Club Car flywheel shroud back bolt frustration

BarnyardEngineering

Well-known Member
Location
Rochester, NY
Trying to get the flywheel shroud off the Club Car golf cart engine to replace the ignition coil. Obviously the cart is designed so that you need to remove the engine to effectively work on it. Obviously I don't want to remove the engine.

I have all the bolts out of the shroud, except the one on the very back of the engine. It's located right against a frame member, and the only way to remove that frame member, is to pull the engine from the cart.

We managed to get a few flats of turn on the back bolt so the shroud is loose, but we can't get it to slide out from behind that bolt. All the other holes around the edge of the shroud are slots. This one appears to be a full hole. Who is the evil son of a ... that designed this thing? All the bolt holes you can get to to remove are slots, the one you can't is a full hole.

Anyone have any tricks to getting the shroud off?
 
Is there a wall behind the bolt you can use a hole saw to cut out a area behind the bolt head, to have access? Stan
 
I have a 1995 engine powered Club Car. I do NOT golf.
I use it as a yard utility vehicle. It pulls my Agrifab lawn sweep, carries tools where needed on my
now diminished acreage, down to 3 acres. I have used it to pull my lawn vacuum during "leaf season". I
hooked it to a light duty hay wagon that I store my pickup camper on to move around. It also gets used
in a volunteer capacity at the annual Yankee Air Museum air show, cancelled this year.
For maintenance, I have not done anything more than grease, change oil, oil filter, air filter, spark
plug and drive belt.
I have made a couple of modifications. I added a rear facing rear seat with a hitch receiver under the
foot board, inserted an extra leaf in each leaf spring to handle the weight of 4 people and bought rear
tires that are an ag stile tread (great for wet grass slopes).
It did suffer one crash 3 years ago. My granddaughter and a friend were driving too fast in the dark
and the right front wheel hit a fence post. They were not hurt but it broke the right suspension and
steering. Beyond my ability to repair. Went to a local golf cart dealer-repair. I was figuring $500+.
WRONG! $250 fixed it.
My point: there are times to bite the bullet and hire work done.
 
Is the shroud sheet metal or plastic?
If there is room and it is plastic I would try to slide a wood burning tool or soldering gun, etc. Down each side of bolt.
Creating a slot out of the hole.
If sheet metal pry it out until the sheet metal tears and then fix the damage prior to reassembly.
 

Screw bolt out as far as possible, then take a knife or hacksaw blade and cut plastic around hole . Then force plastic out and grove it before putting back in. Be patience cutting it. Been there done that and was wondering the same thing when I got there.
 
UPDATE: Between Dad and I we got all but that one bolt out of the shroud. Dad held the shroud out while I stuffed my sausage fingers in there and managed to change the coil.

Long story short we just bent it out of the way to change the coil and then mashed it back into place as best we could.

WE HAVE SPARK!

Of course as soon as we tried to stomp on the pedal to start it, the ball joint on the end of the gas pedal rod under the cart snapped off, rusted away. ARGH!

At least the bolts on this are accessible.
 

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