Ezgo Clutch buttons

hawkeyedm2003 · 04-07-2009, 08:27 AM

Hey all,

I just noticed that the clutch buttons on the driven clutch are worn in the forward direction. My cart is a 1981 EZGO 244 robin that I just rebuilt. Now it runs and drives just fine, but I don't want to damage the clutch with the buttons worn.
I removed the driven clutch main shaft bolt and was sure that the clutch would slide off to get at the driven sheaves to replace the buttons. Well that wasn't happening. Whats the trick to getting the cam assembly off to replace these buttons? Or does the whole clutch have to come off? Can you just remove the the front of the driven clutch and spring to get at this?

Any help is appreciated.

scottyb · 04-07-2009, 09:14 AM

From what I understand you need to remove the clutch as a unit and then disassemble it.

hawkeyedm2003 · 04-08-2009, 04:09 PM

Well....that just sucks. Thanks.

divot61 · 04-10-2009, 03:02 PM

1/2 inch wrench and just pull it off

hawkeyedm2003 · 04-10-2009, 03:22 PM

I removed the bolt.....it didn't want to come off. What's the trick?

divot61 · 04-10-2009, 05:33 PM

do you have a pickle fork? for tie rod ends. or a good size pry bar?
very carfully try to pry in between the driven clutch and the differential, if it doesnt move try squirting some pb blaster or something like that overnite and give it a try the next day, be careful, it will come off, the splines are about 3-4 " long not the entire length of the clutch

divot61 · 04-10-2009, 05:48 PM

be careful when you take it apart, it has a very strong spring inside

hawkeyedm2003 · 04-10-2009, 06:25 PM

Thanks for the replies....I guess I don't get why you can't remove the front sheave without taking the whole clutch off. Seems like you should be able to take individual pieces off.

I guess the next question would be, how do you get the ground down old buttons out. Just drill them?

divot61 · 04-10-2009, 06:40 PM

there is an external snap ring holding the clutch together, if, by chance, you get the snap ring off it would probably break one of your fingers against the frame. ouch!
and about the cam buttons, if they are worn down to the allen head cap screws and it messes up the allen hole then yes, you can try to drill them out, i have had bad luck with that because the clutch is alum. and the cap screws are a lot harder, thus, drifting of your drill bit, if you can break away the plastic cam lobes and get ahold of whats left of the screw with a small pair of vicegrips you may be able to back them out.
that aluminum pot metal tends to grab a hold of other metal and not wanting to let go, pb blaster or any good penetrating oil and let it sit for a while. last option is put some heat to it
hope this helps ya .
chris

04-07-2009, 08:27 AM	#1
hawkeyedm2003 Getting Wild Join Date: Mar 2009 Location: Over there Posts: 76	Ezgo Clutch buttons Hey all, I just noticed that the clutch buttons on the driven clutch are worn in the forward direction. My cart is a 1981 EZGO 244 robin that I just rebuilt. Now it runs and drives just fine, but I don't want to damage the clutch with the buttons worn. I removed the driven clutch main shaft bolt and was sure that the clutch would slide off to get at the driven sheaves to replace the buttons. Well that wasn't happening. Whats the trick to getting the cam assembly off to replace these buttons? Or does the whole clutch have to come off? Can you just remove the the front of the driven clutch and spring to get at this? Any help is appreciated.

04-07-2009, 09:14 AM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,406	Re: Ezgo Clutch buttons From what I understand you need to remove the clutch as a unit and then disassemble it.

04-08-2009, 04:09 PM	#3
hawkeyedm2003 Getting Wild Join Date: Mar 2009 Location: Over there Posts: 76	Re: Ezgo Clutch buttons Well....that just sucks. Thanks.

04-10-2009, 03:02 PM	#4
divot61 Gone Wild Join Date: Apr 2009 Location: indiana Posts: 274	Re: Ezgo Clutch buttons 1/2 inch wrench and just pull it off

04-10-2009, 03:22 PM	#5
hawkeyedm2003 Getting Wild Join Date: Mar 2009 Location: Over there Posts: 76	Re: Ezgo Clutch buttons I removed the bolt.....it didn't want to come off. What's the trick?

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04-10-2009, 05:33 PM	#6
divot61 Gone Wild Join Date: Apr 2009 Location: indiana Posts: 274	Re: Ezgo Clutch buttons do you have a pickle fork? for tie rod ends. or a good size pry bar? very carfully try to pry in between the driven clutch and the differential, if it doesnt move try squirting some pb blaster or something like that overnite and give it a try the next day, be careful, it will come off, the splines are about 3-4 " long not the entire length of the clutch

04-10-2009, 05:48 PM	#7
divot61 Gone Wild Join Date: Apr 2009 Location: indiana Posts: 274	Re: Ezgo Clutch buttons be careful when you take it apart, it has a very strong spring inside

04-10-2009, 06:25 PM	#8
hawkeyedm2003 Getting Wild Join Date: Mar 2009 Location: Over there Posts: 76	Re: Ezgo Clutch buttons Thanks for the replies....I guess I don't get why you can't remove the front sheave without taking the whole clutch off. Seems like you should be able to take individual pieces off. I guess the next question would be, how do you get the ground down old buttons out. Just drill them?

04-10-2009, 06:40 PM	#9
divot61 Gone Wild Join Date: Apr 2009 Location: indiana Posts: 274	Re: Ezgo Clutch buttons there is an external snap ring holding the clutch together, if, by chance, you get the snap ring off it would probably break one of your fingers against the frame. ouch! and about the cam buttons, if they are worn down to the allen head cap screws and it messes up the allen hole then yes, you can try to drill them out, i have had bad luck with that because the clutch is alum. and the cap screws are a lot harder, thus, drifting of your drill bit, if you can break away the plastic cam lobes and get ahold of whats left of the screw with a small pair of vicegrips you may be able to back them out. that aluminum pot metal tends to grab a hold of other metal and not wanting to let go, pb blaster or any good penetrating oil and let it sit for a while. last option is put some heat to it hope this helps ya . chris

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