2 stroke to honda motor swap

sassycat

i just got a good looking honda gsx390 13hp engine that a cart builder guy i met put new rings,rod,bearings and honed cylinder and never been ran yet,,
he told me he always uses castrol 20 50 in his others..
think vavoline 40 would be fine,,and suggestions? in fl also.
i want to crank this engine on my bench and run it a while before building the cradle and installin in my 85 marathon..will it hurt the engine to start it w/out an exauhst?
if so i can build that first then??
i got info that the big starter lug goes to battery,then the small elec connector beside that goes to key switch,then a hot from batt to key switch?sound correct..??
then i see theres a wire on top the motor that has a plug on one end and the other end goes inside the pull cord cage? i assume this is cdi ignition or goes to the magnito or?? its in the bottom pic hangin down past the starter area..does it hook to the same elc conector on the starter that goes to key switch?? where does it hook to?? i think it would go to a key switch to get power when turned on but not sure??
also,is there any honda 13hp wireing diagrams to help me with wireing?
it has a tapperd machined alum slit sleeve bushing the guy made and told me it was so i could use my clutch/.>does it look right in the pics?
i no,,lots of questions but id rather do it right since the cart will be right when completed
i wanna clamp it to my bench set a battery beside it and start it..any help would be appreciated very much..thanks fellas.
my build in below in my signature area also..heres some motor pics

BGW

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sassycat

did i ask to many questions and scare everyone off

slonomo

You'll definitely want a muffler on there. Just use a universal if it will fit. The cool air hitting the exhaust valve can warp it, at least that's what I was always taught. You can run it without for a few minutes, but that's about it. If you wanted to break it in you'll want an extended run time. That will heat the exhaust valve up too much to run open.

No idea on the starter, but you could try it that way. Just get a universal key switch from a tractor and give it a whirl. I'd say the large lug is definitely the hot. You could try it then switch the smaller wires out and not risk any damage, although if you hook it up backwards it might start without the key on LOL?

sho305

It should be that large starter lug is a hot from battery, a larger wire/cable. Ground the block to the battery. The wire from the flywheel you ground to kill the engine, or it will just run by itself, yes its a magneto ignition. The small wire to the starter solenoid should be touched/switched momentary to 12v to activate the starter ('start' on a key switch). Most lawn key switches will do this and also ground the mag wire in 'off' position to kill it. They actually do nothing in 'run'. You can use a car style key switch and get a bosh type relay to run off the 'run/on' position that un-grounds the ignition to run it, then when you turn key off and relay loses power it grounds the ignition and kills it. That is how I run my clone in the G9 that used to have a 12v ignition. The relay and wired plug for it are $3 each on amazon.

Likely you can buy a gx390 clone muffler cheap on ebay that will bolt right on. Here is one for $40 and free shipping you might find one for less. You can use this muffler if you want, but have to make a new pipe to move it where you want it in most carts. I have mine but it might go on another project. Note you will need some metric bolts to fit the muffler on.

Item number: 280949351748

sassycat

thanks both you guys thankfully i have the 2 exhaust bolt and new gasket...
just for cheap,and to get the motor runnin a few good times before i take this plunge,i will make my own flange and pipe and connect it to a new small tractor muffler to run it on the bench..maybe the next couple days..
to do this does this sound right;;
big lug on stater to hot side battery
the magnito needs to be connected to hot to run,and ground this wire to shut motor off? incase i dont get a key switch?or do i have to to start it?

wait,this thing has a pull start..this is prob way easyer than i think..i think way to much by the way..
to start with pull rope i can just connect hot from battery to magnito and pull the rope to start? then diconect the magnito and ground it to shut it off?
sorry if i seem totally stupid about this i might be!

sassycat

i been thinkin again and reading what yall said..so if i pull start it i should just need gas and oil in it correct?
the magnito will let it crank and run and to shut it off touch the magnito wire to a ground on the block or whatever to shut it down?
im making it harder than it is im sure..i hate the thought of wiring but im learning more everyday
im heddin out to the shop now,cant sleep..cart addiction,,least it aint drugs!

sassycat

im ready to start this thing with the pull rope,waiting for advice so i dont screw sumffin up

so wont it start with gas and oil and pull rope? then to shut it down ground out the magnito wire to the block?

sho305

Yes, the ignition takes no power of any kind. Ground the wire to shut it down or put the choke on would likely kill it too. Otherwise it just needs gas/oil/and someone to spin it over.

sassycat

thank you..i have it bolted to my steel welding table and the only thing left to do is cut the flange tommorow from 1/4 plate..already got it marked and center punched.,for the exuahst that is..
then run me a pipe and muffler i have..hope to run it tomorrow

sassycat

ok i made up a flange and temp pipe to be better than nothing..it fires right up with half a pull and i did kill it after a few minutes with the top wire in the pic..

now i need to no in this first pic and another,,the top left is magnito,whats the wire under that? then the other one coming out of the block to the right of the other 2? low oil alert i think?




my make shift exauhst

also,i was told this alum split tapperd sleeve was made to work with golf cart clutch?does this look right?he said to use loctite when puttin clutch on it,i guess since the "key way"in the crank wont be used??