If you are looking for a way to increase the performance of your Yamaha Golf Cart, one of the things you can do is to remove the secondary clutch. By removing the secondary clutch, you can improve the acceleration and overall speed of your golf cart. In this step-by-step guide, we will show you how to remove the secondary clutch on your Yamaha golf cart so that you can get the most out of your vehicle.
Before we get started, it is important to note that you will need some specialized tools to remove the secondary clutch. You should also be familiar with the basic mechanics of your golf cart. If you are not comfortable working on your golf cart, it may be best to take it to a professional mechanic.
With that said, let’s dive into the process of removing the secondary clutch from your Yamaha golf cart. Follow these steps carefully, and you will be well on your way to improving the performance of your golf cart!
Are you ready to take your Yamaha golf cart to the next level? Keep reading to find out everything you need to know about removing the secondary clutch and optimizing the performance of your golf cart.
Table of Contents
Necessary Tools for Removing Secondary Clutch
To properly remove the secondary clutch on your Yamaha golf cart, you will need a few tools at your disposal. Here are the five necessary tools:
Clutch Puller Tool: A clutch puller tool is essential for removing the secondary clutch from the golf cart’s engine shaft.
Socket Wrench: A socket wrench is needed to remove the bolt that holds the secondary clutch in place.
Torque Wrench: A torque wrench is necessary to tighten the bolt back to the appropriate torque specification when reinstalling the secondary clutch.
Screwdriver: You’ll need a screwdriver to remove any covers or guards that may be obstructing access to the secondary clutch.
Safety Gear: Finally, it’s important to wear safety gear such as gloves and eye protection to prevent any potential injuries during the removal process.
Necessary Tools for Removing Secondary Clutch
Socket Wrench Set
A socket wrench set is an essential tool for removing the secondary clutch on your Yamaha golf cart. You will need a socket wrench set to remove the bolts holding the clutch in place. The set should include sockets ranging in size from 8mm to 18mm, as well as a ratchet and a socket extension.
Make sure to use a high-quality socket wrench set that is durable enough to handle the torque required to remove the clutch. A low-quality set may break or wear down quickly, making the job more difficult than it needs to be.
Before you begin, make sure you have the correct size socket for each bolt on the clutch. Using the wrong size socket can damage the bolt and make it difficult to remove.
Torque Wrench
A torque wrench is a necessary tool when removing the secondary clutch on your Yamaha golf cart. This wrench will allow you to apply the right amount of pressure to the bolts without over or under tightening them. Using a torque wrench will prevent damage to the clutch and keep it in good working condition.
When choosing a torque wrench, make sure to select one that is appropriate for the amount of torque needed to remove the clutch bolts. The range for torque is typically between 20-100 ft/lbs, but it’s best to check your Yamaha golf cart’s manual to determine the appropriate range for your specific model.
It’s important to use a torque wrench because over-tightening the bolts can cause them to break, while under-tightening can cause the clutch to slip, reducing the power of your golf cart. Additionally, if the bolts are not tightened evenly, the clutch can become warped or damaged.
Remember to always read the manufacturer’s instructions for using your torque wrench properly. This tool can help you avoid expensive repairs in the long run, so it’s worth investing in a good quality torque wrench.
If you don’t have a torque wrench, you may be able to rent one from a local auto parts store or mechanic shop.
Primary Clutch Puller Tool
A primary clutch puller tool is necessary to remove the secondary clutch on a Yamaha golf cart. This tool is designed specifically to remove the clutch without causing any damage to the golf cart. Without this tool, you could risk damaging the clutch or other parts of the cart.
When purchasing a primary clutch puller tool, it is important to make sure it is compatible with your Yamaha golf cart model. Using an incompatible tool could result in damage to your cart. It is also recommended to purchase a high-quality tool to ensure it lasts for multiple uses.
If you are unsure about purchasing or using a primary clutch puller tool, consult with a Yamaha dealer or mechanic to ensure you are using the correct tool for your cart model.
Steps to Remove the Secondary Clutch
Step 1: Start by parking the Yamaha golf cart on a flat surface and ensuring that it is in a stationary position. Turn off the engine and disconnect the battery before beginning to remove the secondary clutch.
