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skimaniac6

I just bought a 90 Club car DS with a Harbor Freight 13 HP motor. Everything is in good shape the only problem is the motor isn't installed yet. So as I pour over dozens of pages in the forums to gather information I have a few questions I really haven't found easy answers for. I need to cut the crank down, I will be using the stock clutch with the tapered adapter. Do I measure the depth of the clutch and add the spacer length and cut it to that length? after that what size do I drill and tap the shaft, can I use the original bolt for the clutch or do I need a new one? I am going to take it to a shop to have the work done I just have one shot at the cut and want to do it right. I will be posting some pictures of the build and I'm sure many of you guys with more experience will laugh at my pit falls as I wrestle with my new toy.

BGW

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carguymn

I just started a clone build on a 91 DS. The stock clutch bolt fit the crank fine. Follow the many threads on here and you will get there with little frustration.

As for cutting the crank, I only took about an inch off to make it fit where I wanted the engine. Didn't even need to drill and tap the crank further!!

CPP sells a belt for the Club Car for clone swaps that is longer, makes it much easier to place the engine too.

The last clone build I did was on an EZGO Marathon, the DS will be much easier to work with.

Good luck and share your progress.

skimaniac6

Thanks for the reply, I think this should have been put in the clone engine swap section and I should have used a different title. So with the 1 inch cut off did you have enough room on the drivers side for the electronics box? Do you have any pictures of your motor mount, I saw a couple good ones on here but I was hoping to just add a 4 inch lift and some ideas seemed to lift the motor a bit much. Maybe I will just add a 6 inch for more tire options in the future.

carguymn

Haven't gotten to mounting it solid yet, I will start a thread when i get enough done to justify it. It does look like I'll clear the electronics without too much trouble. I plan on using the stock starter/gen and throttle.

sho305

He is right you cut the crank enough to fit the engine/clutch combo in there. Watch out some CC the front spring mount gets really close but I don't know what model that is, and its when they are lifted. It is better for the crank bearing to have clutch closer to the block but nobody seems to have any problems. I did two yamaha and cut the crank to 1 1/8, the most you can cut it to get the most room. The adapter goes right up to the shoulder on the crank, it is still out more than the stock yami engine was. I drill and tap the shaft for the stock bolt, since it fits the stock clutch you are using it works fine. It was different and way deeper so I had to do it, but not that hard really. The spacer you just cut to fit up to the shoulder on the crank, so the adapter can't slide back. When you tighten the clutch the adapter will compress and grab the crank long as it can't slide back.

Far as lift I would recommend you get one to fit 22s minimum, lot better selection of those. I would get an atv tire they don't get punctures in the wild, are 6 ply rated iirc. But it depends on your use. I would go 25s when I do it again if not too much trouble, but that is not as important as the other things. Also try to get offset wheels they make it more stable. You may have to enlarge the main jet on that clone if you mod the airbox or exhaust.

skimaniac6

Thanks for the info, now I just need some extra time to get this started.