woodruff key?

xobon · 01-28-2013, 11:51 PM

Tonight we pulled the clutch to install a power kit. This is only the second time we have done this, but this time was quite different from the first.

The first oddity was that with the clutch puller we could not get the outside plate to come off, we had used penetrating oil a head of time. After several attempts, that may have damaged the plate, we finally got it loose, and when it came off it just basically fell off of the spindle. The spring and other plate could immediately be pulled off of the spindle as well. There was no woodruff key in the slot.

At first we assumed the woodruff key had fallen out when the first plate come loose, but after much searching with lights and magnets we finally gave up looking for it, we have a pretty clean well lit space to work in and I really find it hard to believe we didn't see it.

The conclusion we came to is that maybe there was no key installed. I guess what I am wondering is would it be possible that the clutch could have been working without the key? could the nut have been torqued so hard that the outside sleeve could not slip?

I intend to get a key and put it back the right way, but was just curious if anyone had ever encountered anything like this, and if they have is there any other damage that may have been caused by this setup that I am not aware of?

1989Marathon · 01-29-2013, 12:00 AM

I say from experience... absolutely not. If the key was missing, the outer sheave would have spun and caused the nut to come loose. You would have known it almost immediately.

abieex · 01-29-2013, 07:32 AM

I pulled mine apart about two weeks ago and had the same result! I guess I could have lost it but I doubt it, the area was very clean and I searched for an hour with my hand and a strong light. Picked one up at Lake Erie Carts as they had one in stock. Can we both be crazy?

abieex · 01-29-2013, 07:35 AM

One other suggestion. If you need parts for the clutch call Plowmans, he is the undisputed champ of clutches!

xobon · 01-29-2013, 08:54 AM

Quote:

Originally Posted by abieex

I pulled mine apart about two weeks ago and had the same result! I guess I could have lost it but I doubt it, the area was very clean and I searched for an hour with my hand and a strong light. Picked one up at Lake Erie Carts as they had one in stock. Can we both be crazy?

The guys that I was working with sorta all feel like there is no way that there wasn't a key in there, but none of us can explain where it went. I know it sounds crazy, but I really don't think it was there. If it was, I wish I could find it just for sanity's sake.

xobon · 01-29-2013, 08:59 AM

Quote:

Originally Posted by abieex

One other suggestion. If you need parts for the clutch call Plowmans, he is the undisputed champ of clutches!

I had all ready ordered a power kit from another dealer, but it turns out they messed up and sent me what I think is the spring for an EZGO and not a Yamaha, maybe the whole kit for some other cart, I really didn't look much further after realizing the spring mistake. If I can get that all straightened out, I am going to give plowmans a try.

abieex · 01-29-2013, 09:24 AM

Good move, Plowman is the best. Look at my build at "Another G1 Rebuild" in the Lifted Carts Section. There is a pic of his clutch setup there. Good luck.

sho305 · 01-29-2013, 08:30 PM

My key is always stuck in the shaft, I have to tap it in with a hammer to get it back in if I take it out. Maybe a good thing.

You can take a big rod (3/4) and a 3lb, and hit the back of the clutch between the ramps. That will knock the clutch loose, leave the nut on half way when you do it. Be careful with the rod placement keep it on the beefy part between the ramps. I usually have to do this from under the rear bumper. Keep rotating to different ramps. The longer its been on the harder it comes off. Anyway, that is the backyard way to get it off without destroying anything.

Mike Mac · 01-29-2013, 08:53 PM

Like Sho says, they don't come out that easy! I take them out with a chisel and hammer. There is a small wright up starting on page 457 in the "G8 Club" if your interested. Also, use "anti seize" on all parts, on reassembly. Makes it much easier to take it apart next time.

sho305 · 01-29-2013, 09:10 PM

I can clamp vice grips on mine and wiggle it out. That reminds me I need to take it off and cut my sheave.

01-28-2013, 11:51 PM	#1
xobon Not Yet Wild Join Date: Oct 2012 Location: Lexington KY area Posts: 36	woodruff key? Tonight we pulled the clutch to install a power kit. This is only the second time we have done this, but this time was quite different from the first. The first oddity was that with the clutch puller we could not get the outside plate to come off, we had used penetrating oil a head of time. After several attempts, that may have damaged the plate, we finally got it loose, and when it came off it just basically fell off of the spindle. The spring and other plate could immediately be pulled off of the spindle as well. There was no woodruff key in the slot. At first we assumed the woodruff key had fallen out when the first plate come loose, but after much searching with lights and magnets we finally gave up looking for it, we have a pretty clean well lit space to work in and I really find it hard to believe we didn't see it. The conclusion we came to is that maybe there was no key installed. I guess what I am wondering is would it be possible that the clutch could have been working without the key? could the nut have been torqued so hard that the outside sleeve could not slip? I intend to get a key and put it back the right way, but was just curious if anyone had ever encountered anything like this, and if they have is there any other damage that may have been caused by this setup that I am not aware of?

01-29-2013, 12:00 AM	#2
1989Marathon Gone Wild Join Date: Oct 2010 Posts: 6,730	Re: woodruff key? I say from experience... absolutely not. If the key was missing, the outer sheave would have spun and caused the nut to come loose. You would have known it almost immediately.
1989Marathon Gone Wild Join Date: Oct 2010 Posts: 6,730

01-29-2013, 07:32 AM	#3
abieex Gone Loco Join Date: Aug 2012 Location: Cuyahoga Falls, Ohio Posts: 722	Re: woodruff key? I pulled mine apart about two weeks ago and had the same result! I guess I could have lost it but I doubt it, the area was very clean and I searched for an hour with my hand and a strong light. Picked one up at Lake Erie Carts as they had one in stock. Can we both be crazy?

01-29-2013, 07:35 AM	#4
abieex Gone Loco Join Date: Aug 2012 Location: Cuyahoga Falls, Ohio Posts: 722	Re: woodruff key? One other suggestion. If you need parts for the clutch call Plowmans, he is the undisputed champ of clutches!

01-29-2013, 09:24 AM	#7
abieex Gone Loco Join Date: Aug 2012 Location: Cuyahoga Falls, Ohio Posts: 722	Re: woodruff key? Good move, Plowman is the best. Look at my build at "Another G1 Rebuild" in the Lifted Carts Section. There is a pic of his clutch setup there. Good luck.

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01-29-2013, 08:30 PM	#8
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,443	Re: woodruff key? My key is always stuck in the shaft, I have to tap it in with a hammer to get it back in if I take it out. Maybe a good thing. You can take a big rod (3/4) and a 3lb, and hit the back of the clutch between the ramps. That will knock the clutch loose, leave the nut on half way when you do it. Be careful with the rod placement keep it on the beefy part between the ramps. I usually have to do this from under the rear bumper. Keep rotating to different ramps. The longer its been on the harder it comes off. Anyway, that is the backyard way to get it off without destroying anything.

01-29-2013, 08:53 PM	#9
Mike Mac G8 Specialist Join Date: Jun 2009 Location: Phoenix Posts: 7,799	Re: woodruff key? Like Sho says, they don't come out that easy! I take them out with a chisel and hammer. There is a small wright up starting on page 457 in the "G8 Club" if your interested. Also, use "anti seize" on all parts, on reassembly. Makes it much easier to take it apart next time.

01-29-2013, 09:10 PM	#10
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,443	Re: woodruff key? I can clamp vice grips on mine and wiggle it out. That reminds me I need to take it off and cut my sheave.

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