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Gas Club Car Gas DS, and Precedent golf cars |
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09-18-2012, 08:57 PM | #1 |
Not Yet Wild
Join Date: Sep 2012
Posts: 15
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Issues with ds engine swap and stuck tranny
Ok ,I picked up a DS this past weekend , the original motor was out with all of the good stuff missing '' starter , clutch ect ect '' so I rounded up a few motors here in the shop and went with 212cc honda clone pull start I know I know .
I got this cart for the wife and my 2.5yo twins to play on here at the house so big power is not a concern ''right now '' . I am having issues with making a safe and reliable throttle connection , the original controller box is junk and wont fit with the new engine and that stupid throttle rod is a joke ! So that is my first question , what do you guys do for throttles ? Second , Due to being in a rush I went with a 3.5in belt clutch from Hillard for the engine and at first a 8 in pulley for the rear . Great torque but only ran about 5mph . So I went with a 4in on the rear and not enough power to run it like it should so Im going to try a 6in . Do you guys run this type of clutch ? What would be a decent HP for this cart ? NOW , that trans is stuck , Forward is forward , neutral is Forward and reverse locks it all down tight . Unhook shift cable and shift at trans fine with nice solid clicks and clunks , no binding at all . Is it just a stuck syncro ? Sorry for the many questions , just getting frustrated at it |
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09-19-2012, 04:17 PM | #2 |
Not Yet Wild
Join Date: Sep 2012
Posts: 13
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Re: Issues with ds engine swap and stuck tranny
Must be somthing in the air because my cart is doing the SAME thing..
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09-22-2012, 05:23 PM | #3 |
Not Yet Wild
Join Date: Sep 2012
Posts: 15
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Re: Issues with ds engine swap and stuck tranny
I ended up pulling the top outer cover and giving the syncro a lil love tap , i removed the gov gear while I was in there , not too bad to pull apart
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09-23-2012, 09:12 PM | #4 |
Not Yet Wild
Join Date: Sep 2012
Posts: 13
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Re: Issues with ds engine swap and stuck tranny
So the love tap fixed it?....As for the governor gear, did that increase speed?
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09-24-2012, 10:47 AM | #5 |
Not Yet Wild
Join Date: Sep 2012
Posts: 15
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Re: Issues with ds engine swap and stuck tranny
The gov was never hooked up due tot he engine swap , but I was in there and it was one more thing that could fail and was not needed so I just popped it out .
It shifts fine now but Im still dealing with the rear sprocket size and throttle issues |
09-24-2012, 11:32 AM | #6 |
Not Yet Wild
Join Date: Sep 2012
Posts: 13
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Re: Issues with ds engine swap and stuck tranny
Ok thanks...I will be showing mine some LOVE TAPPAGE tonight then...
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09-24-2012, 12:37 PM | #7 |
Not Yet Wild
Join Date: Sep 2012
Posts: 15
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Re: Issues with ds engine swap and stuck tranny
Drain the gear lube first . If yours is the same as mine , when you pull the case off a drive gear and bushing will fall out , they go to the input shaft , gear goes on 1st then spacer/bushing .
The syncros are the gold rings , one on either side of the shift fork , A small flat head may pop it out , it only moves in and out about 3mm +/-1 . Some file the sharp edges down but I was too lazy . You will prob tear the gasket too so be careful . If you dont know what your looking at it can be intimidating , just pay attention . You will need a 7/16 wrench and socket , a 10 mm socket and a 13 mm and a hammer to tap , TAP the case apart |
09-25-2012, 09:19 AM | #8 |
Not Yet Wild
Join Date: Sep 2012
Posts: 13
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Re: Issues with ds engine swap and stuck tranny
WOW!!!...ok....mine is a transaxle and on initial look, im dont see how to pull it apart with out removing the axel. It there an easier way? I have heard the shifter housing comes off the top of the gear box??????
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