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Old 08-27-2017, 05:01 PM   #1
GearHeadDiver
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Exclamation Honda GX390 in '86 Club Car Questions.....

I've picked up a nice, low hours Honda GX390 engine.....

I'd like opinions (Only from those that have done same swap, Please)...

To use Honda key/ ignition / electric start....
OR to hook up engine to use stock CC pedal start...

If using the Honda starter, with ignition key switch wiring extended and mouneed in dash....
if I hook my battery to the Honda engine/starter... can I leave the stock ignition/start (electronics/solenoid/relay) box in place. ..and just use the cable (modified) to use the pedal/throttle.....

Or.... if using the stock setup..but Honda motor.. which wires do I use on the Honda to hook to original/stock CC wiring harness...

And where should the rear end "governor?" Rod attach to...

I've had replies for a similar question..but the ones who replied and gave advice had the clone in a Yamaha.... not a Club Car.

I can fabricate or adapt anything.... but I just can't seem to be able to picture it in my mind...as well...I REALLY suck at figuring out wiring...lol.

Any real help and advice would be GREATLY appreciated.

Thanks
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Old 08-27-2017, 05:49 PM   #2
Shepard
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Default Re: Honda GX390 in '86 Club Car Questions.....

Honda's use a regulated ignition system [built in rev limiter] - if you want to spin it faster then 4000 rpm you'll have to replace the ignition coil and the flywheel. Then if you want to spin it faster then say 42-4500 rpm you'll need to put in some heavier ft lb valve springs in the keep the valves from floating. Sorry to say this is why you don't see more true Honda builds.
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Old 08-27-2017, 05:58 PM   #3
GearHeadDiver
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Default Re: Honda GX390 in '86 Club Car Questions.....

Thanks for the reply.....
is that in reference to the governor tied to the rear end? Or unrelated?

I'm actually not looking to go any faster... just replacing a blown original engine...


Still looking for best (read: Less Complicated) way to hook it up...

Thanks
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Old 08-27-2017, 07:53 PM   #4
sho305
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Default Re: Honda GX390 in '86 Club Car Questions.....

I do yamaha mostly but I can help you some, you can search here in clones section for club car threads that will tell more detail if nobody comes around soon enough.

It depends on what ignition is in your cart, the older yamaha were 12v. The clone needs no power for ignition you just need to kill it, so you need a kill wire to ground to stop it. In yami you put a relay that goes ground when off to kill it. If your cart had a magneto ignition to start with (no power to it) then it should have a kill wire already.

The start/gen system on a cart you don't have to do anything to it, leave it, and figure out above how to kill the clone is all you do. Make sure it rotates the right way newer CC run backwards and cause problems. You have older one so no problems for you. (93 is cut off I think)

If you run the clone/honda starter then you don't need the starter/gen, but you do need a way to charge the battery so hopefully your honda charges or you may need to put an alternator on it from a car or tractor/etc. Then just mount the key or you can use any magneto key like a B&S key as well and some outboard keys work that way, they have no power to run only power to starter. If you do this you get rid of the start/gen and unhook the power to the key it will disconnect most things but someone with a CC can explain details.

If you use the trans governor that is good in a way but honda and lifan now have 4K rev limit. You just need to make sure your cart clutch shifts under 4K or it will hit the rev limit. It is better to run it this way and not use the engine governor, at least in my opnion, and is why the cart makers do that. Some use the engine governor but again it kicks at 3600 sometimes it kicks in before the clutch shifts as most carts hit at least 3600 WOT, but depends on the cart. I had a 92 Cc I worked on and it also had a rev limit, it must have been around 4K rpm, it only hit if you maxed out the speed of the governor.

You can get a coil for UT2 from NR racing without the rev limit, its about $70 last I looked. It works on UT2 honda and the lifan sold at home depot online. UT2 is the new electronic ignition that advances timing and rev limits at 4K, the flywheel is also different if you want to swap to the old UT1 style with no limit and no advance. So you can get that coil, then HD valve springs ($20), timing key (few bucks), and get around 5K rpm out of it no problems for better top speeds if you want. If you do that you remove the governor from the engine and the cart, you don't use either. Or disconnect the cart one, the engine one is pretty easy to remove.
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Old 08-28-2017, 09:53 AM   #5
GearHeadDiver
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Default Re: Honda GX390 in '86 Club Car Questions.....

I checked out the install instructions on Vegas carts site .....
I've got it all figured out...

Except.... the wiring.

After removing the electric starter, solenoid and key switch....(from the Honda GX390)...
I have 3 wires coming from the engine.

Black - on top of engine....from coil (I'll add an inline kill switch to this wire as suggested by Vegas)
Yellow - back of engine...I'm assuming low oil sensor?. ( will connect to Club Car stock harness, Yellow wire)
White - back of engine...coming out of engine same beside yellow...

The (2) spare wires with connectors I have from the stock CC wiring harness are Yellow and White/black stripe...

Just trying to figure if the stock CC wiring harness white/black wire... should connect to the white wire from the Honda GX390 engine?

Wiring is obviously iously NOT my strong point ;)
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Old 09-03-2017, 04:40 PM   #6
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Default Re: Honda GX390 in '86 Club Car Questions.....

Motor in...made my own spacers/mounts....
Dropped the control box...and will be able to use the stock air filter/box.
made my own brackets for the starter/generator...

I built my own throttle cable, out of the old one...as I have a box of old motorcycle, etc. cables to work with.
Used the stock end for the throttle cable (ball/socket)... Cut off old cable, drilled out, drilled and tapped for a 6-32 set screw to hold cable....
Used the original 90* bends too...pulled all old cable sheathing out...new one slid in...crimped and shrink tubed...
Just need to make a plate/ holder for the cable end (at throttle arm).

Now, just need to fab up exhaust....
Any input on using a muffler off an "off shore" ATV / 4 Wheeler?
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Old 09-03-2017, 04:44 PM   #7
GearHeadDiver
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Default Re: Honda GX390 in '86 Club Car Questions.....

First, can someone tell me (or show me) where the governor rod connects to (from the rear end arm to ?)

Secondly, can someone explain to me exactly how that rear end governor affects the engine? Or does the engine affect the rear end?

Is it crucial to have it hooked up?
or is it omitted when using a clone?

Any help appreciated

Thanks
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Old 09-03-2017, 05:55 PM   #8
HBR
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Default Re: Honda GX390 in '86 Club Car Questions.....

I dont have an '86 so I cant help you with the hookup.

The governor in the rear end controls the rpm of the engine. If you have a tach and watch it you dont have to use the governor in the rear end.
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Old 09-06-2017, 09:23 PM   #9
Streetbu
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Default Re: Honda GX390 in '86 Club Car Questions.....

I would bypass the rearend governor unless you only want to go 6mph....
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Old 09-12-2017, 08:16 PM   #10
GearHeadDiver
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Default Re: Honda GX390 in '86 Club Car Questions.....

Getting closer.... since this pic, exhaust is done and wrapped... just need to compare GX wiring with CC wiring (for kill switch)... double check all bolts, install fuel tank, replace fuel lines and install battery...
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