Issues with ds engine swap and stuck tranny

MobileMarine

Ok ,I picked up a DS this past weekend , the original motor was out with all of the good stuff missing '' starter , clutch ect ect '' so I rounded up a few motors here in the shop and went with 212cc honda clone pull start I know I know .
I got this cart for the wife and my 2.5yo twins to play on here at the house so big power is not a concern ''right now '' .
I am having issues with making a safe and reliable throttle connection , the original controller box is junk and wont fit with the new engine and that stupid throttle rod is a joke ! So that is my first question , what do you guys do for throttles ?
Second , Due to being in a rush I went with a 3.5in belt clutch from Hillard for the engine and at first a 8 in pulley for the rear . Great torque but only ran about 5mph . So I went with a 4in on the rear and not enough power to run it like it should so Im going to try a 6in . Do you guys run this type of clutch ? What would be a decent HP for this cart ?
NOW , that trans is stuck , Forward is forward , neutral is Forward and reverse locks it all down tight . Unhook shift cable and shift at trans fine with nice solid clicks and clunks , no binding at all . Is it just a stuck syncro ?
Sorry for the many questions , just getting frustrated at it

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

BigNut77

Must be somthing in the air because my cart is doing the SAME thing..

MobileMarine

I ended up pulling the top outer cover and giving the syncro a lil love tap , i removed the gov gear while I was in there , not too bad to pull apart

BigNut77

So the love tap fixed it?....As for the governor gear, did that increase speed?

MobileMarine

The gov was never hooked up due tot he engine swap , but I was in there and it was one more thing that could fail and was not needed so I just popped it out .
It shifts fine now but Im still dealing with the rear sprocket size and throttle issues

BigNut77

Ok thanks...I will be showing mine some LOVE TAPPAGE tonight then...

MobileMarine

Drain the gear lube first . If yours is the same as mine , when you pull the case off a drive gear and bushing will fall out , they go to the input shaft , gear goes on 1st then spacer/bushing .
The syncros are the gold rings , one on either side of the shift fork , A small flat head may pop it out , it only moves in and out about 3mm +/-1 . Some file the sharp edges down but I was too lazy .
You will prob tear the gasket too so be careful . If you dont know what your looking at it can be intimidating , just pay attention . You will need a 7/16 wrench and socket , a 10 mm socket and a 13 mm and a hammer to tap , TAP the case apart

BigNut77

WOW!!!...ok....mine is a transaxle and on initial look, im dont see how to pull it apart with out removing the axel. It there an easier way? I have heard the shifter housing comes off the top of the gear box??????