 12-12-2011, 11:12 AM

Take the drive belt off, then grab the rear clutch and see if the two halfs turn easily. It should be spring loaded and only turn one way. If it's not, the rear clutch is the problem and needs to be rebuilt.

9dawgs · 12-12-2011, 07:17 PM

Quote:

Originally Posted by pnshvl68

Take the drive belt off, then grab the rear clutch and see if the two halfs turn easily. It should be spring loaded and only turn one way. If it's not, the rear clutch is the problem and needs to be rebuilt.

Thanks I'll check it out. Is rebuilding the rear clutch a pain? If not is there somewhere I can get a rebuild kit? I was a helicopter mech in the service and do my own work on my other vehicles so I have the mechanical ability to turn wrenches. Just wondering if I'll need special tools to do this if it's bad. Also if you have some pictures it would be great :>)

pnshvl68 · 12-13-2011, 08:57 AM

Its accually kinda simple. Take the 1/2 head bolt out of the center of the clutch and remove clutch. Then with 2 people(i can do it by myself) press down on the cam and remove the snap ring around the splined center shaft. Be careful the cam is spring loaded and will shoot up in your face hence the 2 person deal. 1 holding down 1 removing the snap ring. Then determine the damage once you remove the cam. Usually you can get away with replacing the ramp buttons. But if the cam is messed up then that has to be replaced also. Its easy for me, I have an ez-go dealership here in town, so I can get the parts. After the new buttons are in put back together. I usually put the spring in the (2) of the 3 holes. You will see what I mean when you get it appart. Then push the cam on, not all the way yet. Just get it started. Then rotate one side of clutch counterclockwise about 180 degrees, and finish pushing the cam doun. Sometimes a hammer is your best friend at this piont. Put the snapring back on and let go of the clutch. Should load up with pretty good tension. After that pretty self explanitory. Sorry I Have no pics.... just knowledge. Maybe someone will chime in with pics for you... good luck.

9dawgs · 12-13-2011, 03:52 PM

Sounds good. I'll check it out when I get home and post my progress. Thanks again for the help.

blake80 · 12-13-2011, 04:42 PM

you can also send the clutch to tom at cpp (site sponsor) and he can rebuild it and machine it. he is very fair with his pricing on the work. i sent mine to him last year to have it done. i wasnt able to turn it since it was so worn out, but he did replace the ramps and spring for me. i had my clutch back in 2 days after shipping it to him.
just something to think about.

9dawgs · 12-14-2011, 07:49 AM

Hey guys, how easy should that cam be to press down? I tried last night to get the snap ring off but it was binding so the pliers would just slip right off the ring before it was wide enough to come off the spline. Should I give it a twist or something? If so which way, clockwise or counterclockwise?

9dawgs · 12-14-2011, 09:32 AM

Ok, I got the snap ring off by using a large c-clamp and compressing the cam. This is what I found. Obviously the ramp buttons need to be replaced but the ramps on the cam are scored as well. Can I just grind these flat or does it need replacing all together? Sorry about the quality of the pictures...

pnshvl68 · 12-14-2011, 10:27 AM

I've taken a file to the lobes and cleaned it up a bit. You will notice that they are not flat. There is a bit of a twist to it. When you get it all back together after the load is put on it and snap ring on... it shouldn't loose its load. If it spins completly around and doesn't stop on the ramp buttons, then the cam needs to be replaced.

9dawgs · 12-14-2011, 11:52 AM

Yeah, it just looks like it needs dressing a bit. I'll give it a shot anyhow. I'm picking up the new ramp buttons today and probably put it all back together tomorrow after work. I'll let you know how it turns out :>) Thanks again for all the help.

12-12-2011, 08:59 AM	#1
9dawgs Not Yet Wild Join Date: Jan 2011 Location: Gulf Coast of Florida Posts: 47	Rear End Clunk When Starting Off Hey Guys, I have a 1996 GXT 804 with the 295cc Robin's engine and stock rear end. It has a 4" Jakes lift and off road tires but other than that it's completely stock. It's started to develop a clunk in the rear end that's concerning me. It seems to slip for a second before actually engaging when I press on the gas in forward. Is there anything I need to be looking at to maybe tighten up. I just changed the 30w oil in the rearend but it was doing this before that oil change. I'm new to this so a reply with maybe some pictures pointing at what I need to check would be awesome. Any help would be appreciated. Thanks in advance.

