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Golf Cart Modular Design Series (Part 1)— DIY Chassis Rapid Lift/Lower Module Design

Golf Cart Modular Design Series (Part 1)— DIY Chassis Rapid Lift/Lower Module Design

Golf carts are used in a wide variety of scenarios, including golf courses, community commuting, sightseeing tours, senior mobility, farms, and ranches. Different use cases call for different chassis heights:

On golf courses and in community settings—especially for senior users—roads are generally flat. Customers prefer a lower chassis for easier and quicker entry and exit, so they typically choose lowchassis models.

In scenic areas, and particularly on farms and ranches, the terrain is often uneven, muddy, or rutted. In these conditions, a higher chassis is needed to improve ground clearance and passability, and tires with better traction are also essential. As a result, customers in these environments tend to opt for highchassis carts.To accommodate these diverse needs, most brands manufacture separate chassis frames for low and highfloor versions. However, if an end user later changes their usage scenario, they have no choice but to purchase a brandnew vehicle.

GreenRider offers an innovative alternative: a modular chassis design where both low and highchassis models share the same base frame. The ride height is adjusted quickly and easily using dedicated lift modules—no need to replace the entire cart.

Take GreenRider’s lowchassis model KRG2+2 as an example. It comes with 550 rims and WR028 tires (tire diameter: 50.6 cm). The floortoground height is approximately 35 cm.

If the owner later wants to use the cart on a farm or ranch, there is no need to buy an expensive new highchassis vehicle. They only need to purchase a few parts from their dealer and do the DIY conversion themselves:

1. Parts to purchase from the dealer:

1.1  Lift kit – 2 sets,

1.2  Left and right highchassis knuckle & brake assembly – 1 set

1.3  Front bumper – 1 set

1.4  Side step boards – 2 sets

1.5  Four 14inch allterrain tire & wheel sets – A23B rims / WG03 tires, tire diameter 58 cm

2,DIY Conversion Steps

2.1Rear axle – install the lift kit and replace rear tires

2.1.1.Use a jack to support the chassis. Loosen the two rear shock absorber bolts and the one stabilizer bar bolt as shown below.

2.1.2.Attach the lift kit to the rear trailing arm. Then mount the rear shock absorber onto the lift kit, and secure the stabilizer bar to the lower locating hole. See below.

2.1.3  Replace the rear tires – swap the original WR028 road tires for the WG03 allterrain tires.See below.

2.2, Front axle – replace the knuckle & brake assembly and front tires

2.2.1  Remove both front wheels. Then loosen the following fasteners in order:

Tierod end ball joint nut (knuckle to steering gear)

Front shock absorber bolts (knuckle to shock)

Control arm bolts (knuckle to arm)
Remove the original lowchassis knuckle & brake assemblies from both sides.See below.

2.2.2 Install the new highchassis knuckle & brake assemblies on both sides.

First, secure the knuckle assembly to the control arm.

Then install the two front shock absorber bolts.

Finally, fasten the tierod end ball joint to the knuckle.See below.

2.2.3,Install the WG03 allterrain tires,See below.

3.Final assembly

Finally, install the front bumper and the side step boards on both sides. The cart is now converted to the highchassis version – the KRG2+2H. At this point, the floortoground height is approximately 47 cm.

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