YAY!!!!! More problems...

[joshstep1]

I got the exhaust fixed. TSC ticked me off a little so I ended up replacing the exhaust myself. BUT WAIT! Does it run?... No. I got it out there and after about 30 seconds of riding, literally, I heard a loud knocking. I thought it was the chain because it was rusting a little, causing it to lock up a little, but I took the chain off and turned the small gear that comes out of the transmission and it was still knocking and locking. What's wrong? :(

[KID4LIFE]

i'm not real familiar with the carbides but take your belt off too and try turning it again.
does it have reverse? maybe the linkage is stuck between gears?
it just sounds like something is out of adjustment. it's not an engine knock is it?
it only makes the sound when moving or it does it when idling also??

[BuggyMaster]

knocking while sitting there not moving? Under what conditions does it knock?

[joshstep1]

When it rolls. I took the chain off and turned the small gear by hand and it's something in the reverse transmission.

[PAbuggy]

Try adjusting your cables it may not be going in to gear all the way.

[joshstep1]

Alright. I'll try that.

[joshstep1]

Well I tried tightening the forward and reverse cables and that didn't do anything. What do I do now?

[BuggyMaster]

is it jerking the machine while it's knocking as in it's engaging and disengaging or acting similar to as if the chain is slipping?

[joshstep1]

No. Not really, but the knocking is very loud. I did notice that when I was pushing it would occasionally lock up the rear wheels to where I couldn't move it.

[BuggyMaster]

ya...you're gonna have to pull that side cover at the very least and take a look at the CVT system. If everything looks good there you are going to need to pull that tranny apart and take a look in there.

[joshstep1]

I looked at the parts breakdown of the transmission and... wow... just wow. I'm not taking that thing apart! But I know its not the CVT because it doesn't do this when it's in neutral.

[olderthan]

Josh
if one of your bolts are loose on variator or clutch
it can cause lock-up on pushing
and/or knocking might want to pull cvt cover
olderthan

[KID4LIFE]

pulling that cover off to make sure it's nothing in there is WAAYYYY better than ripping down that tranny.

[joshstep1]

Believe me, I'll take the thing to the shop before I rip the tranny apart, and I know it's not the CVT because it ONLY does this when it's in gear. i.e.- forward/reverse

[KID4LIFE]

have you drained anyfluid out of the tranny to see if there is any metal in it. might give you a clue to what's wrong in there.??

[joshstep1]

Hmmmm, good idea. I'll try that and after, I'll probably just send it to the shop.

[SYCARMS]

The tranny really is not as bad a job as it appears. The reverse assy is nothing but a planetary gear with a fork and spring. The tranny itself is nothing but 3 gears on shafts. You could have a bad bearing which is what it sounds like. TOM

[joshstep1]

Oh. It looked a lot more complex than that in the parts break down, but it's too late to really do anything about it because I got it in a shop yesterday.

[joshstep1]

Ok, so this update is really late. Sorry. On 4/16/10 we took the buggy directly to the shop (yes, the same shop TSC was supposed to send it to, but they "forgot" about it for two weeks) and the guys there said that they were two weeks behind and that the manufacture should cover damages.

[chuckorlando]

I bet you get a clutch arm with a bad spring or something. It allows the arm to flop out and grab the bell. The tranny on these are very simple. You loosen the keeper next to the shift arm and just pop that out. Then it just pulls apart. If it's not the clutch you likely broke a tooth. This happened to my hh250 on the drive side. On that side you just take off the cvt cover. Under the clutch you'll find another cover. Remove that and the gears just pull out. Took me about 1hr to re assemble my 180 tranny afater I got the motor back from Tom. And took about 30min to rebuild the drive side on the hh250. This was my first time in a tranny on both jobs

[joshstep1]

Thanks for the advise, but it's already in the shop.

[Maahs13]

josh please update us when it gets out of the shop because i have a similar problem and i'm scared when looking at the price of the gears in there

[joshstep1]

Will do.

[chuckorlando]

I re built my hh250 tranny for 50 bucks

[joshstep1]

Wow. How complex was it? I know they have a HLNR tranny.

[chuckorlando]

It took about 30min. I did not rebuild the reverse side but I have had my 150 motor with internal reverse completly out and apart. Very easy. Everything just sits in in their own bearing on their own side except the main shaft because it runs through the center to move the reverse gears

[joshstep1]

Did you have to pull the engine completely off?

[chuckorlando]

No just the tires.