12-12-2011, 11:12 AM	#2
pnshvl68 Not Yet Wild Join Date: Jun 2011 Location: Lake Havasu City, Az. Posts: 56	Re: Rear End Clunk When Starting Off Take the drive belt off, then grab the rear clutch and see if the two halfs turn easily. It should be spring loaded and only turn one way. If it's not, the rear clutch is the problem and needs to be rebuilt.

12-13-2011, 08:57 AM	#4
pnshvl68 Not Yet Wild Join Date: Jun 2011 Location: Lake Havasu City, Az. Posts: 56	Re: Rear End Clunk When Starting Off Its accually kinda simple. Take the 1/2 head bolt out of the center of the clutch and remove clutch. Then with 2 people(i can do it by myself) press down on the cam and remove the snap ring around the splined center shaft. Be careful the cam is spring loaded and will shoot up in your face hence the 2 person deal. 1 holding down 1 removing the snap ring. Then determine the damage once you remove the cam. Usually you can get away with replacing the ramp buttons. But if the cam is messed up then that has to be replaced also. Its easy for me, I have an ez-go dealership here in town, so I can get the parts. After the new buttons are in put back together. I usually put the spring in the (2) of the 3 holes. You will see what I mean when you get it appart. Then push the cam on, not all the way yet. Just get it started. Then rotate one side of clutch counterclockwise about 180 degrees, and finish pushing the cam doun. Sometimes a hammer is your best friend at this piont. Put the snapring back on and let go of the clutch. Should load up with pretty good tension. After that pretty self explanitory. Sorry I Have no pics.... just knowledge. Maybe someone will chime in with pics for you... good luck.

12-13-2011, 03:52 PM	#5
9dawgs Not Yet Wild Join Date: Jan 2011 Location: Gulf Coast of Florida Posts: 47	Re: Rear End Clunk When Starting Off Sounds good. I'll check it out when I get home and post my progress. Thanks again for the help.

12-13-2011, 04:42 PM	#6
blake80 REAL MEN GET EM DIRTY Join Date: Jun 2009 Location: rincon , ga. Posts: 3,646	Re: Rear End Clunk When Starting Off you can also send the clutch to tom at cpp (site sponsor) and he can rebuild it and machine it. he is very fair with his pricing on the work. i sent mine to him last year to have it done. i wasnt able to turn it since it was so worn out, but he did replace the ramps and spring for me. i had my clutch back in 2 days after shipping it to him. just something to think about.

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12-14-2011, 07:49 AM	#7
9dawgs Not Yet Wild Join Date: Jan 2011 Location: Gulf Coast of Florida Posts: 47	Re: Rear End Clunk When Starting Off Hey guys, how easy should that cam be to press down? I tried last night to get the snap ring off but it was binding so the pliers would just slip right off the ring before it was wide enough to come off the spline. Should I give it a twist or something? If so which way, clockwise or counterclockwise?

12-14-2011, 10:27 AM	#9
pnshvl68 Not Yet Wild Join Date: Jun 2011 Location: Lake Havasu City, Az. Posts: 56	Re: Rear End Clunk When Starting Off I've taken a file to the lobes and cleaned it up a bit. You will notice that they are not flat. There is a bit of a twist to it. When you get it all back together after the load is put on it and snap ring on... it shouldn't loose its load. If it spins completly around and doesn't stop on the ramp buttons, then the cam needs to be replaced.

12-14-2011, 11:52 AM	#10
9dawgs Not Yet Wild Join Date: Jan 2011 Location: Gulf Coast of Florida Posts: 47	Re: Rear End Clunk When Starting Off Yeah, it just looks like it needs dressing a bit. I'll give it a shot anyhow. I'm picking up the new ramp buttons today and probably put it all back together tomorrow after work. I'll let you know how it turns out :>) Thanks again for all the help.

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