Go Kart Troubleshooting Guide
| Problem | Possible Cause | Action / Solution |
| Engine Stalls Engine backfires Running Poorly Hard to Start Cuts Off |
1.Spark Plug fouled/carbon deposition. 2. Fuel too low. 3.Make sure kill switch is not engaged. 4. Check choke to see if it is open. Too much choke will flood engine. 5. Fuel line/ hose. |
Clean spark plug. Install a new spark plug. Recommend: BPR5ES. Fill fuel tank: min 1/3. Do not overfill. Check fuel switch is on. If motor is warm you will not need choke. Check spark plug is not wet from the petrol flooding the plug. You may need to dry the plug out or replace. Make sure fuel line has no kink restricting fuel flow. |
| Chain Falls Off | 1.Chain Sprockets not aligned. 2.Chain too loose. 3.Excessive chain wear or stretch. |
Align Sprockets. Check sprocket on clutch and bolt holding clutch onto shaft. Adjust chain tension. Motor may need sliding back on adjustable mount. Replace chain. |
| Difficulty Braking Making Grinding noise |
1.Brake pads worn out. 2.Hydraulic brake fluid low. |
Replace brake pads. Bleed brakes |
| Kill switch not working | 1.Kill switch wire plug in connector separated at the engine. 2.Wire end terminal has come loose from the engine. |
Check connection. Push together. Re install or tighten screw holding wire end to engine case. |
| Engine Stops and won’t start | 1.Bad coil assembly. 2.Air cleaner is dirty and dusty. |
Replace coil cap. Clean, shake all dust out. Replace. Never run engine without air cleaner. |
| Go Kart moving or creeping forward, or wanting to take off | 1.Throttle cable engaged. 2.Spring inside clutch may have stretched. This can occur if go kart is used at low revs for extended periods of time. |
Check for kinks, Ensure the inner wire cable is moving freely within the black casing. Check the throttle lever is springing back to off position. Replace spring inside centrifugal clutch. |
Instructions for Replacing Centrifugal Clutch Spring
Tools required:
Circlip pliers, Vice grips, Flat screwdriver, Socket set
1. Remove chain guard.
2. Remove chain by removing joining link.
3. Remove the bolt that holds the clutch onto the shaft - Anti Clockwise.
4. Slide off centrifugal clutch and lay clutch flat on workbench.
5. Remove circlip by the 10 tooth sprocket and slide top cover off.
6. Remove the next larger circlip and spring cover.
7. Remove old spring and discard.
8. Place new spring in position. This may require another pair of hands as the spring needs to be stretched in place.
9. Vice grips will help to hold the plates flat.
10. Hold down firmly or else the plates dislodge and carefully replace the spring cover and large circlip which needs to clip into place. Sometimes it is necessary to finish pushing circlip down with screwdriver.
11. Replace top cover, small circlip and bolt back on to motor.