Step 2: Locate the secondary clutch on the drive belt system of the golf cart. Remove the cover or belt guard to access the clutch.
Step 3: Use the primary clutch puller tool to remove the bolt that secures the secondary clutch onto the drive shaft. Ensure that the puller tool is centered over the clutch and tightened securely before removing the bolt.
Remove the Drive Belt
Step 1: Begin by removing the cover on the drive belt.
Step 2: Use a socket wrench to loosen the bolt that secures the drive belt to the secondary clutch.
Step 3: Slide the drive belt off the secondary clutch and remove it from the golf cart.
Remove the Secondary Clutch Cover
After removing the drive belt, the next step is to remove the secondary clutch cover. Locate the bolts that hold the cover in place and use the appropriate socket wrench to remove them. Keep these bolts in a safe place as they will be needed to reassemble the cover later on.
Once the bolts are removed, gently pull the cover off the secondary clutch. Be careful not to damage any of the components inside the clutch. It’s also a good idea to clean the cover and inspect it for any signs of wear or damage while it’s removed.
If the cover is difficult to remove, gently tap around the edge with a rubber mallet to loosen it. Avoid using excessive force as this can damage the cover or other components of the golf cart.
Use the Primary Clutch Puller Tool to Remove the Secondary Clutch
Once the secondary clutch cover is removed, locate the primary clutch and use the primary clutch puller tool to remove the secondary clutch. This tool is specifically designed to remove the secondary clutch and should be used carefully.
Thread the puller tool into the center of the secondary clutch and tighten it using a socket wrench. This will create tension and eventually pull the clutch off of the shaft.
Once the clutch is removed, inspect it for any damage or wear and tear. If the clutch is damaged, it may need to be replaced before reinstallation. If it is in good condition, proceed with reinstalling the clutch and tightening it to the manufacturer’s recommended torque specification using a torque wrench.
Safety Tips for Removing Secondary Clutch
Wear Protective Gear: Before you begin, make sure you wear protective gear such as gloves, goggles, and a face mask to avoid any injuries or dust particles.
Work in a Well-Lit Area: It’s important to have good visibility when working with heavy machinery. Work in a well-lit area to ensure you can see what you’re doing.
Disconnect the Battery: To prevent any accidental starting of the engine, disconnect the battery before you begin working on the secondary clutch.
Wear Eye Protection
When removing the secondary clutch, it is essential to wear eye protection to prevent any debris or dust from getting into your eyes. Loose particles can be kicked up when removing the clutch, and they can cause serious eye injuries. Wearing safety glasses or goggles will protect your eyes from harm.
It is also essential to check that your eye protection is in good condition before starting the job. Scratched or damaged safety glasses or goggles should be replaced before use to ensure maximum protection.
Even if you wear glasses or contact lenses, you should still wear safety glasses or goggles over them. Your regular glasses may not provide adequate protection, and contact lenses can trap debris against your eyes.
Disconnect the Battery
Firstly, locate the battery on your vehicle and remove the negative terminal with a wrench. This step is crucial to prevent electrical shocks while working on the clutch assembly.
Secondly, ensure that the battery is kept away from the work area and is secured properly. A loose battery can cause damage to both the vehicle and the mechanic working on it.
Lastly, it is recommended to wait for at least 10 minutes after disconnecting the battery before starting any work. This will allow the electrical charge to dissipate, reducing the risk of accidental electrical shocks.
Allow the Engine to Cool Down
Before attempting to remove the secondary clutch, it is important to allow the engine to cool down. This will prevent you from burning yourself on the hot components of the engine, such as the exhaust and cylinder head. It is recommended that you wait at least 30 minutes after turning off the engine before starting the removal process.
It is also important to note that removing the secondary clutch requires a significant amount of force, which can generate heat in the engine. By allowing the engine to cool down, you reduce the risk of damaging the engine due to overheating.
Waiting for the engine to cool down is a simple step that can save you a lot of trouble and expense in the long run. Don’t skip this important step, as it can help ensure a successful clutch removal process.
