Club Car DS electric to gas swap

How to convert a Club Car DS electric to gas.

[@chassenmanoi5750]

What size are the motor shaft so I can order my sprocket. Need help😬thanks

[@ronengle9674]

You just convinced me that instead of buying a new set of batteries for my cart I would be better off going to gas...I have a club car that will have a 57 chevy body put on it that is almost ready to be mounted...your video was excellent but I know there will be questions I will have going forward...thank you.

[@racerxtex3177]

I was the same way. Set of batteries $800. Gas motor $325. If you have any questions I’m here to help.

[@ronengle9674]

I do...besides the Predator motor which I'll go with do you have a list of the other things I will need to buy to start this project...it would help.

[@racerxtex3177]

Ron Engle I got the 40 series clutch. You’ll need the low profile air cleaner kit for 420cc. 5/8 jack shaft. 2 pillar bearings. Sprockets for the jack shaft and electric motor shaft. Pulse pump. Choke cable. Throttle cable. 40 chain.

[@ronengle9674]

thank you...what are you using to charge the battery.

[@racerxtex3177]

Ron Engle the motor chargers the battery.

[@isaiahdrake8380]

Had a guy just give me one of these electric club car golf carts, it needs some work but now I have some idea of direction, thanks for putting this video out. Seriously appreciate it.

[@racerxtex3177]

Thank you. This is my first KZbin video. It was fun to build it. Also go watch BigBlok502. He also built a Club Car DS. If you ever have a question just comment. It was a lot of fun building it.

[@mack_mandarb]

Nice conversion, I see you've upgraded to a gas rear diff. bet that made a world of difference. I wanted reverse and gears so got a 250 4wheeler motor and trans. You could hook stock lights up to the battery and if you turn a cheap alternator off the jackshaft charging system complete.

[@iowabuckinrut760]

Excellent work! I will be using this as a tutorial thank you!

[@dentech987]

Really like the use of the old electric motor shaft and housing. You got to figure out a simple inexpensive reverse now.

[@DisgustedGenXr]

You did an amazing job. Great work. Very talented and well planned

[@racerxtex3177]

Thank you!

[@89Mirageman]

Very nice job! I converted a 94 EZGO a few years back with a 6.5 clone and reverse. Very fun and satisfying project. Glad you went with a larger engine though. Next time around I'll make the rear suspension separate from the frame so that the axle and engine move together.

[@racerxtex3177]

89Mirageman Thank you. It was a fun project.

[@fordfanatic7836]

What was wrong with the 6.5 not fast enough? I've seen a video of a guy doing 20 with a 10t sprocket and 28 with a 8t sprocket with the 6.5, I'm just curious what your experience with it was

[@89Mirageman]

@@fordfanatic7836 It was adequate but ideally a 9hp or better would have been nicer. The 6.5 is for a go kart and a golf cart is quite a bit heavier. Especially with a passenger.

[@fordfanatic7836]

@89Mirageman I was planning on going with a 6.5 with some upgraded parts, but it still wouldn't be close to 13 hp so I'm probably just going to bite the bullet and get the higher horsepower itema

[@89Mirageman]

@@fordfanatic7836 With the price of these larger Honda clone engines being so affordable these days, it's kinda crazy not to just start out with something larger and bone stock. From my experience when you start modding the 6.5 you lose reliability and they're harder to start.

[@G56AG]

Very nice job, good looking as well! Well done.

[@christyc911]

Thanks for the guide on how to do this ! Looks nice and fast …and sounds good

[@racerxtex3177]

45mph

[@hankhill5860]

I thought about this before but the only thing you won't have his reverse but great job 👍

[@samconard3357]

Just did mine! I couldn't have done it without your video. Thank you again!! I made a short KZbin video but no where near in depth as yours

[@racerxtex3177]

Sam Conard Thank you!! I’ll go check out your video.

[@racerxtex3177]

Sam Conard I tried to comment on your video but it won’t let me. Thanks for the shout out!! I got some questions. I like your drive better than mine. Can you email some pictures of it? [e-mail] also you live in Texas? Did you remove the governor? Wow 47 mph!!

