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Gas golf carts Harley Davidson, Melex, Pargo, Taylor-Dunn and other Misc. Carts. |
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#11 |
Not Yet Wild
Join Date: Jul 2024
Posts: 30
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![]() Well, Charlie,, I really dislike leading folks on wild goose chases but this one just could not be avoided,,,,HA,,!! As you know,,the starter is a 3 bolt design and when I removed the old starter, I (thought) I noticed the connector for the battery cable was pointed straight up,,which made sense for ease of a hook up...BUT,,,the HEAD of the starter case which has the 3 bolt design head is offset from center of armature,,,, SO, when installing the new starter I (mistakenly) installed it where the battery terminal was looking straight up and the 3 hold down bolts did in fact line up,,,which placed the bendix teeth exactly 1/16" higher than the flywheel teeth. Same dang thing with the new starter,,,WTH,,,?? The more I studied the sitiiation, it finally became apparent the started was installed wrong. So I unbolt it and roll the case one bolt towards the pass side and LO And Behold,,,the bendix is NOW exactly where it will engage the flywheel and to be sure,,I hit the solenoid and the bendix engaged the flywheel just as pretty as you please,,,,,I'm happy ,,,,NEXT JOB to solve is to fashion some repairs to the "T" on the intake. It has 3 ugly and big cracks on the rubber "T". Have you ever done A REPAIR to that "T",,????
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#12 |
Gone Wild
![]() Join Date: Dec 2012
Location: Central North Carolina
Posts: 587
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![]() I have never needed to repair the rubber T, but heard that they are available from www.directparts.com. You will be much better off buying a replacement, since any leak, even tiny, will mess with the carburetor mixture and the engine won't run right.
When you get to rebuilding the carburetor, be certain to replace the accelerator pump diaphram as well as the float and needle valve. These don't come in any rebuild kit, but you will need that too for the gaskets, etc. Brass floats and even the foam plastic floats can absorb gas over the years and not float at the required level any more, flooding or making the engine run rich. Cleaning the tiny passage ways of the built up varnish is absolutely necessary too. Mechanical fuel pumps are also un-obtanium, and even if you can find one, it's rubber parts are old and will likely fail quickly. You will be better off buying an electric fuel pump and making a plate and gasket to plug the original mechanical pump's hole in the crankcase. I mounted my electric pump on the side of the chassis under the driver door. First pump came with a filter for the inlet from the tank. While an inlet filter is very necessary, the one that came with the electric pump had a tiny crack in it, letting air get in. I had all kinds of trouble figuring out where the air was coming from, but finally changed the filter and no more trouble. Wiring is easy. Black wire to frame and red wire to key switch, or nearest source of key controlled power. Connect the output of the electriv pump directly to the carburetor and throw away the bypass filter. Be sure to plug the inlet to the fuel tank where the bypass filter side connection fed excess fuel back to the tank. The electric fuel pumps are self regulating to maintain fuel pressure and not positive displacement, like the OMC fuel pump, so they don't require the bypass filter and return line to the tank. If your carburetor is a Keihin, there may still be a tiny tubular screen filter in the inlet to the carburetor. They are also un-obtainium, but plug up with age. Just pull it out with needle nose pliers and discard it. A good inlet filter between the fuel tank and the electric fuel pump is all you need. Charley |
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#13 |
Not Yet Wild
Join Date: Jul 2024
Posts: 30
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![]() Good Morning Charlie,,The way I addressed the fuel pump was to replace the old electric pump with a new "Low Pressure" 3-5# electric as the PO had already used an electric, but was hanging on from a ,,,,,you guessed it a piece of bailing wire,,,,,LOL. As per a suggestion from somewhere,,I installed a fuel filter between the tank and the fuel pump to save the pump internals. I have no idea where on the OMC the mechanical pump would be,,,?? My project for the day is the two resistors AND asssociated ignition wiring. Neither resistor has any wires connected to them,,?? The resistor closest to the coils will not pass any current going thru it from either direction,,,? Numbers on the porcelin body are:60 OHM, 10% 25W. What do I need to order? The second resistor has NO numbers anywhere,, and what is it for? I know I need a better wiring diagram and would pay for a clear and legible copy. I downloaded two copies from www.sillylittlecars.com but keep losing too much clarity in the downloading process,,,?? The area at the ignition wiring is where it is not very clear on my copies.