How to Clean and Reinstall the Secondary Clutch
Regular cleaning of your secondary clutch is important to keep it functioning properly. Dirt and debris can build up and cause issues with the clutch’s operation. Here are some steps to help you clean and reinstall your secondary clutch.
Gather the necessary tools: Before you begin, make sure you have the necessary tools to remove and reinstall the secondary clutch, including a clutch puller tool, a socket wrench, and cleaning supplies such as brake cleaner or carburetor cleaner.
Remove the secondary clutch: Follow the steps outlined earlier to remove the secondary clutch from the machine. Once you have removed it, use your cleaning supplies to thoroughly clean the clutch and all its components, including the bushings, rollers, and shaft.
Inspect the clutch components: While you have the clutch removed, inspect all the components for any signs of damage or wear. Replace any worn or damaged parts as needed before reinstalling the clutch.
Reinstall the secondary clutch: Follow the steps in reverse order to reinstall the clutch, making sure to torque all bolts to the manufacturer’s specifications. Once you have reinstalled the clutch, test it to ensure it is functioning properly before using the machine.
Clean the Clutch Components
Before reinstalling the secondary clutch, it’s important to clean all the components to ensure smooth operation. Here are the steps to follow:
- Remove any debris or dirt from the clutch components using compressed air or a soft-bristled brush.
- Clean the clutch components with a degreaser or brake cleaner, and wipe them with a clean cloth.
- Inspect the components for any signs of wear or damage. If any parts are worn or damaged, they should be replaced before reinstalling the clutch.
- Lubricate the clutch components with a light coating of manufacturer-recommended grease or oil to prevent rust and ensure smooth operation.
Once you have completed these steps, you can move on to reinstalling the secondary clutch.
Apply Lubricant to the Clutch Components
Step 1: Use a clean cloth to remove any excess grease or debris from the clutch components.
Step 2: Apply a thin layer of clutch lubricant to the clutch components. Make sure to cover all surfaces evenly.
Step 3: Use a clutch alignment tool to ensure the clutch is centered on the shaft.
Step 4: Install the clutch onto the shaft and tighten the bolts to the manufacturer’s specifications.
When applying lubricant, be careful not to use too much. Excessive lubricant can cause the clutch to slip and reduce performance. Use only manufacturer-recommended lubricant and avoid using household or automotive oils, as they can damage the clutch components. Finally, make sure to properly align the clutch before installation to avoid premature wear or damage to the clutch components.Reinstall the Secondary Clutch and Drive Belt
- Place the clutch onto the transmission shaft: Position the clutch onto the transmission shaft, making sure the shaft slides into the clutch hub.
- Tighten the bolt: Secure the clutch by tightening the bolt to the manufacturer’s recommended torque specification.
- Reinstall the drive belt: Slide the drive belt onto the clutch and the driven pulley, making sure it is seated properly.
- Adjust the belt tension: Check the belt tension by pressing on the belt midway between the two pulleys. The belt should have about 1 inch of deflection. Adjust the belt tension as needed.
- Reconnect any electrical components: Reconnect any electrical components that were disconnected earlier, such as the clutch safety switch.
Once you have completed the reinstallation process, start the engine and let it run for a few minutes to check for any unusual sounds or vibrations. Take the vehicle for a test drive to ensure that the clutch is engaging and disengaging properly.
Common Secondary Clutch Problems and How to Fix Them
Worn Clutch Components: Over time, the clutch components can wear down, resulting in poor performance and decreased power transfer. The solution is to replace the worn parts with new ones to restore the clutch’s proper function.
Slipping Clutch: A slipping clutch is a common problem that occurs when the clutch does not engage properly, causing the engine to rev higher than usual. This can be caused by a worn belt, dirty clutch components, or a misaligned clutch. Cleaning the clutch components and realigning the clutch can solve the problem, but if the belt is worn, it must be replaced.
Sticking Clutch: A sticking clutch can cause the clutch to remain engaged, resulting in difficulty shifting gears and decreased power transfer. This can be caused by dirt, debris, or rust on the clutch components. Cleaning and lubricating the clutch can solve the problem, but if the clutch is damaged, it must be replaced.
