Difficult shifting F to R and back with clicking sound.

[Diemaster]

So I finally got my V-twin in the ST480 running reliably. I currently have it set to start and idle by the key. if in forward or reverse it will creep along like a car, but I noticed a problem.

When I set the idle and other settings to EZGO and Briggs & Stratton specs, the motor idles too fast (I think.) This makes it very difficult to shift gears forward to backward for example. If im in forward and want to shift to reverse, with my foot on the brake and not moving, it stays in forward with the lever moved in full reverse and if I take my foot off the brake and roll forward it makes a loud clicking sound. That can't be good or by design.

I can get around this by shutting off the motor and it shifts when the RPM's drop. But this jerks the kart and if feels very rough on the drivetrain.

Is my idle too fast? (it's 1K RPM; anything lower and it sounds like coughing or trying to die) Is my belt too tight? Is my clutch miss-adjusted or worn out? (Or do i need different springs?) Am i not doing something i should be?

This is my first kart and i dont want to break something because of negligence.

[army]

My EZGO with a 390 clone engine does that too. I have the RPM down in the weeds and the belt has enough slack that the driven clutch shouldn't spin at idle but it does it anyway. I have the cart apart for a rebuild right now so while I'm at it I'm adding a driven clutch brake using an old garden tractor clamp style drum brake. I've been hoarding it for 30 years and I finally found a use for it. So far it's just tightened on with the driven clutch bolt but I'm also going to drill and tap some holes in the clutch hub so the brake drum doesn't loosen up and start spinning. The cart is still apart and I have yet to try it out but I'm pretty optimistic it'll work. I'm gonna add a "clutch" pedal to the left of the brake pedal that will only be used when completely stopped and shifting the transaxle.

[BBBHC]

Originally Posted by army

I have the cart apart for a rebuild right now so while I'm at it I'm adding a driven clutch brake using an old garden tractor clamp style drum brake. I've been hoarding it for 30 years and I finally found a use for it. So far it's just tightened on with the driven clutch bolt but I'm also going to drill and tap some holes in the clutch hub so the brake drum doesn't loosen up and start spinning. The cart is still apart and I have yet to try it out but I'm pretty optimistic it'll work. I'm gonna add a "clutch" pedal to the left of the brake pedal that will only be used when completely stopped and shifting the transaxle.

Very clever! I'm interested to see how well this works!

[army]

Should work good but real world testing will tell. We use the cart around our 3 acre property and shift back and forth fairly often. We have to shut the engine off to shift now. I've gotten so I can switch the engine off, shift and turn it back on before it dies but my wife has to shut it right off and sometimes floods it trying to re-start it. It's frustrating for her (and me).

[Diemaster]

would perhaps a bicycle brake work?

quick 30 second idea in paint:

[army]

I have some bicycle brakes somewhere in my stash of parts. Thought about doing that and having the brake pads clamp down on the outer part of the driven clutch. They seem too light for the job but I might have tried it anyway if I hadn't had the drum brake. The shifting issue is pretty irritating sometimes.

[Diemaster]

couldnt I move the motor closer to the driveaxle to reduce the belt draging? or is there a bigger belt availible?

i was hoping this was going to be a easy fix.

[Diemaster]

Actually after brainstorming (and a migraine afterward) I cant use the bike brake. The belt moves to the inside the faster it goes. So I'd get the brake adjusted and the faster I go, the clutch would self brake when it spread. Like a poor mans governor.

[kellett5261]

Originally Posted by Diemaster

So I finally got my V-twin in the ST480 running reliably. I currently have it set to start and idle by the key. if in forward or reverse it will creep along like a car, but I noticed a problem.

When I set the idle and other settings to EZGO and Briggs & Stratton specs, the motor idles too fast (I think.) This makes it very difficult to shift gears forward to backward for example. If im in forward and want to shift to reverse, with my foot on the brake and not moving, it stays in forward with the lever moved in full reverse and if I take my foot off the brake and roll forward it makes a loud clicking sound. That can't be good or by design.

I can get around this by shutting off the motor and it shifts when the RPM's drop. But this jerks the kart and if feels very rough on the drivetrain.

Is my idle too fast? (it's 1K RPM; anything lower and it sounds like coughing or trying to die) Is my belt too tight? Is my clutch miss-adjusted or worn out? (Or do i need different springs?) Am i not doing something i should be?

This is my first kart and i dont want to break something because of negligence.

did you ever find out the problem? im having the same issue with my set up now, engine turns the drive clutch and having issues getting it back in reverse.