INSTALLATION INSTRUCTIONS
CAUTION:
Remember to always wear appropriate eye protection while performing the tasks in this instruction.
Be sure to remove the key and disconnect the negative battery cable to prevent accidental start-up.
Kit Parts List
1
Drive Clutch Tuning Spring
1
Brass Wire Connector
Clutch puller part number NP-5545 is required for clutch removal.
Remove the seal plate on the drivers side.
Pull up the rubber mat to expose the accelerator cover.
Remove the accelerator cover and disconnect the start switch wires. Using the supplied brass
connector, connect the two wires together (tape all exposed connections).
Make sure the wires are positioned so they will not interfere with any moving parts. Reinstall the
cover, mat and seal covers.
Remove the seat assembly and make sure the battery negative cable is disconnected. Raise the rear
of the cart and support the body with jack stands.
Remove the drive belt by rolling the belt off the driven clutch by grasping the belt (while pulling
upwards) and rotating the driven clutch by hand. Loosen the starter/generator bolts and remove the
starter/generator belt.
Remove the drive clutch mounting bolt and with the use of a proper puller, NP-5545 remove the
clutch assembly. Mark the dust cover, outer flange and inner sheave with straight lines to insure the
clutch will remain balanced. Failure to use alignment marks will cause improper reassembly of the
clutch.
Remove the flange cover screws using caution as the flange will have some spring tension. Remove the
dust cover and with light air pressure clean out any loose debris.
Remove the existing spring and replace the spring with the new tuning spring. Align the dust cover
marks to the inner sheave and flange cover, press the flange inward until the screws can be started.
Tighten the screws in a criss cross pattern until 48 inch pounds is achieved.
Install the drive clutch on the cart and torque the mounting bolt to 42 foot pounds. Rotate the drive
and S/G belts back into place (opposite of removal). Connect the battery.
Adjusting the Idle Speed
Place the shift handle in the neutral position and lock the detent by rotating the lock out
(located on the transaxle). Make sure the wheels are off the ground! Start the engine and
adjust the idle barely below the clutch engagement point (1200 rpm). When adjusting the rpm,
make sure the belt does not drag on the drive clutch at idle. If the belt drags, shifting to
forward or reverse from neutral may damage the transaxle!
Note: it may be necessary to adjust the throttle linkages to allow for proper rpm adjustment.
To ensure the throttle closes completely when the accelerator is released, shorten or lengthen
rod number 3 or 4. The idle speed can now be adusted at number 2 idle screw. With the
throttle seated against the idle screw (2), raise or lower the idle speed by adjusting the
number 2 idle screw.
Verify the voltage at the battery is over 13 volts to ensure the starter/generator is charging
correctly.
Shut the engine off and put the seat back on. Lower the cart and test drive the cart to make
sure of all the adjustments are in order.
