G2 starter generator

Jackofall

I am doing an engine swap. Took out original engine and put in duromax 16 hp motor. I know the starter that comes on the motor can not maintain the battery with lights and radio. I want to wire the original starter generator to charge my battery and not use to start the motor. How do I hook it up to do this? Please put in simple terms.

BGW

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JRLX

If you have a drive pulley, might want to use a small alternator removed from some foreign car. An alternator will be a quarter of the weight and half the size, and double the amp output. Easier to wire up too as most alts have internal regulators. You've gotta create amount for either, and the alternator will output at low RPM. As you state, it will not start the engine.
If you choose an alternator, try to cut the harness off when picking the thing. Then you can wire up a charge light.
When doing the install, use the largest drive pulley you can cram onto the engine. Might be able to fab a drive pulley from the power steering or harmonic drive on the donor car. Think tiny japanese or korean donor vehicle. Some outboards have cute, minature alternators with high output, but I'd guess that they are right valuable compared to junkyard donors.
The wiring is simple...if you go this route, choose your parts, get it mounted and post what you're using. ID the wiring for you then.

JRLX

Small Mercury outboard alternators all over eBay.
Whatever you do for mounts, do quality work. Don't want that puppy shaking off. Your engine will likely not be as smooth operating as an OEM golf cart motor.

sho305

If you want to keep the stock gen/starter just leave it all in there, then tape up the wires/plugs to the stock coil/ignitor/pickup (the ignition stuff). Mount the engine/starter so they work like stock, you may have to use a different length belt, make sure you can adjust it, may have to make the top adjusting bracket I used one off an old lawnmower gen. Usually you can align the drive belt and the stock gen should be in line, but it depends on how forward/back you mount the new engine if you need to move it so it can adjust. Measure the shaft center distance before you take it apart, I was able to use the stock belt had to grind a notch in the block foot to clear the shifter shaft. Later put a different clutch on and had to move it, but stock clutch it worked fine with stock belt.

I'd recommend you mod the carb or get the adjustable vegas 460 carb if they still have it, so you can set the idle mix, and then make it idle really slow like the stock engine it will start better.

To shut it off you will need to fit a 5 pin relay, the post is in the stickies in clone section.

The air intake is the hardest part in the G2/9 there is little room to the carb. I cut the crank to 1 1/8 inch so the adapter is right on the shoulder of the crank in order to fit the recoil starter. If you have the hurricane style airbox you can mod the intlet and run pvc to the stock airbox though it may be restrictive at high speeds.

Here is how I did it, back before vegas made mounts. http://www.buggiesgonewild.com/clone...-clone-bb.html

Jackofall

I had already ripped out the old wiring harness before I put everything new in. So I am going to have to start from scratch on wiring. Can I just wire the voltage regulator and generator side only?

sho305

You must use the constant duty solenoid to keep the gen/starter on all the time it is running as well as have the VR wired up, it charges through the battery cables. The old gens do charge and not start, but I don't know how you do that with a cart gen it may be possible it may not. I have searched around the net looking for that and not found it yet. The gen will want to start it when you turn it on just like a stock cart. All a stock cart does is get power via key, then through the pedal switch, then it powers solenoid and ignition if equipped to make it run.