Pioneer Conversions L.L.C.

Should a conversion be done with or without a clutch?


Clutchless (we don't recommend)

In both systems, the hub adapter slides onto the shaft of the motor (and is sized for it) and has a bolt pattern to bolt to some original part or another adapter.

In a system with no working clutch, the hub adapter bolts to the clutch disk, which slides onto the splines of transmission input shaft. Sometimes the clutch disk is cut down, as you don't use the clutch friction plate surface at all with that system. There is no way to release the clutch in this system.

Using a clutch (we recommend)

In a system with a working clutch, the hub adapter bolts to the original flywheel. The clutch pressure plate is also bolted to the flywheel (as it was originally), and the clutch mechanism grabs the driven clutch plate, and squeezes the clutch plate between the clutch pressure plate and the flywheel. The flywheel could be cut down in size or thickness, as a heavy flywheel is no longer needed to smooth out the engine. The clutch plate is splined to the transmission input shaft. This system retains all the original clutch actuating system, whether it used mechanical linkage, or a small hydraulic system (master and slave cylinders.)

Comparison

In a clutchless system, shifting is more difficult at speed, as the motor RPM has to be carefully matched to generate the correct transmission input speed to make the shift. In a clutch system, you have much more lattitude in speed matching, and shifting is much easier. Also in a clutchless system, you start up without using the clutch. Simply pressing on the accelerator pedal will signal the controller to start to apply power to the motor. If you use a clutchless system and try to start uphill, you apply a significant current (power) to one set of comm bars and brushes before the motor turns over, and this can easily overheat one set of comm bars. We have seen a few clutchless systmes which have damaged the electric motor comm bars due to 'hill holding' or starting from stopped going up a hill.

In a clutch system, starting uphill requires judicious use in engaging the clutch, but is very doable with just a little practice.

Many of the lower voltage EV kits on the market use the 6 inch D and D motor with a clutchless design. Converting these to a clutched system will require finding a source for the missing clutch parts.