reverse

Posts: 4 · Joined: 23 Aug 2008 Posts: 4 Pictures: 0

I finally got the Sahara 150 with a GY6 motor running. It was a battle. The information I gathered on this forum was unbelievable. I had a problem with the belt and found a post with my identical problem. After work I got into it and fixed the problem within a half hour. Now, I need a little more info. My automatic choke is shot. Where does the signal come from that controls the choke? Is there a specified voltage and has is it activated? One more thing. I have no reverse. I took it all apart and every thing looks fine. The cable is tight. When it's put in reverse I get no noise or anything. It still wants to go forward. I also need a ebrake cable...thanks

Posts: 1889

Start by downloading the service manual off SpiderboxPerformance.com and take a look at the choke troubleshooting section.

The choke runs off AC voltage directly from the stator. As the choke heats up, a pin extends out of it to block the enrichment circuit. There is no other control for the choke other than this heating action.

You will need to remove the reverse assembly from your output shaft and look for obstructions that prevent reverse from engaging. Typically when the cable is slack, it is in forward gear. When you apply tension to the cable the gears will mate with reverse. SpiderboxPerformance.com and BuggyDepot.com have good explanations with diagrams on how the reverse assembly works.

Some of the dealers on this forum should be able to provide the cables and parts you need.

Posts: 2577

ACBlind is a reverse guru.
Okay, he's my son so I can say that with some pride.

Honestly, he knows how they work and how to set them up. Send him a PM to look at this post... I'll try to remind him in the morning as he's sleeping now. He has school in the morning.

This picture is actually swapped. But it shows the inside of the gearbox.

The other type of gearbox (like the ones I got from buggydepot for my Y'Dog) have a nut on a threaded shaft that comes out that secures the outer shell of the reverse gearbox. If it's too tight sometimes the gears don't have enough room to move. It may also prevent the gearbox from moving freely.

If you can post some pictures of your gearbox we'll be able to help you with further troubleshooting.

Basically what Adam has taught me (that's the cool part, learning from your kid)... Is that sometimes it's just best to take it all apart, inspect it all to make sure everything is okay, then put it back to together.

We'll have you up and running in no time...