Today I did break the gearbox down, and now I fully understand how it works.
What I did do was install a very thin shim between the splined "sun gear" and the bushing/spacer on the back half of the case. (giving me a tiny bit more clearance between the halves when the lever is pulled up)
I also gave myself some slack on the cable so it doesn't pull the gear box quite as hard.
Lastly I did 2 things.
1. I only went about 1/8 turn more past "snug" on the output shaft retaining nut.
2. I tightened that retaining nut before I tightened the mounting bracket. The first time I didn't do that, and I think I may have pulled the gearbox out of alignment causing me some issues.
I now no longer have the chain bind i did, the kart rolls very easily now by hand, and the flakes of metal are now gone.
I did still order the longer shaft because I stll like the idea of having more spline surface area than the 1/2" - 5/8" I have now.
Last edited by xlint89; 09-19-2012 at 09:25 PM.
|