[@samconard3357]

@@racerxtex3177 if you're on Facebook look me up and I can send all the info.

[@Kronos2361]

Really good job. Lots of patience and thought.

[@racerxtex3177]

Thank you. A lot of trial and error. But I finally got it right.

[@lorenmeyer5290]

You did an excellent job! Beautiful paint job too!♡♡

[@racerxtex3177]

Thank you

[@ryanlynch1414]

Thanks for getting back to me. I’ll be starting mine soon.

[@racerxtex3177]

Good luck.

[@johnsonjohnw74]

Nice, I used a gas frame with the rear end out of the gas cart so I would have reverse and installed a gs550e motor 6 speed. Unfortunately had engine failure so looking to drop another cycle engine in the future.

[@68fairlane351c]

i love it. your voice and video makes me think, "Days of Thunder" when Harry is talking to the car before he builds it haha

[@bobatbilletcreations]

Nice job, Thanks for sharing!

[@wadealbert138]

You did a great job I hope mine turns out as good

[@racerxtex3177]

wade albert Just take your time and it’ll turn out great.

[@rlachermeier]

Great job. Giving me some ideas. I have a 420 sitting in the garage looking for a home 👍

[@racerxtex3177]

It was a fun build.

[@fernandorufino-jimenez5982]

Yes sir you did a superb job there!

[@racerxtex3177]

The new video of upgrades and dependability are coming. Let me just say SPEED!!!

[@tonyfremont]

Any updates. I'm looking at a 90s club car electric with a bad motor, the guy is asking $300, and really want to do something like this. Our community just passed an ordinance allowing golf carts in town. Be being me, I need one that will do at least 35. Looks like if you removed the governor, you should be able to get it up to about 45mph without blowing it up. That'd be perfect for me.

[@racerxtex3177]

tonyfremont I did some to make it go faster. I also got a gas rear end for it. Haven’t changed it out yet

[@samconard3357]

I can't wait to see how fast mine goes! I have the same cart and engine except my axle has the 6:1 gears and running a 10 tooth on the axle shaft and a 10 tooth on the clutch

[@racerxtex3177]

Sam Conard you need a bigger sprocket on the clutch. Mine is a 16 tooth. And I’m thinking of going bigger.

[@samconard3357]

@@racerxtex3177 I've found clutch sprockets all the way up to 19 tooth. But was just curious because of the fact mine is a 6:1 ratio axle vs the factory 15:1-or 12:1.

[@samconard3357]

@@racerxtex3177 by the way, THANK YOU!! This is by far the BEST video on KZbin for showing how to do this conversion!!

[@Kronos2361]

What an awesome job!Well done and congrats.

[@racerxtex3177]

Kronos2361 Thank you!

[@jasonkmett8247]

So you made it interchangeable that was smart.

[@christyc911]

Nice job . And thank you for taking the time to make this video . Just curious ..but now you don’t have reverse ?

[@racerxtex3177]

At first I didn’t have reverse. But later I found gas rear end and swapped it out.

[@Motociclista760]

Great Job!

[@MiaBoelema]

What would be the best way to run a throttle cable so that the cart can run better

[@shaungosser400]

About how much did this conversion cost? You did a great job on it

[@racerxtex3177]

Around $500 without cart.

[@mr.jannise2662]

do you by chance have a parts list of the parts bought cause i'd LOVE to do the same thing you did!!! at least for the engine, centrifugal parts, fuel pump. etc...

[@tonyfremont]

@@mr.jannise2662 it's standard stuff, a harbor freight 420, a pulse fuel pump and probably a 40 series torque convertor. You can get the fuel pump and torque converter from any go-kart site or eBay.

[@scottjames5861]

So obviously your driven clutch is bored for a 5/8 shaft. What brand and series is your torque converter. Yours is the exact set up I'd like to put on mine. Your video is sweet, by the way!!!!