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#14 |
Gone Wild
![]() Join Date: Dec 2012
Location: Central North Carolina
Posts: 587
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![]() The original mechanical fuel pump was located roughly under the timer (distributor). There will probably be a cover and two bolts covering the hole if the fuel pump isn't there. One resistor of about 60 ohms was originally in the coil circuit, but most have removed them for better spark. The 2nd resistor was likely the first one that had gone bad. Most of my engine running problems have been fuel system and carburetor problems.
How much rust ddo you have in the fuel tank? Mine had 1/4" of rust in the bottom and plugged the filters rapidly. I ended up buying a tank restoration kit , consisting of an etchant, detergent, and an epoxy-like coating for the interior. New gas tanks of the needed size are also un-obtainium, so this kit was the best fix. I bought it through Amazon. Over about a week of several hours of intermittent attention in small segments, I used the etchant, but added a hand full of small crushed gravel, and shook the tank hard and long, even strapping it inside my cement mixer and let it run for a few hours, then cleaned that out and used the detergent to get the tank as clean as possible. After letting it dry with all of the openings wide open, I again plugged the openings, but added the epoxy liner material and sealed the tank back up. I then rotated and flopped the tank in all directions to assure that the entire interior was coated, then drained the excess, cleaned the small tubing ports with large pipe cleaners (actually fuzzy fake candy cane material), and left the tank completely open so the liner material can dry. This process ruined the fuel cap, so I bought a replacement at auto parts store. Take the spring and valve out of the cap so the air vent in it works like the original cap (it's designed for the new sealed systems and won't work in the Cushman without modification). The .pdf files are quite clear when printed on a good printer. Your problem printing them is very likely your printer. Maybe you can get someone else to print at least the needed pages on their printer to see if they are better. If it is a laser printer, taking the cartridge out, shaking and tilting it end to end and then returning it to the printer usually fixes this problem. Charley |
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#15 |
Not Yet Wild
Join Date: Jul 2024
Posts: 30
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![]() Good Morning Charlie,,I looked for the mechanical fuel pump and it appears to have already been removed and blocked off,,Good. On the resistor at the coils, can it just be left off? If not replaced will it harm the coils,,I would much rather have a good spark quality for the engine,,? 60 OHMs seems a bit much restricting the spark,,,?? I did remove the fuel tank while waiting for parts location and delivery to repair the fuel gauge and now am going to remove tank again to check for cleanliness,,,,LOL.
I am glad to announce that I am finished with fabricating the replacement rubber "T" Intake with one of 1" copper tubing that was actually a dang good fit,! I used a 1 1/4"radiator hose with hose clamps and looks almost factory. The old rubber T had several cracks and two areas where the cracks were all the way thru the rubber and could not be seen from front of engine.,,!! What are you gonna work on today?? |
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#16 |
Gone Wild
![]() Join Date: Dec 2012
Location: Central North Carolina
Posts: 587
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![]() I had built a complete Pro Digital Photo/Video studio upstairs in my home about 5 + years ago, and today I'll be doing a couple of photo shoots. I've been a photographer since about 1955, went full digital in 1998, and finally have my own complete photo/video studio.
I attached a photo to give you some idea of my work. Print it out and give it to your wife. Women appreciate this shot more than we do. I set up do work like this when it's a bad day outside, or I have no other work coming in. Today it will be 97 outside, so I'll do my best to stay inside in the air conditioning. Charley |
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#17 |
Gone Wild
![]() ![]() Join Date: Nov 2016
Location: near Calgary, AB, Canada
Posts: 1,577
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![]() Great picture Charley.