[kliff]

Like Chuck says, these little gear boxes are a piece ' cake. But if you're in doubt, carry a digital camera with you, and take pics of everything you do, then folllow the reverse order of your pics for reassembly.
After you've done it once, you'll wonder why you didn't do it earlier. A tranny fix, is a real confidence builder for someone with even a little mechanical ability.

[joshstep1]

But if you took the side plate off that houses the tranny components, wouldn't they just fall out?

[kliff]

nope.

[joshstep1]

How come?

[chuckorlando]

Cause each one has a slot or bearing to go into. They will either stay in the tranny or in the cover. If one does fall out that might be the problem. These things are held together with c-clips andd case covers

[joshstep1]

Sorry for that typo up there. And oh. Thanks for the info, but again, the buggy's already in the shop, but I will definitely do my own work next time something like this happens. I'll keep you all posted.

[chuckorlando]

Man you just missed our Tn bash last month. We had about 25 buggies at Prentice Cooper

[joshstep1]

I should get the buggy back aaaaaaany day now.

[Maahs13]

i ordered the parts for my carbide a week ago it was the two final gears

[joshstep1]

Nice. Have you taken the gearbox apart?

[Maahs13]

yep it kinda fell apart on me but i got the gears in yesterday and hope ill get it back together

[joshstep1]

How hard was that?

[Maahs13]

not bad im 16 and was able to figure it out on my own the hard part was sliding all the parts in at the same time, its leaking oil right now (even though i put in a new gasket) and i cant figure it out so i might have to take it back apart again

[joshstep1]

Cool. I'm 16 too and I'm really good with mechanical and technical stuff so I probably could have figured it out. As for your leak, I don't know what could be causing the it.

[kliff]

not bad im 16 and was able to figure it out on my own the hard part was sliding all the parts in at the same time, its leaking oil right now (even though i put in a new gasket) and i cant figure it out so i might have to take it back apart again

Most of the OEM gaskets are a grey color, hard to distinguish from the aluminum case. Sometimes a piece of old gasket material can be over loooked, causing a leak.... solution...you already know that one.:eeek:

Glad to see a young man tackle a problem head-on like that. Only way to learn, then your accomplishments can speak for you. Well done man.

[BuggyMaster]

You got it Chuck. Glad to see these guys taking on these problems. Great experience. If I had a dollar for everything that I had to do twice from getting screwed over by something I missed (or simply bad luck) I'd be rich!

[Maahs13]

pulled it apart again and your right piece of old gasket missed so put it back together and my brother broke a bolt in it so back apart again but finally got it back together and no leak

so was out at camp enjoying it till now

[kliff]

pulled it apart again and your right piece of old gasket missed so put it back together and my brother broke a bolt in it so back apart again but finally got it back together and no leak

so was out at camp enjoying it till now

Well done. Enjoy the ride :biglaugh:

[joshstep1]

pulled it apart again and your right piece of old gasket missed so put it back together and my brother broke a bolt in it so back apart again but finally got it back together and no leak

so was out at camp enjoying it till now

Awesomeness. Enjoy it while it still runs.

[joshstep1]

UPDATE: Is there really even a point in me making this point? I don't know. Oh well. I called the shop, again, and they said they got all of the warranty stuff covered and I should get a call from them on Wednesday. YAY! Right?... Hmmm, probably not. When I called them May 7th they said that it should have been done the 14th. So, who knows.

To be continued...

Yeah, I know. This is so stinkin' exciting. Isn't it?... I didn't think so.

[BuggyMaster]

man...next time I'd say fix it yourself! We could have got you running faster! Keep us updated and fear not, you'll get it back.

[SYCARMS]

I would not shoot the messanger yet. Some companies will have the repair shop send the bad parts to them than ask many questions to determine if it falls under warranty or abuse, before sending the parts to repair. I am not bad mouthing the manufacturer or sticking up for the repair shop cause I do not know the situation, but have seen both sides of the fence. This is a problem many run into when they purchase from a big box or from the internet where they drop ship. They sell the product than should you have a problem the warranty is either done by you or shipped to a third party. I know for a fact TSC gets the buggies in and designates a sales person to assemble it. I worked on a customers TSC buggy just as it went off warranty. He had a very simular problem. When I went to drain the final drive oil less than an ounce come out of the unit. Needless to say all gears and bearings as well as clutch, rollers and belt had to be replaced all at the cuastomers expence. He was told the oil was good to go when it still had the breakin oil still in it. A sales person is not a mechanic and if the customer isn't proficient with mechanical this can be trouble. This is the reason the larger companies do not drop ship or sell the internet even in slow economic times. All these big box stores and many online stores are after is the almighty dollar and could care less about customer service. And yes you also have some dealers who fall into this catagory as well but not to the same extent since they rely solely on the customer to keep them in business. Just my opinion and I'm sticking to it. TOM

[joshstep1]

man...next time I'd say fix it yourself! We could have got you running faster! Keep us updated and fear not, you'll get it back.

