Engine Went THUNK!

[crash12888]

Do you have the Flywheel off?
Sounds like you might have tangled the mag/stator up under the flywheel.

[Dave Box]

The big end is probably welded to the crankshaft which is what happened to mine. The good news is that this will not affect spliting the crankcase. The bad news is that you will undoubtedly need the complete overhaul kit which runs at ~$400. When I did mine I also took the opportunity to replace the carburetor and now the engine runs like it is new (which of course it is).

Have you removed the clutch and the flywheel yet? Both require special techniques as well as some blood, sweat and tears. If you need help shout out.

Dave

[Obee]

Flywheel is off and so is drive pulley. Made my own stuff and didn't even require learning new words.

Glad to hear I can split the case. Gonna do that today, I hope. I already figured on a whole new setup for it. Going to buy the fuel pump too just for giggles.

Thanks again guys!

Regards, Jeff

[Obee]

Got my case apart and the crank bearings were shot. Couple of questions:

1. Is there suppose to be gas in the lower end? I had about a cup or so in there.

2. The bearings on the crank were sealed bearings. Do they need to be open?

3. The case has a crack in it, know where I can find the fan side case half? Might be able to have it TIG welded. I assume the case needs to hold some pressure?

4. What kind of sealer should be used on the case halves?

Thanks!

Regards, Jeff

[ScooterMcTavish]

Hey Obee,

I can answer some questions for you:

1. There should be some gas, as there needs to be a fuel/oil mixture in the crankcase to lubricate the bearings. A cup sounds a bit high, but the crack in the case could contribute to this as depending on your fuel pump, there could be fuel sneaking back down the suction line.

2. Uhhhh, Dave?

3. Wow, that's a toughie, as the case does need to be air tight for the crankcase pressure to drive the fuel pump. I guess welding could work, but it it must be an airtight seal, or not interfere with the mastic sealing the case halves together.

4. I believe the guys who cracked their cases use a Permatex Gray mastic

Best I can do for you Jeff, and I'm sure Dave'll be around to straighten me out if I told you the wrong thing.

[Obee]

Appreciate the reply! Just trying to get things in order when I get my parts it can go together.

Thanks!

Regards, Jeff

[Dave Box]

Everything that Scooter said, plus if you go here

http://thegolfcart.blogspot.com/sear...&max-results=7

and scroll down you will see the re-build kit and the three main bearings which are clearly open. Perhaps someone fitted the wrong bearings (the size is generic so this is a possibility) and thus your problem.

Dave

[madoc1]

the bearings are not sealed. they are lubed by the oil/gas mixture. is the rod moving on the crank? if it is, and you can't feel any up or down play it should be ok. i bet you can weld that crack up just fine. any sealer will work as long as it is gas resistant, altho the permatex is nice because of the color and was made for this type of case--i.e. motorcycles.
be sure to replace both crank seals while you are in there. you also need to correct the gas problem. probably a bad fuel pump, but not sure. dave or brew will jump in and answer that.

if you replace the top end, run 40/1 for the first tank and then 128/1. good luck.

[Obee]

Got it welded up this afternoon, gonna be just fine. I figured they needed to be open for the lube factor, just checking cause mine were sealed and I too thought that was the problem.

Going to do the whole kit top and bottom, all seals and gaskets, don't know the history so I will just do it all and be done with it. Going to add new fuel pump to the list as well as carb. Hope it will run for a long time.

I am also going to fab up a different intake system from where it draws it's air. Right now where I live the course is always very dusty and it seems to like to draw the dust up off the ground from the front tire.

If anyone has any other suggestions to do while it's apart I would surely entertain their thoughts. Don't want to do it again for a while.

Thanks!

Regards, Jeff

[crash12888]

Jeff, As for the remote air intake, I got a small shop vac from a yard sale that was broke for $2.00.
I kept the flex hose to make a remote intake and a couple of the ends to adapt the air filter canister to and threw away the rest. Hoping to mount it to the seat back or up the top strut.
Just throwing out Ideas, Shop vac, old house vac hose, old pool vac hose maybe?