[@racerxtex3177]

Scott James it’s a 40 series torque converter. I got it on Amazon. I had to order another belt for it. I got a Comet belt. Thank you for the compliment on my video.

[@rustyshackelford9414]

Nice cart. Was it worth it? And will it climb hills ok? I would like to convert to gas. Batteries are expensive when they go out and I'm tired of waiting on it to charge.

[@Coolcarting]

I have done this too, but I also installed a forward reverse gearbox too. If you want to see more, contact me.

[@racerxtex3177]

The gear box is great but you can’t change the gears inside for speed.

[@nickelnoserestos2598]

Nicely done.

[@ryanlynch1414]

How fast is your cart? Great video and description!!!

[@racerxtex3177]

45mph

[@raybornwade3568]

Great job!! My torque converter burnt the belt and tore it all the pieces. What did I do wrong 😔???

[@tituskrabill1542]

What is your center to center from the engine shaft to center of jack shaft? And what size belt?

[@HenryRacing57]

What muffler did you end up going with? And sizes for inlet and outlet? Thanks we just picked up a 98 club car ds and batteries are toast. We have racecars so we wanna go fast Haha. Saw your video and was best one we seen and very clear of how everything was done. Picking up our motor tomorrow.

[@racerxtex3177]

I got my muffler at O ‘Reilly’s. 1 1/2 inlet and outlet. I also grew up building race cars. Drag cars and mud bog. I working on my new video of mods since I made that video. Thanks for the compliment of my build.

[@thetruth9361]

Nice installation very clean.

[@racerxtex3177]

Thank you!

[@chiefestilette9572]

I don't understand how you rigged up the back end you put a pulley on that chat and a clutch on the motor Cajun land Church Point Louisiana you done a good job look good

[@scottjames5861]

Hello sir, I need to know what diameter and how long of a jackshaft you used. Also would like to know how you attached the jackshaft to your driven clutch. And sprocket sizes. I have the exact same cart, and you have inspired me to swap mine to gas. My batteries are starting to get weak, so I'd rather do a one and done swap on it.

[@racerxtex3177]

My jackshaft is a 5/8. It’s 16 inches in length. The driven clutch has a 3/16 key way and so does the shaft. My front sprocket is a 18 tooth and my rear sprocket is a 10 tooth. Batteries are around $700 for a set. And heavy. Swap it with a 85lbs gas motor.

[@tarzanmukai808]

What type of accelerator cable did you use to attach it to the gas pedal and how did you attach it so that it works flawlessly, any hel with this is great thank you.

[@racerxtex3177]

I used a clutch cable from a Ford Mustang. I hooked up one end to the electric throttle control. I had to modify it.

[@WANAMASSA]

Good job. Looks great!

[@Driven716]

Awesome job, what size of a sprocket did you use that mounted on the shaft of the electric motor?

[@racerxtex3177]

10 tooth

[@thomasbowling6198]

RacerXtex what length is your jackshaft and where did you buy it from? Also great video and excellent build just starting my build on a club car

[@racerxtex3177]

The jackshaft is16” in length. I got it on Amazon. Thank you for the compliment. Please post a video when you get done.

[@wadealbert138]

Dd you think about putting a reverse gear in it??

[@wadealbert138]

did you think about putting rererse gear

[@edbaca6945]

Nice job what did you use for a gear box so you have a reverse gear .

[@racerxtex3177]

At first I didn’t have reverse. Now I installed a gas rear end.

[@jacklabloom635]

Nice job.

[@kristinmedley2573]

What's the gear size on your clutch, jack shaft, and electric motor jack shaft? I'm working on a 1990 ezgo marathon. Put a 212 in mine. Thanks.

[@racerxtex3177]

I put a 16 tooth on the jack shaft and a 10 tooth on the rear end shaft.

[@gabyrivera1963]

Hi what pulley do I use since I see that it is longer than the one that comes from the factory?

[@bradleyburns489]

What muffler did you use? Size dimension roughly?