![]() I will save it for the next Valentine's card that I make for my wife. |
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#18 |
Not Yet Wild
Join Date: Jul 2024
Posts: 30
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![]() Hey Charlie,, That IS a beautiful arrangement for the right lady altho,,my wife of 53 years passed two years ago after a very long battle with Diabetes.
On a better note, I finally got finished on fashioning a replacement T at the intake to carburator by using a copper tubing "T" along with a radiator hose of the almost idential ID as the old rubber T,,,It took some ffinagling but after some coaxing it finally gave up and slipped into place,,,,, THEN,,,Charlie,,,THEN,,,I put a spark in the engine and the OMC fired right up and it runs Great,,!!no smoke out the exhaust,,except for a small fuel leak at one corner of the KEIHIN carburator. I am stoked at how good the engine runs,,,,after being parked for so long. Many THanks Charlie,,!!!!!!!! |
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#19 |
Gone Wild
![]() Join Date: Dec 2012
Location: Central North Carolina
Posts: 587
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![]() You are lucky that it started this easily. Usually the final nightmare is the fuel system and carburetor.
Now enjoy it, but don't go too far for a while. Stay near your shop and tool until you put some mileage on it. There will likely be many small problems that require a tweak or to before it becomes reliable. Sorry to hear about the wife, but you will find someone to give it to. Charley |
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#20 |
Gone Wild
![]() Join Date: Dec 2012
Location: Central North Carolina
Posts: 587
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![]() @threecw,
I did a photo shoot for Valentine's Day, but it involved a full table of food, wine, hot chocolate, decorations, and of course the heart shaped box of hot chocolate. I'll see if I can find the file and I'll post that one too. Don't save this one for Valentine's Day. I tend to do these to stay busy when no work is coming in. I've been quite amazed by the number of friends asking for prints of them. I've been a photographer since high school. A teacher liked my snap shots that I was showing my friends, and put me to work using the school's Graphlex Press Camera to shoot sports, club groups, etc. for the school yearbook, likely because he was supposed to be doing it, but I learned that camera quickly and got quite good with it. I learned stage lighting from the art teacher, who was responsible for the school's plays and stage shows. This ended up with me getting the job of stage manager of a Summer Stock Off-Broadway Theater after my high school graduation. I became an electrical engineer and left the theater behind after that job, but knowing photography got me a job working on a special camera guidance system for NASA. This camera was designed to orbit the Moon in a rocket and take mapping photos of the Moon. But with 1960's camera and film technology, the camera needed to be locked on a position when the camera was taking low light timed exposure shots, especially of the dark side of the Moon. I worked on that portion of the camera system. Being a photographer got me involved with several other projects over my career too that also involved image capture and processing. My studio for most of my life has been the center of my living room, and all of my gear (what little that I had) was stashed in a closet until needed, then packed up and put back in the closet, until next time. I did use the theater stage as a studio a few times with all of the curtains closed, but otherwise I never had a studio, until 5 years ago when I realized that there was a large 2nd Master Bedroom Suite upstairs in my home that was not being used, other than for storage. I went to work on it, creating the photo/video studio that I have now. The shooting room (former bedroom) is 19 X 26' and it has a double sink full bath and walk-in closet off of it. The hair make-up and break area area is in the large hallway at the top of the stairs. A fridge, microwave, and bottled water, soft drinks, and coffee or tea is available there. At 82, with metal knees from fire fighting, 8 heart surgeries, including a valve repair, 9 stents, and a pacemaker later, plus surviving Cancer twice, I am still here, but not exactly sure why. I bought my Cushman Truckster from a friend who's father had been a Cushman Scooter collector before he died. It had sat unused for about 13 years before I bought it from his son. There were trees growing up through the pedal holes. Charley |
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