Worn Clutch Buttons
If your secondary clutch is slipping or not engaging properly, it may be due to worn clutch buttons. Over time, the buttons on the clutch can become worn down and smooth, causing a loss of friction and reduced performance. Here are some steps to fix this issue:
- Step 1: Remove the secondary clutch from the machine following the instructions in your owner’s manual.
- Step 2: Inspect the clutch buttons for signs of wear. If they are smooth or have flat spots, they need to be replaced.
- Step 3: Use a clutch button removal tool to remove the old buttons from the clutch.
- Step 4: Install new clutch buttons using a clutch button installation tool. Make sure they are evenly spaced and flush with the surface of the clutch.
- Step 5: Reinstall the secondary clutch onto the machine.
It is important to regularly inspect your clutch buttons and replace them when they show signs of wear to ensure optimal performance of your secondary clutch and overall machine.
Damaged Clutch Sheaves
Clutch sheaves are the grooved wheels that grip the drive belt to transfer power from the engine to the wheels. If the sheaves are damaged or worn, they may not grip the belt properly and can cause slippage or decreased performance. Here are some common signs of damaged clutch sheaves:
- Rough or damaged surfaces: Inspect the clutch sheaves for any rough or damaged surfaces that may prevent the belt from gripping properly.
- Cracks or chips: Check for any cracks or chips in the clutch sheaves that may affect their ability to grip the belt.
- Worn grooves: Look for any signs of wear or unevenness in the grooves of the clutch sheaves. This can cause the belt to slip or wear out faster than normal.
- Noise: Damaged clutch sheaves can also cause noise or vibration, especially during acceleration or when changing gears.
- Decreased performance: If you notice a decrease in power or acceleration, it could be a sign of damaged or worn clutch sheaves.
If you suspect that your clutch sheaves are damaged, it is important to replace them as soon as possible to prevent further damage and improve the performance of your vehicle. Consult your owner’s manual or a professional mechanic for guidance on replacing clutch sheaves.
Loose Clutch Components
If you notice that your secondary clutch is vibrating or making a rattling noise, it may be due to loose components. Loose components can cause damage to the clutch and other parts of your vehicle if not addressed promptly.
To fix this issue, start by checking the torque on all the bolts and nuts that hold the clutch components together. Tighten any loose bolts or nuts to the manufacturer’s specifications.
If the problem persists, inspect the clutch for any signs of wear or damage, which may require replacement of the affected parts. Additionally, make sure to follow the manufacturer’s recommendations for regular maintenance and inspections to prevent future issues.
Frequently Asked Questions
What tools are needed to remove the secondary clutch on a Yamaha golf cart?
Removing the secondary clutch on a Yamaha golf cart requires several tools, including a clutch removal tool, a torque wrench, and a socket set. It is important to have the right tools to avoid damaging the clutch or other parts of the golf cart.
How do you access the secondary clutch on a Yamaha golf cart?
To access the secondary clutch on a Yamaha golf cart, you will need to remove the clutch cover and the drive belt. The clutch is located on the engine’s crankshaft, and it is connected to the drive belt. Once you have removed the drive belt, you can access the secondary clutch.
What are some common issues that may require you to remove the secondary clutch?
Common issues that may require you to remove the secondary clutch include worn clutch buttons, damaged sheaves, or loose clutch components. Removing the clutch can also be necessary for routine maintenance, such as cleaning and lubricating the components.
What precautions should you take when removing the secondary clutch on a Yamaha golf cart?
When removing the secondary clutch on a Yamaha golf cart, it is important to take several precautions to avoid injury or damage to the golf cart. This includes wearing protective gear, such as gloves and eye protection, and making sure the golf cart is securely supported. You should also follow the manufacturer’s instructions carefully and use the right tools for the job.
How do you reinstall the secondary clutch on a Yamaha golf cart?
After you have removed the secondary clutch on a Yamaha golf cart, you will need to clean and inspect the components before reinstalling the clutch. The clutch should be installed in the reverse order of removal, and you will need to torque the clutch nut to the manufacturer’s specifications. It is also important to apply lubricant to the clutch components before reinstalling the drive belt and clutch cover.