[@tomwarren5258]

Looks great I'm trying to take a 88 dies from Electric to gas seeing how you did to jackshaft do you have reverse on yours

[@racerxtex3177]

At first no. But now I do. I bought a gas rear end and swapped it out.

[@twistedmichigander4907]

Great video, a great source for those looking to do similar projects. I may be getting an '81 club car - the batteries, the price seems right (have yet to see it up close) so if I get it, I will be doing a conversion to gas. Always nice to see how others succeeded in doing similar conversions. Could you tell me the size of the sprockets used on your jack shaft, and drive axle (tooth count)?

[@racerxtex3177]

My jack shaft sprocket is a 16 tooth. My rear sprocket is a 10 tooth.

[@twistedmichigander4907]

@@racerxtex3177 thank you.

[@miataman1985]

nice cart.What paint color did you use

[@racerxtex3177]

Ford/Mazda 25W red fire pearl

[@Tampaboys]

Good show

[@wadealbert138]

Hi RacerX great job on GC. What size torque converter you used was it a 30 or 40 series without the backing plate????

[@racerxtex3177]

wade albert First thank you. I used a 40 series. The rear pulley is directly on the jack shaft.

[@SPR1326]

Hey Racer! Thanks for making this video. I'm working on mine now and wanted to know if you used a solenoid?

[@racerxtex3177]

Just the one on the starter.

[@SPR1326]

@@racerxtex3177 Thank you sir. That's what I was thinking would be the one to use.

[@raysanchez7962]

I’m in Florida. If I bring you my golf cart can you convert it ? I already stripped the club and put a gas engine , gas rear end.

[@racerxtex3177]

😂

[@bricebeal3803]

Are those plates that you built the jack shaft on from a frame machine? Like a bee line?

[@racerxtex3177]

No. Actually they are from a locomotive hand rail. I work for a short line railroad.

[@ournextbackyard708]

Do you have a list of everything you bought and how much it cost

[@racerxtex3177]

No sorry

[@titusstewart15]

I have the same motor but can’t get the top end out of it you think you could tell me what sprockets you have

[@racerxtex3177]

I have a 24 tooth on the front and 10 on the rear end.

[@henrygibson2906]

What size sprocket did you use on the electric motor shaft? Inner diameter and tooth size? Thank you

[@racerxtex3177]

I had the shaft turned down to 3/4 with a 3/16 key way. Then I was able to use a 10 tooth sprocket.

[@wadealbert138]

Hi Racer hows your golf cart doing just checking how the torque converter holding up are you having trouble with the belt shedding? Thx

[@racerxtex3177]

wade albert So far so good. The belt is doing good. It’s a comet belt.

[@olruss6513]

Wade, i noticed it too . Something gotta give !!

[@samconard3357]

One more question, where did you buy the 10 tooth sprocket that mounts on the old shaft from the electric motor?

[@racerxtex3177]

Sam Conard Amazon

[@bradnixon5895]

Sounds good! Keep it up!

[@jakobneel1841]

with the 420 on this golf cart is there enough room to put a gearbox in so i have reverse?

[@racerxtex3177]

I really don’t know

[@scottjames5861]

Hello racer, getting closer to finding all my pieces. What bore size is the sprocket for the electric motor shaft. Did you weld it on or have the shaft keyed for the sprocket?

[@racerxtex3177]

The shaft is 1 1/8. At first I welded a 12 tooth on it. That’s the smallest I found. Then I removed the sprocket took it to a machine shop had it turned down to 3/4 and a 3/16 key way added. Now I got a 10 tooth sprocket.

[@racerxtex3177]

Also go check out BigBlok502 video. He also built a Club Car DS.

[@rudeopen]

Did u drill in the head cover to add vacuum to the pulse fuel pump?

[@racerxtex3177]

Availble Ble Yes. Drilled and tapped the threads.

[@walterschilling4512]

could you give me a measurement from the sprocket on the electric motor shaft to the sprocket to the jack shaft roughly.Thanks

[@Cherokee-sz7xi]

What tooth sprockets did you use?

