1992 Cushman Truckster with Roketa 200cc

92cushman

I bought a 1992 cushman truckster about a year ago with a honda gx340 engine in it. the engine smoked and ran poorly. i rebuilt it and ran the cart for a while, but ended up needing the engine for a pressure washer, so i pulled it out and the cart has been sitting. I painted the whole body with rustoleum bedliner and added some led headlights, taillights and clearance lights along the side. i lifted it 2 inches front and rear to clear some 22-11.00-8 inch quad tires i had. just yesterday i picked up a Roketa 200cc atv with a 4 speed manual with reverse. and pulled the engine, wiring harness, and rear axle out. the quad iis chain drive to a solid axle which will really help me because my biggest problem before was belt slippage and losing traction with the open diff. I am welding the engine and axle mounts to the original swingarm that holds the engine and rear end. the quad had hydraulic disc brakes that i will need to adapt the master cylinder to the cart brake pedal. i am going to put the tires off the golf cart rims onto the rims off the quad so that all the tires still are the same size, since the quad also uses 8 inch rims. i will post pics as soon as i get batteries for my camera.

BGW

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Unforgiven

I'd be concerned with power of the 200cc in the heavy Truckster. Really just depends on what your plans are. Or how you going to use it.

Unforgiven

Oh BTW,... welcome too BGW

92cushman

I mostly want to just put around the neighborhood and occasionally take it down into a local dry riverbed. if it doesnt have enough power, i will keep my eyes open for a bigger atv engine, but the fundamentals will basically already be there.

92cushman

I got the rear axle cut off both the quad and cushman today,and the motor mounts off the quad. Starting to mock up what needs to be welded and where. A family friend is coming over and he is a certified welder. i trust his welds much more than the chicken scratch i put out. hopefully today or tomorrow i will have the axle and motor mounts at least tacked in.

Unforgiven

I hear ya on the welding.

Good luck and post some pictures of your progress.

92cushman

Any tips or suggestions will be greatly appreciated.

92cushman

I got the quad rear axle in and narrowed the cart swingarm to clear the tires. i mounted the stripped down atv wiring harness in the engine bay of the cushman, ready to plug in the coil wire, starter wire , an engine ground and the plug to the rotor and stator. Tomorrow morning i will finish getting the motor mounts on and bolt the swingarm in to check for clearances.

cfherrman

When your done drive it, check some hills, push it a bit, probably will have to gear it down

92cushman

I got the motor mounts welded in, the throttle cable hooked up to the pedal and the exhaust welded up, I still need to hook up the shifter, clutch and brakes,i am thinking about running dual rear wheels with 22/11.00/8 tires because the quad axle is pretty narrow. i would make a spacer on a friends lathe to connect the wheels together. I am going to have a shifter between the driver and passenger with the quad clutch handle on it, so i can just pull the clutch in, shift, and let it out all with 1 hand. I got it running and kinda got impatient to drive it, so i just ran the clutch cable up to the handle, and just reached around behind to shift it. i took it up some pretty steep hills and it did perfectly fine. Plenty of power, and pretty responsive too.