93' CC swap to GX390 Build...and so it starts!!

clubcar5

Current Specs: FE290 6" lift with 22's, machined driven with power spring (Tom @ CCP)

I picked up a gently used Honda GX390 from craigslist with electric start for $300 (Thanks to nocerus03) a few months ago. Looking to get more low end grunt and not so much top speed.
Goal is to use the factory wiring with starter/generator. I plan on running the OE drive clutch with the adapter from CCP. I also purchased the longer 1" belt from Tom to get more clearance from the rear end to the Honda starter. Governor will not be removed.
I pulled the motor out this weekend and set the Honda in to check clearance. First issue, in order to clear the black control box, the front end of the motor will have to be lifted 2+ inches and 4-1/2" in the rear to sit level. This did not worry me until I noticed the honda's air filter and cover will hit the bottom of the seat when closed. So first issue being addressed will have to be if I can run the open air filter without the cover without changing the jetting. If so, I can cut the long bolt that the air filter and cover screw onto and do as planned. If not, I my end up researching other flexible intakes to only raise the motor in the rear but still clear the black box. I will post more pics tonight but here are ones with the motor out.

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	cc motor in.JPG (507.3 KB, 0 views)
	cc motor in rear.jpeg (461.9 KB, 0 views)
	cc motor out.jpeg (580.2 KB, 0 views)
	cc motor out-2.jpeg (507.4 KB, 0 views)

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nocerus03

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dubs27

I recently put a gx390 in my ez-go this thing is a beast. I haven't found hill yet I cant climb. The biggest upgrade I made was using one of Vegas carts tunable carbs and an aftermarket exhaust.

clubcar5

dubs27, i read through your posts and really glad to hear your happy with it. I want to get some of the fab done and motor in before I start deciding on a new carb and exhaust. I will hit you up when I get to that point. Here is my fix for limited space (pic below). I am going cut some flanges at work today and start the intake manifold. This way I can keep the front at the same height and just raise the rear to make it level.

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honda_gx390_0.png (850.9 KB, 0 views)

Springbok

Subscribed. :popcorn:

dubs27

That looks pretty cool.

clubcar5

Made some progress this weekend. Removed the clutch from the FE290 (soon to be on craigslist) and disassembled the clutch. Replaced the slides but everything else looked good. Was quite a bit of dirt and dust in there, prolly robbing me of a few MPH's. As you can see, the Honda shaft was about 2" longer than I needed. Placed the adapter from CCP on and used a cut off wheel which went through it with ease. Located center, drilled, and tapped. Mounted the new clutch and ready to go. I also welded a pc of 2x2x1/8 sq tube in the rear above the original brace to mount the new motor plate to. I used my OE plate to check level and I have a slight positive degree but I'm good with that since it's a splash motor. I am cutting my new motor plate today and will post pics when it's done.

Attached Images

	side by side 1.jpg (159.6 KB, 0 views)
	sidebysideadapter.jpg (132.1 KB, 0 views)
	shaftcutntapped.jpg (141.8 KB, 0 views)
	bracing.jpg (178.6 KB, 0 views)
	motormountlevel.jpg (157.3 KB, 0 views)

nocerus03

**** brah.... Your gonna have that thing up and running in no time. Looking good. I wish my swap was this easy. Keep us updated, and keep posting pics!!

clubcar5

Got the motor mount painted last night, I think it turned out really good. As long as it's naked, going to get the frame painted and remaining clean-up done tonight. I drilled the holes for the bolts to hold the mount and welded the nuts at the bottom. I did this so I won't have to hold a wrench on the bottom when tightening everything down. Hopefully this weekend I will start putting the puzzle back together.

Attached Images

TRD motor plate.jpg (156.3 KB, 0 views)

clubcar5

I managed to find some time to work on the GC. I have the motor installed and clutches aligned. I used a large drywall straight edge and lined it up as close as possible. The belt tension is roughly the same before the swap. First test drive will hopefully confirm this. Since the carb and intake manifold are to long and run into my black box, I was leaning towards a custom intake to move the carb over the fly wheel. However, for the sake of keeping the motor as close to original, I re-located the solenoid to behind the battery and under the air box. I am currently looking for a weather proof container to put it in and bolt it down. Now, I have room to trim the black box and mount the carb as mfg'd.

Attached Images

	motor in.jpg (160.6 KB, 0 views)
	motor side.jpg (134.8 KB, 0 views)
	solenoid top.jpg (200.7 KB, 0 views)
	carb problem.jpg (160.2 KB, 0 views)