[@davidcastle65]

what is the brand and size of pulse pump

[@dangh405]

Where did you get the choke cable from and how did you mount it into the charging port?

[@racerxtex3177]

dangh405 I got from tractor supply. It’s a choke cable for a tractor. I used a hose clamp to hold the cable that I wrapped around the air filter.

[@wadealbert138]

is there a reason that you did not use the backing plate for the 40 series, or it did not come with one?? What size belt you used for it???? Thank you

[@racerxtex3177]

Yes. I had to use a jack shaft and the plate goes to low and would hit the frame.

[@racerxtex3177]

I used a 29 inch comet belt

[@tjrox03]

Hi, just wondering how that rear axle assembly has held up for you. I've heard that the rear transaxle has a nylon gear and can be stripped very easily due to torque from the gas engine.

[@racerxtex3177]

It worked great. Burn outs was a breeze.

[@tjrox03]

@RacerXtex thanks for the reply! If you don't mind me asking would you happen to know the year of the cart? I'm currently building one of my own and our frames look very similar, ive been doing research and know club car can be very sneaky with parts! I just worry that with the gas torq-esc 420 engine my Axle spline may strip.

[@racerxtex3177]

@@tjrox03 1999

[@tjrox03]

​@RacerXtex how was fitting the engine in? I've decided to go alternator setup and im afraid I might have to notch too much out of the frame to fit it and loose structural integrity

[@racerxtex3177]

@@tjrox03 relocate the alternator

[@robertposs3889]

Great video. Where did you get the muffler?

[@racerxtex3177]

Oreilly’s auto parts.

[@wadealbert138]

Racer did you ever and the reverse gear to your golf cart, please let me know. Thank you

[@racerxtex3177]

No.

[@PrivateChannel1300]

Is there a part list anywhere? I just bought an electric shell for $50! Wanna get started right away.

[@racerxtex3177]

Cody Hudson I don’t have a parts list. Most of the stuff I built from scratch. Trail and error.

[@philwebb6285]

Hey racer, I have a Club Car DX I'm going to convert like you did. I use mine for sporting clays shooting in San Angelo, TX....Mine has larger tires on it and I need a little hill climbing ability. What do you think of using a 1 inch jackshaft and pillow blocks, turned down to what ever the driven clutch diameter is, with a 32 tooth on it and a 20 tooth on the 11/8 shaft on the electric motor shaft......would that work?

[@racerxtex3177]

I don’t see why not it wouldn’t work.

[@philwebb6285]

@@racerxtex3177 Thanks buddy.......your video is great, with some funny shit mixed in.

[@kristinmedley2573]

Cool I'll try that. Nice cart and good work. Very clean. What's the rpm of that 420? My 212 is around 3400-3600.

[@racerxtex3177]

Kristin Medley I have no clue of the rpm. The governor is still hooked up.

[@cabincruiserlittlebigtime8445]

What hp preditor engine is that and how well will it pull up a hill with 2 people?

[@racerxtex3177]

429cc. It pulled the wife and I really good. 40 mph

[@nobodyizhome1]

What rear sprocket did you use and where can I get one? Can you send me a link?

[@racerxtex3177]

I had the motor shaft turned down to 3/4 with a 3/16 key way. It’s a 10 tooth. Got it on Amazon.

[@TheLonesometoad]

If you can locate a junk gas car from 1984 thru 1991 you can use the transmission from it. It will bolt in place of the electric motor with NO modifications and will allow you to have Forward, neutral and reverse.

[@racerxtex3177]

I already found one. Installing it as we speak. I’m making a new video of it and other mods I’ve done.

[@henrygibson2906]

Does it have reverse? And what about a charging system to run a radio or lights ?

[@racerxtex3177]

The original build did not have reverse. I do now with a gas rear end. I making a new video of the swap. I don’t have a charger system. Right now I have no radio or lights.

[@wesleylandry3948]

How much did the whole swap cost and where did you get the clutch and fuel pump at?

[@racerxtex3177]

Around $500. Amazon

[@wesleylandry3948]

RacerXtex ok thanks!

