• TSB164 3171 Fun-Kart Engine Mounting Plate
www.amsportworks.com • 800-643-7332
3171 FUN-KART ENGINE MOUNTING PLATE
TSB164
PREPARED BY: Anthony Musco
DATE: 10 July 2014
PAGE 1 OF 2
Models affected: 3171 with VINs prior to L6KDC0140HCB00564 or built prior to 4/10/2014
Description of problem: The engine mounting hole pattern was drilled
out of position causing the distance between the driver and driven pulley to
be larger than specification and the drive belt too tight.
Identifying the issue: Measure from the centerline of the jackshaft tube
to the centerline of the rearmost engine mounting bolt as shown in figure 1.
The measurement should be 55mm. If the measurement is 60mm or
greater, this Technical Service Bulletin applies.
Before re-assembling, inspect all components to determine if any other
items need to be repaired or replaced and do so as necessary. Inspect the
driven pulley to make certain all buttons are present (quantity of 6) and the
two halves of the pulley are indexed correctly. See figures 2 and 3 below.
INCORRECT DRIVEN PULLEY
Button
fig. 2
fig. 1
Solution: Replace engine mount.
Procedure:
1. Remove the choke and throttle cable from the engine along with the
electrical connection to the engine stop switch.
2. Remove the belt guard, the driver pulley from the engine output shaft,
and the belt from around the driven pulley.
CORRECT DRIVEN PULLEY
3. Remove the engine from its mounting plate.
4. Remove the driven pulley from the jackshaft.
Button
5. Use the chain adjuster to relieve the tension from the chain and
remove the chain from the small sprocket on the jackshaft.
6. Remove the keyed washer, key, flat washer and sprocket from the
jackshaft noting the location of the washers so that they can be
re-installed in the correct order. Remove the jackshaft from the right side
of the engine mounting plate. You do not need to remove the castle nut.
7.Remove the engine mounting plate’s chain tensioner and front mounting
bolt and remove it from the swingarm.
fig. 3
continued on page 2
www.amsportworks.com • 800-643-7332
3171 FUN-KART ENGINE MOUNTING PLATE
TSB164
PREPARED BY: Anthony Musco
DATE: 10 July 2014
You will receive one of the engine mounting plates shown below in figure 4.
One has slots and the other has holes drilled in the correct location.
PAGE 2 OF 2
TAV with slots
Procedure:
1. Installation is in the opposite order of removal.
2. When installing the engine, leave its mounting bolts loose. Position the
engine so that the distance from the center of the engine output shaft to the
center of the jackshaft is 171 mm / 6.73” as shown in figure 6. Tighten the
engine mounting bolt s and continue with the rest of the installation.
fig. 4
TAV with holes
Procedure:
1. Installation is in the opposite order of removal.
2. Once the engine is installed and prior to installing the driver and driven
pulley, confirm the distance from the center of the engine output shaft to
the center of the jackshaft. This distance should be 171 mm/6.73” (see
figure 6).
3. Before installing the belt, check the alignment of the fixed sheaves of
the driver and driven pulley using a straightedge as shown in figure 5.
Adjust the driver out board, if needed, by installing a ¾” washer behind the
driver.
fig. 5
4. Before riding double check that all the bolts are tight and that the belt
guard has been reinstalled.
fig. 6 (NOTE: measurement shown above is not correct / photo is for reference ONLY)
3. Before installing the belt, check the alignment of the fixed sheaves of
the driver and driven pulley using a straightedge as shown in figure 5.
Adjust the driver out board, if needed, by installing a ¾” washer behind the
driver.
4. Before riding double check that all the bolts are tight and that the belt
guard has been reinstalled.
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