How to Fix a Burning Clutch on a Go Kart

Go karts provide lots of fun until they start to break down. Like all motorized vehicles, go karts require maintenance and regular repair, particularly in the engine. Given the abuse and changes that occur when using a go kart, the clutch can go through serious abuse. With a lack of lubrication the part can get hot and start to deteriorate. The key to preserving the clutch is to keep plenty of transmission oil in the system.

Instructions

1

Drain the engine transmission oil into a metal pan, using a crescent wrench to remove the drain plug. Use a socket wrench and crescent wrench to open up the engine case. Put all the removed hardware in a cup to avoid losing the bits. Locate the clutch inside the engine.

2

Unscrew the clutch securing nut with a socket wrench. Use a clutch tool to leverage the clutch off the crankshaft axle. Place the removed hardware in the cup and place the clutch on a workbench.

3

Examine the clutch for burn marks. Turn the clutch over and locate the snap ring that retains the clutch parts together. Place the clutch assembly in a vise clamp and compress it. Remove the snap ring carefully with needlenose pliers. Decompress the clutch. Place all the parts in a metal pan.

4

Spread out the parts in the pan. Locate the cork plates. Examine the damage and loss of cork on each of the plates. Replace these plates with new ones when rebuilding the assembly. Soak both the new cork plates and separation plates with new transmission oil. Re-assemble the clutch and place it in the vise again. Compress the assembly.

5

Re-insert the clutch snap ring. Pop it into place and decompress the clutch again, letting out the vise clamp. Take the completed assembly and re-install it back on the axle inside the go kart engine case. Twist on the securing nut. Tighten the nut using the socket wrench.

6

Apply a new engine case gasket after using a plastic spreader to scrape off the old one. Close up the engine case gasket and tighten the engine case bolts with the socket wrench. Pour in new transmission oil. Check that there are no leaks letting oil out from the engine case.

7

Start the engine again. Test the performance by driving the go kart around. Monitor the performance over the next 30 days. Open up the engine case again and examine the clutch. Replace the unit if the old one is burned out again.