[@bradleyburns489]

What size bore did you use for the sprocket on the motor shaft? And what number of teeth on both sprockets did you use ?

[@racerxtex3177]

Bradley Burns At first I bought a 1 1/8 bore for the motor shaft and welded it on. But realized the sprocket was to big. I could only find a 14 tooth in that size. So I took the motor shaft to a machine shop and had it turned down to a 3/4 in with a 3/16 key way. That way I got a 10 tooth sprocket on it now. My front sprocket is a 18 tooth. I just bought a 24 tooth to put on the front to get more speed. I’ll make a new video of my sprocket swap.

[@racerxtex3177]

curtisupdike No. Not yet. I have it but been lazy. Since you asked I’ll do it in the next couple of days. And I’ll make a video of it. And give you a shout out!

[@rickgalvan5319]

What is the muffler you put on that motor I have a 420 Nd want to install a muffler but I don’t know which to choose would you mined telling me the part number of the muffler please thank you

[@racerxtex3177]

I don’t have a part number. I just went to O’reillys and told them what I’m looking for. The smallest car muffler with the smallest inlet and outlet. It was a 1 1/2 was the smallest they had. I think I paid around $40 for it.

[@marte1a256]

I bought one with a predator 420 motor already in it. I cannot get it to go past 12 miles an hour though and it’s annoying because the joint is lifted and wonderful to ride but too slow.

[@racerxtex3177]

You need the smallest sprocket you can get on the rear and a big one on the front’

[@marte1a256]

@@racerxtex3177 mine doesn’t even have a sprocket. It’s just a belt going to some type of transfer case I guess it’s called on the rear end. Is there any way I can send you a video? Just so you can see how it’s laid out

[@garygogo9048]

Wow, that is bitchen!! Nice work and thanks for sharing!!

[@racerxtex3177]

Thanks dude

[@jaleon27]

I’m wanting to do something like this on my golf cart but I’m afraid I’m going to mess it up. Lol I’m a welder and can fabricate anything but when it comes projects like this I wouldn’t know where to start

[@racerxtex3177]

Believe me I’m no engineer. I drew it out on paper first. I placed the engine in different spots first before I did any cutting. What kind of cart do you have?

[@jderouen89]

How did u get the shaft out the rear end

[@racerxtex3177]

Like out of the motor?

[@rydesprojects4738]

nice job mr.

[@racerxtex3177]

Rydes & Projects Thank you

[@timothyhand6050]

Where did you get the jack shaft and the bearings at

[@racerxtex3177]

Amazon

[@Amy-wh3dt]

Really nice good job

[@racerxtex3177]

Amy R Thank you.

[@timhenry2028]

Thanks I will get one.

[@roccomane1558]

Very nice job thu

[@frankgomez1965]

How did u do the throttle set up with the stock pedal?

[@racerxtex3177]

I took apart the throttle resistors and rigged up with a bracket.

[@tylerlongo4336]

Can you post a parts list we’re trying to do this on a golf cart for a high school shop.

[@racerxtex3177]

Is it a club car?

[@Cherokee-sz7xi]

Why is your clutch on backwards?

[@racerxtex3177]

I later fixed it

[@Cherokee-sz7xi]

What size jack shaft did you use?

[@racerxtex3177]

5/8

[@jkjgb17m26]

Any issue with the chain tension as the suspension travels?

[@racerxtex3177]

Yes at first. I put a tensioner on it for the travel

[@jkjgb17m26]

@RacerXtex ok I am getting ready 2 do the same swap. Happen to have a picture of the tensioner?

[@racerxtex3177]

@@jkjgb17m26 sorry no. And I sold the golf cart

[@donaldcampbell7894]

Get my conversion kit for the rear end 5:1 ratio. 2500 rpm nets 40 plus mph. 2500 on a 12:1 ratio gets you 13 mph at best. Let’s be honest. We don’t go through this much work for 13 mph.

[@thomasbowling6198]

Where would one you find your conversion kit