Is this noise normal

broschb · 07-18-2022, 12:18 AM

I have a 1984 CC DS, stock.

Now that I have my cart running, i'm wondering if this noise is considered normal. If it is no worries and i'll move on, if it's not, then I would like to figure out what the cause is.

If you watch this video here, you can hear the sound of the motor with the throttle down. It is a constant whirring noise.

When the pedal is released and the cart is coast it has an intermittent rubbing sound.

If this isn't normal any thoughts on what this could be and what to look into?

NismoGriff · 07-18-2022, 08:16 AM

I'm nowhere near as qualified as many others on here, but that doesn't sound normal to me at all. Can't really tell if it is the motor or the rear diff. I'd be checking the fluid in the rear diff and maybe use a screwdriver as stethoscope against the case of the motor. Obviously raise the cart up on something that will safely hold it while you listen.

Bama Brad · 07-18-2022, 08:22 AM

Nope, not normal...something needs attention in the rear end.

broschb · 07-18-2022, 11:44 PM

Looking at the differential I decided to flush and replace the oil. The outside was covered in old caked on oil, so I figured if anything it could use a flush. When flushing I saw metal in the oil, and decided that I needed to tear it open and check it out.

That is where I am at, this is my first time working on something like this, any help is appreciated. I attached some images below, you can see metal flakes on the gears, so something is wearing. The lower bearing was all apart, i'm not sure if that happened when I opened it or if it was that way.

What would next steps be and what parts do I need to rebuild this?

PXL_20220719_042114903.MP.jpg
PXL_20220719_042125619.MP.jpg
PXL_20220719_042138289.MP.jpg

broschb · 07-19-2022, 01:06 AM

In looking at this and checking it some more. All of the bearings feel good other than the two bearings on part 51 from this diagram.

It looks like the bearings are attached and not removable from that piece. One is completely off, the other has a lot of play in it.

Does anyone know where I can get that part, or how to repair it?

Fairtax4me · 07-20-2022, 08:57 AM

Ball Bearings are not supposed to come apart. That bearing is trashed and probably the pinion gear (the small gear next to the bearing) as well.

Bearings are press fit and will require a press and some adapters to remove and install new ones. But bearings are easy, the bigger problem is damage to the gear teeth which will require replacing gears. It's not easy to find parts for those old axles anymore so you may be looking for a whole axle assembly.
I can't tell from looking at the guts of it, is that the old Kawasaki axle?
How many splines are on the input shaft?

broschb · 07-20-2022, 10:44 PM

Thanks for taking a look. I was able to get a bearing puller and pull the bearings, you can from this image how worn the bearing was.
PXL_20220721_031039421.MP.jpg

I have new bearings on the way, the one that was opposite the destroyed one had play in it so i'm replacing that as well.

I think the gears look pretty good from my inspection, nothing looks broken off or worn in an odd way, here are some pictures of the gears.

PXL_20220721_030923413.MP.jpg
PXL_20220721_030941888.MP.jpg

The housing below were that bearing was does look a little beat up, but it looks like the bearing should slide in and sill has a ridge to seat on.
PXL_20220721_031122272.MP.jpg

I'm feeling like I should be able to rebuild this.

I have another question about where the motor attaches that I'll ask some question in the next post.

broschb · 07-20-2022, 10:51 PM

As I was cleaning everything the gears slid out where the motor connects. This isn't a problem but I want to make sure I didn't lose any parts.

I highlighted the parts in question. There is rubber seal. It has a spring clip on one side of it, it doesn't look like that does much, possibly add some tension.

Looking at the part diagram I see two parts 18 and 30. The rubber gasket looks like part 18. If the spring clip is not part 30, then I'm not sure what that part should be.

PXL_20220721_031115578.MP_2.jpg

PXL_20220721_034624440.MP_2.jpg

Fairtax4me · 07-21-2022, 08:45 AM

30 is a shim that sets clearance between the bearing and the case. It keeps the input shaft from walking back and forth in the case which would wear the case out. The shim may not be there if the case tolerance is close enough.

The small spring is just a tension spring that should have been inside the seal. Replace the seal when you put it all back together.

broschb · 07-21-2022, 01:51 PM

Thanks, do you know what size that shim is so I could look for one in case it is needed, or do you know where I can order an OEM shim?

