Secondary clutch hits generator

crvaughn

Finally got back at my 75D after about two years of inactivity. Tore apart the driven clutch cause it rattled so bad, replaced bushing/pin with one from a donor cart. I even measured the length and there both exactly the same. After installing the rattling is gone and it seems to work as it should. Except at full throttle it expands far enough to hit the generator belt and it’s shredding it and scraping the flange on the clutch. Any ideas?
Also having a heck of a time with timing, been researching on here but can’t see, to find a step by step of electronic conversion some people do?
Thanks for any help.

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

johnny reb

did you inspect your motor mounts? mine did that the starter/generator pully ate the secondary slightly. the cause was the motor mounts. i got a front set from a donor and she works fine. i also plop some big washers on top so the center of the mount wont drop below the top of the mount.

johnny reb

as for timing tew45 has a diagram for a timing stop for easier timing. i always clean the flywheel and put white paint on the 2 timing dots. if its together a flat screwdriver through the timing hole cleans the rust off the flywheel except for the dots. i use a ohm meter set your points .020-.022 then adjust the timing plate to where the points close in both directions where both dots are visible through the timing hole. i just put a new cylinder set so i did it while the engine was on the stand as for electronic ignitions i havent gone there yet but if i do the vellerman looks nice. here are some pics with a home built set up and a link. https://www.vellemanstore.com/en/vel...r-ignition-kit

Attached Images

	67 plus points.JPG (94.8 KB, 0 views)
	HEImodForPoints-1.jpg (91.2 KB, 0 views)
	timing stop.jpg (119.6 KB, 0 views)
	SAM_0110 - Copy.JPG (307.1 KB, 0 views)

Attached Files

Harley Davidson Timing Stop.pdf (114.9 KB, 0 views)

Lochlin

Motor mounts are bad and allowing too much flex. New ones are made in China, obviously. Sometimes they work and sometimes they don't. I actually add some spacers between the head of the motor mount bolt and the frame to minimize flex.

crvaughn

Shouldn’t I be able to grab the engine and move it back and forth if the mounts are shot? Seems pretty steady, but I could be wrong I guess.

johnny reb

its usually the back mounts the motor pulls the front ones up and pushes the back ones down when it produces forward torque. I put big washers on the top like they have on the bottom so it wont push through the mount. yours should look like the picture the mount should look the same on both sides. i saw these a while back and they say made in USA and are cheaper than the China ones. https://www.ebay.com/itm/MADE-IN-THE...4383.l4275.c10

Attached Images

	motor mount.png (88.2 KB, 0 views)
	motor mount2.jpg (8.2 KB, 0 views)

crvaughn

I’ll change em out but I wonder if that’s the problem. I put a couple washers under the body above the axle on each side and it raised the engine up enuf that the clutch clears the generator pulley. But it still extends far enuf forward to hit the belt. Wouldn’t new motor mounts just move the rear of the engine upwards? When it seams like I need it to go forward? Or am I overthinking it?

Lochlin

I hear what you are saying but those engines put out a lot more force that a person can. Those motor mounts are stiff and tough to move via a person. I have done what you are saying, shaking the motor by hand, to check mounts. That provides a little movement but not much. The engine revving provides a lot more force.

One thing that hasn't been mentioned yet is your drive belt. If it's not the right one (ie, too short) then it will pull the clutches together as well. You may want to try a new one (assuming the one you have isn't new). Really, clutches coming together has to be an alignment issue someone. I can't fathom anything mechanical that would cause that.

You may have done this already but jack the back of your cart up and closely watch the clutches as you rev things up. If you see the engine rotating toward the secondary then your mounts are probably bad or you need some spacers.

Regarding the electronic ignition conversion, there is a sticky post on top of the Columbia forum that describes that process in detail. It's easier than people think.

top-cat

you got the wrong starter generator belt on it. Its too long.