Major drive issues

[shane0524]

so my 1989 ds is having so big issues, was driving it any heard metallic crack sort of noise, but it kept driving as normal. When I can to a stop, it would not take off again. It makes a loud screech noise as you can hear in the video. Also the belt seems very loose. It will still drive if you push it to about 5 mph and jump in. I think this is the culmination of many issues which have not been fixed, but now i have no idea what is wrong with it.

1. For a long time it has been taking off from a stop with jerking and clunking.
2. recently while driving one of the triangular lobes (on the thing in the pic below)broke off at speed, but it didnt seem to affect anything in term of drive ability.
3. Now this thing is really broken, and idk how to fix it, the belt stay still when you start the engine.

all help will be greatly appreciated

https://www.youtube.com/watch?v=qbOlYevOoBw


ps please ignore the fact that my throttle is zip tied open

[Springbok]

There should be a good amount of play in that belt, but it looks like you have an issue with your driven clutch (the rear clutch back on the axle). It looks to be stuck open, which is causing your drive belt to be even looser than it should be, and will definitely cause some major issues (and noises) as you've described. But under normal circumstances with the cart shut off, there should still be enough play in the belt to remove it by hand with no tools or adjustments.

When the driven clutch is operating normally, the drive belt will sit high between the sheaves; and as you speed up, the belt will then sink down into the driven clutch as the sheaves open up. Since the sheaves on your driven clutch appear to be already stuck open, it's easy to see what the problem is. In the video your driven clutch didn't even appear to be spinning.

[Conversely, with the drive clutch (the clutch on the motor), it's the opposite; the belt starts low between the sheaves and as you speed up, the sheaves come together, pushing the belt upwards towards the outside perimeter of the clutch. In the video your drive clutch appears to be working correctly.]

Removing and replacing the driven clutch *should be easy. You should be able to remove the center bolt on the outside and it should slide right off (the input shaft that it sits on is just a keyway shaft). No special tools should be needed.

*I say should be easy...because with some driven clutches that have been on a cart for many years don't always slide off the input shaft easily and need some extra effort to remove, in some cases requiring heat or cutting wheels. If yours doesn't want to come off easily, don't try to use a pry bar against the transaxle case. It's aluminum and will crack under the stress, so be oh-so-careful.

[Springbok]

If you have to replace the driven clutch, this would be the one you want:

http://www.ebay.com/itm/like/2223990...&ul_noapp=true

[shane0524]

Originally Posted by Springbok

There should be a good amount of play in that belt, but it looks like you have an issue with your driven clutch (the rear clutch back on the axle). It looks to be stuck open, which is causing your drive belt to be even looser than it should be, and will definitely cause some major issues (and noises) as you've described. But under normal circumstances with the cart shut off, there should still be enough play in the belt to remove it by hand with no tools or adjustments.

When the driven clutch is operating normally, the drive belt will sit high between the sheaves; and as you speed up, the belt will then sink down into the driven clutch as the sheaves open up. Since the sheaves on your driven clutch appear to be already stuck open, it's easy to see what the problem is. In the video your driven clutch didn't even appear to be spinning.

[Conversely, with the drive clutch (the clutch on the motor), it's the opposite; the belt starts low between the sheaves and as you speed up, the sheaves come together, pushing the belt upwards towards the outside perimeter of the clutch. In the video your drive clutch appears to be working correctly.]

Removing and replacing the driven clutch *should be easy. You should be able to remove the center bolt on the outside and it should slide right off (the input shaft that it sits on is just a keyway shaft). No special tools should be needed.

*I say should be easy...because with some driven clutches that have been on a cart for many years don't always slide off the input shaft easily and need some extra effort to remove, in some cases requiring heat or cutting wheels. If yours doesn't want to come off easily, don't try to use a pry bar against the transaxle case. It's aluminum and will crack under the stress, so be oh-so-careful.

okay, here are a few more details, when i put it into neutral/service mode, the driven clutch does move. The belt rises on the drive and falls on the driven. Also when you try to move the cart when it is in gear, like you saw in the video, the drive clutch spins, but the driven doesnt move. It is as if the belt is not gripping the drive clutch and is just slipping on it.

Im not sure if that helps, but I want to believe that the driven clutch is functioning because it does move.

[Springbok]

It sounds like your driven clutch is not working properly when under put under load. You said yourself that part of the driven clutch broke off already. The problem is obviously in your driven clutch. Get a rebuild kit with the parts you need, or just replace it.

[shane0524]

Originally Posted by Springbok

It sounds like your driven clutch is not working properly when under put under load. You said yourself that part of the driven clutch broke off already. The problem is obviously in your driven clutch. Get a rebuild kit with the parts you need, or just replace it.

Does this look like a good replacement? Do you know who sells rebuild kits for the old cc's?

Look at this on eBay http://www.ebay.com/itm/361921801905

[Springbok]

Originally Posted by shane0524

Does this look like a good replacement? Do you know who sells rebuild kits for the old cc's?

Look at this on eBay http://www.ebay.com/itm/361921801905

You want the newer style (1988+) with the finned outer sheaves, not the one with the flat steel sheaves. That steel-sheave style you posted is not the right clutch to match your 1988+ drive clutch. Technically, it will work, but the belt alignment is slightly off, and it's not a perfect match. I don't know why these cart suppliers don't make note of this. Club Car hasn't run the Salsbury drive clutch in their new carts since mid-1987. There seems to be a lot of conflicting information out there.

This is the driven clutch you want:
http://www.ebay.com/itm/Club-Car-Gas...25.m3641.l6368