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Big Block Talk! Everything about swapping a big block engine into your cart!



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Old 08-01-2012, 12:38 PM   #1
TJL
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Join Date: Jul 2012
Location: Central Florida
Posts: 409
Default newbie/88 club car ds swapping kohler 18hp

Hello all, ive been lurking on here for the last few days trying to get info for a swap. i have a kohler ch18s at my disposal so i decided i should drop it in a golf cart. i didnt know anything about golf carts before starting this but i am familiar with 12v wiring and work on alot of small motors.

here's my cart. 1988 club car ds. came with a messed up motor already pulled from the cart. previous owner said the motor had bad rings but i found the valves are not moving in it when you spin the motor. he said it was a "wisconsin 10hp" motor, its a flat head. i was not going to use the stock motor so made no difference to me. got it from a redneck guy who used it to run around fields and splash in mud. fortunately after a good cleaning i found the cart to appear to be in great shape where it counts.

i tried posting pics but im not a member long enough... oh well.
i have the body off the cart and im waiting to order some goodies to complete it.


as of right now i know i need a suspension lift and a new clutch to get the kohler v-twin in there.

a few questions i have are which clutch is the best bang for the buck? i know i have limitations with the clutch since apparently there is spring clearance issues.

i want to use the stock gas tank, what do you do to the stock fuel pump? just disconnect from it and leave it?

i want a 6" a-arm lift and have seen a few differences in them, some i like and some i have some issues with the design. whats the recommended 6"a-arm lift?

also i know i need to replace the snubber, the rubber discs on the motor mount plate and the leaf spring bushings.

im pretty good mechanically, have been doing my own work/mods. have no problem with most fabrication and welding but i dont have the gear to weld aluminum.

thanks in advance for any advice.
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Old 08-01-2012, 04:41 PM   #2
bigbird110
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Join Date: Feb 2012
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Default Re: newbie/88 club car ds swapping kohler 18hp

I have a 96 ds I used a Polaris clutch off a 500 Polaris for drive clutch and I'm going to order big block driven clutch from cart parts plus tommorrow so I ca run a Polaris belt. This seems to work good to me. I also have a jakes 6 inch a-arm lift from buggies unlimited that works good, looks good, and rides good. Good luck with your build I hope to have mine done by this weekend and post pics soon.
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Old 08-03-2012, 07:23 PM   #3
TJL
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Default Re: newbie/88 club car ds swapping kohler 18hp

change of plans for now. im building this car for my parents to use so i decided i didnt want to put the v-twin in it. the cost of the lift, clutch and wheels is too much for now. i'll save that fun stuff for the next cart which will be mine.

SO for this club car i bought a duromax 16hp, i'll get the tapered clutch adapter use the original clutch. found the brakes were shot, pads worn to metal and killed the drums. got new drums/shoes on the way.

still need to get new bushings for the knuckle/kingpin to fix the wobbles, new snubber, tie rod end on the steering ram is totally shot, boots on the steering are ripped up, new bushings in the leaf springs and rubber blocks for the motor tray. i think thats about it for parts, the rest is just cleaning/painting, wiring for the motor and s/g.

hopefully should be driving it in 2 weeks or so.
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