fix sticking clutch on EZGO golf cart- DIY specialty tools 

Good info. The only thing missing was the use of PPE. Cheers!

Clear, concise and straight to the point. If you are not a professor or teacher you missed your calling. thanks

I can by looking at your clutch, the drive clutch is stuck closed.i had the same problem but mine was from a whole bunch of tall grass that got tightly wound up in the end of the clutch. It was preventing the sheave from the drive clutch sliding back and forth and keeping it in the closed position at rest and the driven clutch was in essence open. Therefore it was stuck in the high gear and jumping from idle.

At the beginning of the video I could see that the belt was sitting way too low in the back pulley. It should have been sitting even with the top of the rear pulley and at the bottom of the front pulley. That's where all the slack in the belt was coming from. Great video with instructions of how to make your own tools.

The bearings are shot in the starter/generator. Thats what that loud whining sound is.

I have the exact same problem, just got my removal bolt today - thank you!

Good job! I knew there had to be a way to disassemble the primary clutch without buying special tools. I have a welder so I'm going to improvise a tool like you did using whatever is handy. I have to remove the clutch to replace a leaking crankcase cover gasket so I might as well service the clutch while it's off the cart. I'm glad I don't live where they salt the roads!

I used a yellow torch for about a minute in the hole where you removed the bolt from the driven clutch and a light tap from a rubber mallet and it popped right off. I have to say I did everything else and it took me 4 Saturdays to finally get it off.

Lol! I built a very similar tool before I found out someone else was as crazy as myself? Used a old spanner wrench that was made for another type of primary clutch so basically everything was there for it, I just needed to add the 3 pins to catch the spider of the Ezgo Comet clutch. My clutch had been through probably 3 engine replacements over its years in service. So it was pretty worn out and if I damaged it, at this point it wouldn't really matter? So upon getting it apart and the spiffy removed found that the shaft was worn out in the area that moves the most on the clutch. Being I own a lathe, I was able to cut the shaft down and make a new sleeve for it to bring it back to specs. While everything was apart as well, I made a new bronze bushing for the moving pulley half and cut the faces of both the sheaths on the lathe. Amazing they were pretty worn down especially the aluminum half of course. So after doing all this BS to the primary clutch, it was time to tackle the problem of getting the secondary off the transaxle input shaft! Which was the most difficult part of the entire process! It had unfortunately sat around uncovered for a few years outside. The clutch was basically one piece with the transaxle shaft now of course. But welding to the steel center section of the secondary clutch a big 5/8" nut and using a chrome-moly 5/8" threaded rod with another nut welded to its end I made a self pulling tool to push against the transaxle shaft while applying a sh1t ton of heat to the secondary center section. Eventually it broke loose and slow and painfully I was able to remove it from the shaft. Replacement of the nylon buttons of course was needed long before I melted away the remaining pieces with the heat of the torch. It had been digging into the helix for a while. Thankfully I was able to salvage the pulley sheaths and resurfaced them as well, but had to order a new helix buttons and shims. Otherwise it was just a labor of love I guess? It saved me a lot of money being able to rebuild both the front and rear pulleys, which are now perfectly in tune with the 2 stroke Polaris /Ezgo which now powers the TXT and for a little 244 cc engine, with a exgo bottom end and Polaris top end the thing is pretty damn quick. It idles now in gear like a engine should do. The transaxle was taken apart and I put in a neutral detent position in the shift shaft. This is a great way to start your engine and not having to worry about running someone over with it if you wish to blow out any excessive oil. Otherwise yes there's no such thing as impossible or as many people say non- serviceable parts! My @ss! Everything is serviceable to an extent of how much dedication you wish to put forth, bottom line! Glad you made this video for people to see who believe things like this sh1t can't be done?! Goof luck with your Ride man.

Great video,,, super informative

thanks for this video,, pretty cool showing how nice they work after ,, but your air compressor kicking on near the end like to give me a coronary ,, how does the removal bolt work anyway ,, does it push against the crankshaft and thread into the clutch?

I have exact same color and exact same cart. I have the exact same problem....I think lol. Cart just sits there and looks like the clutch quivers....if I hold gas long enough it engages the motor and finally goes

You have an excellent impact gun but that hose is killing it. Get a full sized 3/8" hose.

Excellent video! My only comment: Please use jack stands to prevent a disaster (lost a friend because of this).

Can anyone tell me what the back clutches job is for? Does it make it go into a higher gear. Thanks

How much would ya charge a person to make the tool for taking the clutch apart ?

I wanted to see you remove the primary clutch.

How'd you take off the clutch on the motor

There are chemical products to remove oxidation from aluminum, which is a lot easier mechanically grinding/sanding it off. Here is a video on how to remove oxidation: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-U3m5woUulpw.html and another great video from the same guy: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-aTXAHFVItFU.html

Skipped taking off the clutch