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Old 08-17-2009, 07:59 PM   #1
56servi
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Default Machining Stock ezgo 4 stroke Drive Clutch

Getting ready to get my stock 4 stroke EZGO drive clutch modified to use on my 16HP Vanguard. The Vanny has the 1" X 3" crank stub.

I have seen 3 threads about machining the clutch.

Billys Buggie had a sleeve machined to fit inside the stock clutch & then pinned in place.

Pizzamaker had is crank stub machined to a taper to match the clutch.
I have straight shaft so don't want to do this

DirtySouth did some kind of machining to the clutch then drilled & tapped holed for set screws to hold it on to the crank stub. Not sure if a sleeve was made or what.

Questions:
How long should the sleeve be
What is the finish ID of the sleeve to fit over the 1" shaft
What type of steel should the sleeve/insert be made from
Do you cut off the crank stub to bring the clutch closer to the block

I think if I buy by buddy a few Stroh's he will do it in his machine shop

Billys Buggie Modified clutch
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File Type: jpg Mod clutch 3.jpg (5.9 KB, 142 views)
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Old 08-18-2009, 05:16 AM   #2
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Default Re: Machining Stock ezgo 4 stroke Drive Clutch

Had my buddy machine mine as deep as original and had it broached. I also ended up cutting about one inch off my shaft to line up the clutches. test fit a couple times and make sure you don't go to far. I didn't need any shims.
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Old 08-18-2009, 07:30 AM   #3
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Default Re: Machining Stock ezgo 4 stroke Drive Clutch

When you say "machined mine" do you mean made an insert. The stock clutch is already bigger than 1"
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Old 08-18-2009, 07:38 AM   #4
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Default Re: Machining Stock ezgo 4 stroke Drive Clutch

Billy's is the way to do it, i tapered mine because it started out as a generator taper engine.
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Old 08-18-2009, 03:05 PM   #5
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Default Re: Machining Stock ezgo 4 stroke Drive Clutch

like pizzamaker said like billies. my buddy machined the inside of mine big enough to except a new sleave that was broached for 1/4" keyway. He slid it in and put 2 pins opposit sides to keep it from moving. If you look at billies buggy build that is exactly like that.
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Old 08-18-2009, 03:12 PM   #6
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Default Re: Machining Stock ezgo 4 stroke Drive Clutch

my stock clutch was tappered 1 1/8 to 1" .
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Old 08-18-2009, 07:41 PM   #7
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Default Re: Machining Stock ezgo 4 stroke Drive Clutch

Thats what I needeed to know. I have an old pully that was on the vanny when I got it. I will use that for the ID measurment
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Old 08-18-2009, 07:57 PM   #8
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Default Re: Machining Stock ezgo 4 stroke Drive Clutch

Quote:
Originally Posted by 56servi View Post
Thats what I needeed to know. I have an old pully that was on the vanny when I got it. I will use that for the ID measurment
you can just have your machinist turn down the old pulley to fit the clutch and save some work! it works great.
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Old 08-19-2009, 09:22 AM   #9
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Default Re: Machining Stock ezgo 4 stroke Drive Clutch

Good idea. I will take it up there
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