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Old 12-03-2018, 08:21 AM   #1
scubadog
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Default Secondary Clutch falls off

I have a 2014 Yamaha EFI cart. After about 3 years the "top hat" washer that holds the secondary clutch on wore and the clutch slipped off the shaft. Called and had repair consisting of replacing the washer. The repair guy took about 5 minutes and I was on the road again. 2 months later same thing. This time I went to a dealer and purchased the washer and replaced it myself. My question: How do I stop the wear on this washer. I purchased an extra for the next time it wears out but would like a permeant fix.
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Old 12-03-2018, 09:41 AM   #2
CP241
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Default Re: Secondary Clutch falls off

Have you tried loc-tite? If that doesnt work I'd try and stake the nut.

Chances are either it's not been torqued properly, or the threads on the shaft are worn/damaged from the clutch coming off previously. Loc-tite (blue) should be good.
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Old 12-03-2018, 10:29 AM   #3
scubadog
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Default Re: Secondary Clutch falls off

I guess I did not explain my problem very well. The bolt is still there and tight. The washer that is between the bolt head and the collar is worn completely away. Part 14 and 15 are still in place. part 13 is gone except for a small portion around the bolt. Picture here https://www.shopyamaha.com/parts-cat...(YDRAX4_-_2014)
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Old 12-04-2018, 08:15 PM   #4
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Default Re: Secondary Clutch falls off

Here is the issue.
Im going to assume you didn't have the cart serviced on a regular basis, or you used a shop that didn't know the issue with the secondary clutch.

Put the new washer on and tighten it down. Now check the clutch to see if it "rocks" on the shaft. If it does, then you may need a new clutch and/or a new input shaft.

Whats happening is there is wobble and it is breaking that washer. Its a simple 2 minute fix if caught early enough in the carts life.
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Old 12-04-2018, 08:33 PM   #5
drift240se
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Default Re: Secondary Clutch falls off

Golf cart guy nailed this. That is not a wear item. The washer should last the life of the cart pretty much. If I had to guess, that bolt wasn't tight when new or shortly after was loose and never tightened causing another issue. I've never personally seen anyone ever have to replace.
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Old 12-04-2018, 08:55 PM   #6
smallblock450sl
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Default Re: Secondary Clutch falls off

Or as in my opinion...the washer is just to "thin" of material to do the job.
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Old 12-06-2018, 09:26 PM   #7
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Default Re: Secondary Clutch falls off

The design had one minor flaw, but was a very easy fix. Those that didn't get caught in time, have the issue of the clutch continuing to break that washer.
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Old 01-02-2019, 10:57 PM   #8
Berex
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Default Re: Secondary Clutch falls off

I have had this issue on my 2014 since it had about 90 hours on it.I have tried a number of things to fix it with no real luck. I would be interested to know what the easy fix was that would have prevented this from happening.
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Old 01-03-2019, 06:37 AM   #9
meimk
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Default Re: Secondary Clutch falls off

I've mostly dealt with older ones, but your '14 is probably much the same. That washer is only intended to hold that outer sheeve on, not to keep it parallel to the inner. Once it has developed a "wobble", from worn bushings and plastic spacers, it can wear the opening in that outer sheeve till it has too much side to side play. Once it's worn like that, it's time to replace it.
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Old 01-03-2019, 10:45 AM   #10
Berex
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Default Re: Secondary Clutch falls off

Do you think it would have caused damage to the input shaft or would a new clutch solve the problem. I keep the input shaft well greased so I would think that it should be fine but honestly don’t know. Thanks in advance for your help
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