07-18-2022, 12:18 AM	#1
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27	Is this noise normal I have a 1984 CC DS, stock. Now that I have my cart running, i'm wondering if this noise is considered normal. If it is no worries and i'll move on, if it's not, then I would like to figure out what the cause is. If you watch this video here, you can hear the sound of the motor with the throttle down. It is a constant whirring noise. When the pedal is released and the cart is coast it has an intermittent rubbing sound. If this isn't normal any thoughts on what this could be and what to look into?
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27

07-18-2022, 08:16 AM	#2
NismoGriff Not Yet Wild Join Date: May 2020 Location: Northeast Ohio Posts: 73	Re: Is this noise normal I'm nowhere near as qualified as many others on here, but that doesn't sound normal to me at all. Can't really tell if it is the motor or the rear diff. I'd be checking the fluid in the rear diff and maybe use a screwdriver as stethoscope against the case of the motor. Obviously raise the cart up on something that will safely hold it while you listen.

07-18-2022, 08:22 AM	#3
Bama Brad Gone Wild Join Date: Jul 2018 Location: Ramer, AL Posts: 1,449	Re: Is this noise normal Nope, not normal...something needs attention in the rear end.

07-18-2022, 11:44 PM	#4
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27	Re: Is this noise normal Looking at the differential I decided to flush and replace the oil. The outside was covered in old caked on oil, so I figured if anything it could use a flush. When flushing I saw metal in the oil, and decided that I needed to tear it open and check it out. That is where I am at, this is my first time working on something like this, any help is appreciated. I attached some images below, you can see metal flakes on the gears, so something is wearing. The lower bearing was all apart, i'm not sure if that happened when I opened it or if it was that way. What would next steps be and what parts do I need to rebuild this? PXL_20220719_042114903.MP.jpg PXL_20220719_042125619.MP.jpg PXL_20220719_042138289.MP.jpg
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27

07-19-2022, 01:06 AM	#5
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27	Re: Is this noise normal(Update Differential Rebuild) In looking at this and checking it some more. All of the bearings feel good other than the two bearings on part 51 from this diagram. It looks like the bearings are attached and not removable from that piece. One is completely off, the other has a lot of play in it. Does anyone know where I can get that part, or how to repair it?
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27

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07-20-2022, 08:57 AM	#6
Fairtax4me Bonafide Nincompoop Join Date: Dec 2015 Location: Charlottesburg Va Posts: 8,987	Re: Is this noise normal Ball Bearings are not supposed to come apart. That bearing is trashed and probably the pinion gear (the small gear next to the bearing) as well. Bearings are press fit and will require a press and some adapters to remove and install new ones. But bearings are easy, the bigger problem is damage to the gear teeth which will require replacing gears. It's not easy to find parts for those old axles anymore so you may be looking for a whole axle assembly. I can't tell from looking at the guts of it, is that the old Kawasaki axle? How many splines are on the input shaft?

07-20-2022, 10:44 PM	#7
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27	Re: Is this noise normal Thanks for taking a look. I was able to get a bearing puller and pull the bearings, you can from this image how worn the bearing was. PXL_20220721_031039421.MP.jpg I have new bearings on the way, the one that was opposite the destroyed one had play in it so i'm replacing that as well. I think the gears look pretty good from my inspection, nothing looks broken off or worn in an odd way, here are some pictures of the gears. PXL_20220721_030923413.MP.jpg PXL_20220721_030941888.MP.jpg The housing below were that bearing was does look a little beat up, but it looks like the bearing should slide in and sill has a ridge to seat on. PXL_20220721_031122272.MP.jpg I'm feeling like I should be able to rebuild this. I have another question about where the motor attaches that I'll ask some question in the next post.
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27

07-20-2022, 10:51 PM	#8
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27	Re: Is this noise normal As I was cleaning everything the gears slid out where the motor connects. This isn't a problem but I want to make sure I didn't lose any parts. I highlighted the parts in question. There is rubber seal. It has a spring clip on one side of it, it doesn't look like that does much, possibly add some tension. Looking at the part diagram I see two parts 18 and 30. The rubber gasket looks like part 18. If the spring clip is not part 30, then I'm not sure what that part should be. PXL_20220721_031115578.MP_2.jpg PXL_20220721_034624440.MP_2.jpg
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27

07-21-2022, 08:45 AM	#9
Fairtax4me Bonafide Nincompoop Join Date: Dec 2015 Location: Charlottesburg Va Posts: 8,987	Re: Is this noise normal 30 is a shim that sets clearance between the bearing and the case. It keeps the input shaft from walking back and forth in the case which would wear the case out. The shim may not be there if the case tolerance is close enough. The small spring is just a tension spring that should have been inside the seal. Replace the seal when you put it all back together.

07-21-2022, 01:51 PM	#10
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27	Re: Is this noise normal Thanks, do you know what size that shim is so I could look for one in case it is needed, or do you know where I can order an OEM shim?
broschb Not Yet Wild Join Date: Jun 2022 Posts: 27

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