Secondary Clutch Install Made Easy

grantspec

Hey everyone! I wanted to share my process for installing the secondary clutch on my G9. I have had this thing on and off several times now and have improved my method and made a tool that makes things much easier for me. These springs have quite a bit of tension and it is tricky to compress easily. I have tried ratchet straps and other techniques but always worry about damaging the clutch bushing surface from asymmetrically loading the sheave.

Here is the tool I made, it’s 3/8” threaded rod with an M12 nut welded on that threads onto the input shaft, i ground down the O.D. Of the M12 nut with my angle grinder so that it would fit through the I.D. Of the sliding sheave. I used two 1” drive sockets to push on the sliding sheave but you could also use a piece of pipe:



Here is everything ready to go on, machines sliding sheave, and U-max spring, clutch compressor threaded on and a clamp to hold the helix:



Here it is with the clutch compressed:



And the tool that makes your life very easy.... the secondary clutch fixing tool! I purchased this for $59 on amazon, but oh man is it worth every penny!



Now with fixed sheave installed and a better view of the fixing tool. It slides over the helix and sliding sheave to keep it compressed.



Hope this helps someone install their secondary clutch. Sorry for the dark pics, I only get a chance to work on this thing when the kids go to bed!



Please let me know if you have any other tips or tricks!

Happy carting!



Sent from my iPhone using Tapatalk

BGW

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slonomo

Wow nice write up! I never knew that tool existed lol. Nicely done

Shepard

I love homemade tools -- excellent job.

grantspec

Thanks guys. Highly recommend the fixing tool. That thing makes this job very effortless.

I have my tranny all torn down again now to replace the input shaft. It was pretty worn and I was still getting a growling noise with the new rear sheave.

griffo002

Good one ol mate...Stick this thread as some good info here.
Thx.

C&L golfcarts

How to you remove the helix off of the input shaft to replace?? I cannot get mine to come off.