Harold Bawlzangya Racing

Modifications

What were they thinking?

Both Unitized Kawasaki rear ends I bought had bad input shaft bearings.  One rear end still rotated smoothly by hand, but the other was just shy of being locked up.

Guess which oil guide belonged to each rear end:

poorrearenddesign-7

Not sure how the designers/engineers thought any oil would get to this bearing!?  Oil guide blocking the bearing on one side:

poorrearenddesign-4

Governor sprocket on the other side:

poorrearenddesign-5

At least the other side has a little room for oil to get to the bearing.  The clutch side bearing of both rear ends was in much better shape.  I’m sure it was still out of spec, but it wasn’t obvious to the naked eye.

poorrearenddesign-1

This is the governor side bearing from the rear end that was toast.  The inner race shouldn’t be able to do that.

poorrearenddesign-8

When that happens, things start rubbing that shouldn’t:

poorrearenddesign-9

So Club Car’s solution to this bad design are sealed bearings:

poorrearenddesign-11

I’m going trust this over what was used from the factory:

grease

Being very careful, got the seals removed:

poorrearenddesign-12

Grease in the other bearing:

poorrearenddesign-13

Got all the grease out and ready for the red stuff:

poorrearenddesign-15

I know you can over-pack a bearing with grease, but I figured that they used the bare minimum at the factory.  With the factory grease being dark in color, it was a little tough to gauge just how much was in there.  So I tried to add as much as I could while still allowing some room for extra grease to move into as the bearing got some use.

poorrearenddesign-17

Time will tell how well this holds up.

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One EXP conversion done, working on two more

The parts needed to make a few Rekluse conversions:

expparts

One is done and out the door today.  Just waiting on a few parts to finish the others.

conversionoutthedoor


2016 Summer Project – 1992 Gas Club Car build

Bought this in June 2016.  This is part of the reason I didn’t do any riding over the summer.  That and it was really stinkin’ hot.  Most of my time and all free money went towards this project.

1992clubcar

Tear down:

clubcardisassembly-3

clubcardisassembly-2

clubcardisassembly-1

clubcardisassembly-4

engineremoved

24 years of oil, dirt, grass and twigs:

gunk

old290

New engine:

new290

Machined driven clutch and 8:1 gears:

machinedclutch8-1gears

rearend

The kids have been driving this to school for a couple of months now.  With the 8:1 gears, it will do about 22-23 MPH at around 3,000 RPM.  The engine could run safely at 4,000 RPM, but teenagers don’t need to be going that fast on most of the paths.

finishedgascc-2

finishedgascc-1


NoToil comparison

After using the FilGuard filter I bought a while ago, I wasn’t that impressed.  But to be fair it was exceptionally dusty and the dust was so fine that it lingered in the air a long time.

Back when I did my air filter test, the NoToil filter performed very well.  Thinking that all NoToil filters where the same, I ordered one of the pre-oiled ones:

notoilcomparison-10

Right out of the bag I was surprised:

notoilcomparison-5

Years ago I used NoToil oil but had oil settle to the bottom of the filter and drip in the airbox.  I thought it was just be over-oiling, but I read complaints from others as well.  I stopped using it.  I am certain the machine that applies the oil in the factory is putting on the bare minimum, so I wasn’t expecting to see it settle out in the bag.

notoilcomparison-13

Without opening the inner bag, the filter material itself looked different than the one I tested years ago:

notoilcomparison-12

I went into the other room and turned the desklamp over:

notoilcomparison-6

I wasn’t liking what I was seeing:

notoilcomparison-15

I called RockyMountain up and got my return authorization for the pre-oiled filters I bought.  A quick check on eBay and I found a non-oiled NoToil filter.  A few days later this is what I received:

notoilcomparison-9

notoilcomparison-11

A quick side-by-side and you can easily tell that the foam isn’t the same between the two:

notoilcomparison-17

Nothing special about the sealing surface like on the Moose filters:

notoilcomparison-1

Now this is what I was looking for:

notoilcomparison-8

Seems like you give up quite a bit for the convenience of not having to oil the filter.


Image

First of several Rekluse EXP modifications

ClutchMods (1)

 (click picture to enlarge)


Letting the oil flow

As I’m putting the 220 together, this was a good time to modify the clutch hub I have been using.  One of the used YZ clutches I bought a while ago came with a Hinson hub.  That hub had a lot of big oil holes in it:

YZHub

 (click picture to enlarge)

The stock hub has 4 small holes:

HubOilHolesBefore

 (click picture to enlarge)

So without going too crazy, I went from 4 small holes to 16 larger ones:

HubOilsHolesAfter

 (click picture to enlarge)


That is more like it

220CylinderHead (1)

(click picture to enlarge)

Looks like I won’t be needing to hand-cut any gaskets for a little while now:

220TopEndGaskets

(click picture to enlarge)