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15. Inspect the grease seal located inside the bore from
which the drive shaft was removed. Replace if worn or
damaged. To remove the grease seal, use a flat blade
screwdriver to carefully pry the seal from the bore.
16. Clean the inside of the gear housing.
Housing Gasket
Pump Housing Socket Screw
Front Cover
Front Cover Screw
Installing the clutch Rotor assembly, clutch
Field and Drive Shaft assembly
1. If the drive shaft grease seal was removed, press a new
seal into the bore from which the old seal was removed.
2. From the clutch side of the gear housing, insert the drive
shaft assembly into the bore, through the grease seal, and
through the ball bearing on the gear side of the gear housing.
3. From the gear side of the gear housing, insert the snap
ring into the groove on the drive shaft hub in front of the
ball bearing.
4. Place the housing gasket over the gear housing dowel pins.
5. Carefully place the pump housing assembly in front of the
gear housing assembly, lining up the gear housing dowel
pins with their corresponding holes in the pump housing.
Slide the pump housing onto the gear housing until there
is no gap between the housings and gasket.
IMPORTaNT: Do not force the pump housing and gear
housing together.
6. Locate the four socket screws and lock washers that
secure the pump housing to the gear housing.
7. Using a 1/4" hex wrench, snug and tighten the socket
screws in a crossing pattern. Torque to 200–230 in./lbs.
8. Line up the four holes around the outside of the clutch field
with the four set screw holes in the gear housing. The
clutch field wires should be at approximately the 1 or 2
o'clock position.
9. Route the two clutch field wires through the hole and into
the control housing.
10. Carefully slide the clutch field into its bore in the gear
housing until it "bottoms out" within the housing. Do not
pinch the clutch field wires during installation.
11. Thread one of the pointed set screws into its hole. Using
an 1/8" hex wrench, rotate the screw slowly until it contacts
the clutch field. Do not tighten the set screw. The tip of
the set screw should mate with the drill point hole in the
field. Check the clutch field for rotation. If it rotates within
its bore, the set screw is not seated within the drill point.
12. When the set screw is properly seated, install the remaining
three pointed set screws. Do not tighten the set screws.
13. Using a crossing pattern, tighten each of the pointed
setscrews until they are snug. Once all four pointed set
screws are snug, use a crossing pattern to tighten and
torque the set screws to 70–80 in./lbs.
IMPORTaNT: It is very important to evenly snug, tighten,
and torque the clutch field pointed set screws in a crossing
pattern. This ensures the clutch field will stay centered in
the gear housing.
English
Plug
Grease Seal
Bearing
Snap Ring
Small Snap Ring
15. Line up the three screw holes and dowel pin hole on the
clutch rotor with the screw holes and dowel pin on the
drive shaft assembly hub. Place the clutch rotor onto the
hub.
16. Using a 3/16" hex wrench, thread the three socket screws
and lock washers through the clutch rotor and into the
drive shaft assembly hub. Evenly snug, tighten, and
torque the socket screws to 75–85 in/lbs.
17. Make sure the friction surface of the clutch rotor is clean
and free from oil or grease.
18. Locate the two clutch field wires in the control housing.
Gently pull the wires fully into the EPC housing so that
there is no slack in the gear housing. Connect the wires
to their proper terminals on the relay (refer to the labels
created earlier in this procedure or the electrical schematic
in the Parts List section of this manual).
19. Carefully place the heat sink assembly over the control
housing taking care not to pinch any wires.
20. Install the four screws that secure the heat sink assembly
to the control housing. Tighten securely.
Mating the Gear housing and the clutch housing
1. Place the gear housing assembly onto the cart in front
of the clutch housing. Line up the dowel pins in the
gear housing with their corresponding holes in the clutch
housing. Slide the gear housing assembly onto the clutch
housing until there is no gap between the housings.
2. Thread the four hex screws and lock washers through the
clutch housing and into the gear housing.
3. Using a 12 point, 5/16" wrench, snug and tighten the hex
screws in a crossing pattern. Torque to 140–155 in./lbs.
4. Using a 9/16" socket, thread the hex screw that secures
the gear housing to the cart through the underside of the
cart and into the gear housing. Torque to 100–120 in./lbs.
5. Connect the wire from the EPC housing to its mating
connector on the engine wire harness.
checking the clutch Gap
1. Remove the plastic plug from the top of the clutch housing.
Look through the port to locate the clutch armature and
the clutch rotor.
2. Check the gap between the clutch armature and the clutch
rotor using a .016" feeler gauge and a .035" feeler gauge.
a. Insert each feeler gauge through the port and into the gap
between the clutch armature and the clutch rotor. The
.016" feeler gauge should fit in the gap. The .035" feeler
gauge should not fit in the gap.
b. Pull the engine pull cord several times to rotate the clutch
armature, checking the gap with each feeler gauge
between each pull.
c.
If the .016" gauge does not fit or the .035" gauge does
fit at any checkpoint, the gap must be readjusted. This is
done by relocating the clutch hub and armature assembly
on the engine shaft. Refer to the "Removing/Replacing
the Clutch Armature Assembly" procedure.
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