Buggies Gone Wild Golf Cart Forum - View Single Post

sho305 · 07-29-2018, 06:17 PM

I did two of them, 420 clones. The stock clutch works great on a stock 420 if you want the cart to work like it has stock....except have a lot more power. I don't know about a replacement. So I would agree make sure the clutch is good, if its worn out you are better to address that now.

What I did is cut the crank off to 1 1/8" long of the 1" diameter part. You have to drill the hole deeper and then tap it, its not hard I wacked it off with an air grinder, you can also hack saw it with some elbow grease, or sawzall it. Wrap tape around it and follow that with the saw. Reason you cut it shorter on a G2 or G9 is you don't have much room to the fuel tank if you want to keep the recoil on for emergency starting. Or you can leave it longer and space out the adapter, its about 1" long and 1 1/8 max length for the crank or you have to spacer it. Most come with a spacer. Then you stick the clutch on like normal. IIRC and maybe wrong but it was a 1/2-20 fine thread in my G9.

What I did is sat the engine in the foam it came in on the recoil, and hand drilled the tap size deeper, measuring how far. Then I sat it on the foot and cut it off. Then I tapped the new thread in it. It was off a little. The second one I kept moving around the engine as I drilled it and that one came out pretty straight lol. They both work fine the bolt goes through a lot of air before it gets to the crank anyway. You always drill on an angle with a hand drill, that is why moving around helps. Its the taper that keeps the clutch straight.

Then you have to align the clutches on your new mount, its a really good idea to measure it all and straight edge it before you do the swap, is what I did, and was able to run the same distance and belt as stock. It worked like a charm. All the details are in here: http://www.buggiesgonewild.com/clone...-clone-bb.html

Now the first clone I had rebuilt the stock clutch, back then you could buy the sheave reasonable. That cart is still running great today. The second one I later modded the engine, modded the clutch for more rpm but it refused at some point. Then put a replacement ezgo 94c on it. 94C has the pucks in it, pound on the puller bolt and the cover falls off to get at the pucks and spring, some replacements are 94c. Its the same as yamaha but the taper is deeper in the clutch, which gives me more room on the recoil side. I had to redrill my mount but then later I found the belt was too tight and could not move the engine it was hitting the trans. I had to use a scrambler belt and move it away from the trans, but its working really well now. I managed 41mph gps the other day with a vegas cam and rod in it. Most importantly it has enough power to spin the tires some, I rarely go that fast with it. But the stock 420 had roughly twice the power of stock engine.

07-29-2018, 06:17 PM	#5
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,443	Re: Using stock clutch on clone I did two of them, 420 clones. The stock clutch works great on a stock 420 if you want the cart to work like it has stock....except have a lot more power. I don't know about a replacement. So I would agree make sure the clutch is good, if its worn out you are better to address that now. What I did is cut the crank off to 1 1/8" long of the 1" diameter part. You have to drill the hole deeper and then tap it, its not hard I wacked it off with an air grinder, you can also hack saw it with some elbow grease, or sawzall it. Wrap tape around it and follow that with the saw. Reason you cut it shorter on a G2 or G9 is you don't have much room to the fuel tank if you want to keep the recoil on for emergency starting. Or you can leave it longer and space out the adapter, its about 1" long and 1 1/8 max length for the crank or you have to spacer it. Most come with a spacer. Then you stick the clutch on like normal. IIRC and maybe wrong but it was a 1/2-20 fine thread in my G9. What I did is sat the engine in the foam it came in on the recoil, and hand drilled the tap size deeper, measuring how far. Then I sat it on the foot and cut it off. Then I tapped the new thread in it. It was off a little. The second one I kept moving around the engine as I drilled it and that one came out pretty straight lol. They both work fine the bolt goes through a lot of air before it gets to the crank anyway. You always drill on an angle with a hand drill, that is why moving around helps. Its the taper that keeps the clutch straight. Then you have to align the clutches on your new mount, its a really good idea to measure it all and straight edge it before you do the swap, is what I did, and was able to run the same distance and belt as stock. It worked like a charm. All the details are in here: http://www.buggiesgonewild.com/clone...-clone-bb.html Now the first clone I had rebuilt the stock clutch, back then you could buy the sheave reasonable. That cart is still running great today. The second one I later modded the engine, modded the clutch for more rpm but it refused at some point. Then put a replacement ezgo 94c on it. 94C has the pucks in it, pound on the puller bolt and the cover falls off to get at the pucks and spring, some replacements are 94c. Its the same as yamaha but the taper is deeper in the clutch, which gives me more room on the recoil side. I had to redrill my mount but then later I found the belt was too tight and could not move the engine it was hitting the trans. I had to use a scrambler belt and move it away from the trans, but its working really well now. I managed 41mph gps the other day with a vegas cam and rod in it. Most importantly it has enough power to spin the tires some, I rarely go that fast with it. But the stock 420 had roughly twice the power of stock engine.