Yeah, next time I will definitely do my own work. This is stupid, but now I'm really, really excited because I'm hopeful that they will call tomorrow!... But I probably shouldn't get my hopes up too high.

[Maahs13]

i brought my buggy in within 30 days in to the shop was great but the company wouldn't support them, and they said they had troubles when ever they had to deal with them

my tires were bald

[joshstep1]

Was it because of the bald tires?

[joshstep1]

UPDATE: So today's the day I'm eagerly anticipating the call.

To be continued...

[SYCARMS]

Good luck man!!!!!!!!!!!!!!!

[joshstep1]

Thanks. I'll need it.

[joshstep1]

UPDATE: So that call never came. We'll call them tomorrow and see what they say.

[joshstep1]

UPDATE: This is a good one. No. unfortunately they're not done, but we know what was wrong. They said that the problem is with the gears. They weren't meshing properly on top of the fact that that two of them had broken teeth. They said another week, but so far, what they've said has been just as legit as what Obama says.

TO BE CONTINUED...

[kliff]

"...another week..." sixteen days ago...WHASSUP?

[joshstep1]

Haha, yeah. They've used that one a few times. We went there last Friday and they said the parts they ordered were back ordered until the 22nd of this month. Then there's a few days for delivery and a few more for installation. Woohoo!!!! More waiting...

[joshstep1]

UPDATE: I am very, very excited to tell y'all that I will probably have the buggy back Monday! I know they have said that for three months now, but today they said they got the parts, installed them, reassembled the engine, and now all they have to do is reinstall the engine and test it! I CAN'T WAIT TO GET IT BACK!!!!

[SYCARMS]

Good Luck

[willy110]

Hope they come thru this time!

[joshstep1]

So do I. Tomorrow's the day... I hope.

[SYCARMS]

Well tomarrow is now today. Whats the verdict, or are you to busy ridding? Hopefully you are busy ridding. TOM

[joshstep1]

Nope. I never got it. I SHOULD get it back any day now because all they had to do was remount the engine.

[chuckorlando]

I would'nt use these guy's again. Took me 2hrs or less to yank my cfmoto 250 and maybe an hr to do a 150

[joshstep1]

Yeah, I definitely won't be having these guys work on my buggy again... or my other one, or any buggy/atv/whatever I may buy in the future.

[SYCARMS]

Was this not a warranty job? If so I would be on the phone with ASW daily from now on until your satisfaction is met. TOM

[joshstep1]

Yeah, the warranty has it covered. I would be mad, well, madder, if it wasn't. I looked the cost of the gears and it was $35 for one and $80 for the other.

[SYCARMS]

I would sill be calling to complain to ASW about having to be without a ride for so long due to warranty work. Afterall you did not purchase it to not drive all summer. If its the dealer who is the problem they need to know about it and drop them as a warranty service provider. TOM

[joshstep1]

Oh. Well they are FINALLY done!!! We're going to pick it up tomorrow morning. Hopefully this is the last time something like this ever happens. The end of this nightmare is here.

[BuggyMaster]

definately keep us updated.

[joshstep1]

On what? They're done with it.

[BuggyMaster]

experience says the story's not over till you have it in your possesion and have ridden it and all is normal. THEN they're done.

[joshstep1]

Alright. I think we're going to go pick it up in a little bit. I'll probably post something here tonight telling y'all how it went.

[joshstep1]

Ok. I forgot to tell y'all this yesterday, but I did finally get the buggy home and got to drive it around for about an hour yesterday. It ran great. I didn't get to drive it at all today because I wasn't home all day, but I'm glad for it to be home and for this nightmare to be over.

THE END

[joshstep1]

Man you just missed our Tn bash last month. We had about 25 buggies at Prentice Cooper

Wow, sorry, I just saw this post. Where is Prentice Cooper?

[olderthan]

glad you finaly got it back