2013 & 2014 EZGO RXV Front End "Clunk"

[Smokinguntoo81]

Seems as though many of the 2013 and 2014 EZGO RXV's were fitted with front shocks that were manufactured with plunger shafts that are too long. There is a "rubber damper doughnut" on the plunger shaft, however when you hit a bump that fully collapses the shock absorber, the shaft bottoms inside the shock body before the rubber damper can soften the blow. This is what causes the "clunk" noise.

Thankfully the fix is really simple and cheap. You can add an additional "rubber damper doughnut" ($3.60/pair) on top of the existing one. Just double up.

Remove the headlight to allow easy access to the top shock absorber bolt. Remove the 15mm nuts on both sides that hold the front bumper and remove it by sliding it out at the top and down to release it.
Removed the second 15mm nuts, washers and bolt (head is 15mm too) that will allow you to tilt the shock outward.
Compress the coil spring (I used a couple of pairs of vice grips).
There are wrench flats on the top of the shock absorber shaft and the top mounting eye is threaded and needs to be removed.
I had to grind down the thickness of a 15mm wrench to make it fit on the wrench flats of the shock plunger shaft.
That done, I held the shock shaft with the modified wrench and used a long skinny punch to unscrew the top shock mount (standard right hand thread).
Remove the top mount from the shock plunger shaft.
Removed the spring retainer disc.
Install the second rubber damper bushing on top of the old one.
Reassemble.
You're done. No more "clunk".

Smokinguntoo81

[Cobra,1]

Nice write up👍

[Smokinguntoo81]

Thanks Cobra, 1.

I was just doing a search for my next problem when I saw your reply. I appreciate it.

There may be an error in what I was told by the dealer here. Either the plunger shaft of the shock absorber is too long OR THE SPRING COIL BINDS ON COMPRESSION. I haven't measured the compressed height of the spring - YET. The fix is still the same.

I have a 2013 RXV an use it for golf in a "golf cart community". What amazes me is that even a small mismatch in the cart path concrete will cause the shock to "bottom out".

That's telling me that the coil spring is insufficient. I am searching the forum for upgrade coil springs to overcome the issue. Haven't found them or a post about them yet.

Smokinguntoo81

[steve33blair]

Can not find bushings for front shocks anywhere

[rickter]

I tried this but still have a clunk... Any one else have an idea??? Thanks

[Rich427]

Originally Posted by rickter

I tried this but still have a clunk... Any one else have an idea??? Thanks

Rickter, even though this didn't work for you, and since this is an old post, can you tell me where you found the rubber donut that goes on the shock absorber shaft?

I have posted on this site a few times over a couple years asking for help on this issue and this is the first post I have seen that tries to address it. I have a 2012 RXV and it is not lifted, but I am running 14" low profile tires and the clunk is driving me crazy. I do believe it is on the compressions stroke of the shock that is the issue. I am on my golf course with my cart 3 or 4 times a week, so it sees a lot of unlevel surfaces. On the paved road from my house to the club house is no issue. So, if you can share where you found the rubber donut to fit the shaft of these shocks I would appreciate it!

Thanks

[ojo]

I've never noticed this issue but, I'd replace both front struts, they are not expensive.

[rickter]

https://www.amazon.com/dp/B0CL6V1Z8T...t_details&th=1