DD2 clutch shot, or something else?

This topic has 6 replies, 3 voices, and was last updated 11 years, 11 months ago by Mark Grossman.

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- August 22, 2014 at 6:24 pm #32466
  
  tony zambos
  Participant
  
  Mark,
  
  Your clutch could be worn out, or there is grease on the shoes and drum, or one of the pivot posts has broken away. The link below is for the dd2 repair manual with the older clutch. Can’t find a speck for the clutch but the picture of a new clutch in the manual might help.
  
  http://www.srakarting.com/wp-content/uploads/2012/01/DD2_repair_manual_EN.pdf
- August 24, 2014 at 2:16 pm #32521
  
  Mark Grossman
  Participant
  
  it’s a wet clutch, so grease isn’t the issue. The pads are about 1mm thick which is the point where Rotax says to replace them. But of course they no longer sell those and have a new clutch kit for $650….. ouch.
- August 25, 2014 at 11:26 am #32575
  
  Mark Grossman
  Participant
  
  decided to get things rolling and ordered the new clutch retro-fit kit. That was one expensive weekend….
- August 25, 2014 at 6:20 pm #32606
  
  mark sawatsky
  Participant
  
  Could it be just your axle coupler slipping? I had the old style coupler (lots of teeth) and the axle moved over and it disengaged. I also have had the coupler slip on the axle when the 4 plastic bushings inside are worn out. It feels a lot like the clutch not engaging.
  - August 26, 2014 at 8:01 am #32648
    
    Mark Grossman
    Participant
    
    the coupler slipped on a friend awhile back, so I did check that. Didn’t see any movement and fully engaged. Wish that was it, but will double check it while I’ve got everything apart. From what I’ve read about the old clutch, my days of using that were numbered anyways. Thanks for the tip.
- September 4, 2014 at 7:11 am #33117
  
  Mark Grossman
  Participant
  
  Purchased the clutch retro-fit kit, the needed tools, Loctite etc and put things together last night. While doing so, I spotted what happened and hopefully this can save someone some $’s down the line if they still have the original style clutch.
  
  The drive gear that is bolted to the clutch drum was loose. The lockring was still against the nut but it loosened just enough to allow the clutch drum to spin on the gear. Granted, the pads were worn and everyone I kart with has had to replace the thing when the springs break, but still killed me to see I could’ve been up and running again by tightening that thing down.
  
  The project was actually pretty fun and though I haven’t fired it up yet, optimistic everything will work just fine, and my new thinner wallet will save me some weight…….
  
  Mark
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