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Old 02-21-2014, 06:09 PM   #1
XxMertxX
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Yamaha
 
Join Date: Oct 2013
Location: Minnesota
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Default Polaris Trail Boss motor into Yamaha G2

Hey guys, im starting a project of using an air cooled 2-stroke Polaris Trail Boss 250 into a Yamaha G2. I have already pulled the motor and all electrical wires/parts needed from the ATV as well as chock cable and throttle/oil pump cable.

I am pretty confident that the primary clutch from the donor motor and the golf card secondary will work well together and fabricating a proper motor mount should not be a problem.

My main concerns are as follows:
- Is the stock rear end of the golf cart going to hold up and is there anything suggested to make it stronger?
- The G2's fuel pump uses a pulse line from the motor, the new donor motor doesn't have a pulse line, it used gravity feed. Can I install a pulse line into the crankcase of the ATV motor, and if so, can I do it without splitting the case?

Those are my only questions at the moment...as the project progresses, im sure im going to have more questions.
Thanks for any help in advance


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Old 02-21-2014, 10:12 PM   #2
XxMertxX
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Yamaha
 
Join Date: Oct 2013
Location: Minnesota
Posts: 38
Default Re: Polaris Trail Boss motor into Yamaha G2

Pulled the motor from the golf cart tonight then set the donor motor in for a 'dry' fit to check clearances for the motor, clutch and exhaust. So far everything looks like its going to line up quite nicely. The exhaust will need a little modification, but it shouldn't be a problem like I thought it was going to be. Im planning on keeping the pull start on the motor as a back up, just in case the batter dies for some reason.

Original motor


Donor ATV motor (dry fit)


Tomorrow im planning on pulling the entire swing arm and will do all the fab for mounting the motor with that whole assembly.
I think im also going to drill a hole in the crankcase for a pulse line for the fuel pump. Since the motor is easy move around, i should be able to flush out any metal shavings that might get into the lower end.
I'll post more pics as things progress.


If anybody is interested, i'll likely be selling the original motor after I get things running with the swap. Original motor ran great, I just wanted a little more power and had quad with no title sitting around.
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Old 02-22-2014, 12:53 AM   #3
stuff4mason
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Default Re: Polaris Trail Boss motor into Yamaha G2

Nice!! Be following your build!!! So far, my Polaris 500 isn't hurting my stock G16 rear end a bit.....(knock on wood)

Cooling that motor might be a challenge in deep summer, but should run awesome!

I'd set the motor to run a Titanium Polaris belt. Be a little more expensive, but worth it!
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Old 02-22-2014, 10:04 AM   #4
XxMertxX
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Default Re: Polaris Trail Boss motor into Yamaha G2

The back side of the clutch also serves as somewhat of a turbine, so i think im going to try to find a way to fabricate a cover around the clutch and exhaust it onto the motor to help cool it, sort of like it was when in the ATV. Otherwise I may look for a way to install a fan in front of it, which might actually be easier. Something to ponder as things progress.

Was your carb fed gas through a fuel pump, or gravity fed? Im still trying to resolve the issue of fuel supply.
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Old 02-22-2014, 10:53 AM   #5
smallblock450sl
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Default Re: Polaris Trail Boss motor into Yamaha G2

Cool project. How many CC's/HP is that engine? I would think you'd be fine drilling into the case, I would recommend using grease in the drill bit and going slow, should keep all shavings out of the engine. Yoy could JB weld a brass fitting in the hole, just make it the same size "OD" of the "ID" of the stock yamaha pulsar line hose. Good luck on your build
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Old 02-22-2014, 11:13 AM   #6
XxMertxX
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Default Re: Polaris Trail Boss motor into Yamaha G2

The motor is only a 250cc. Not a huge jump, but with the change in clutching, it should ad some more torque and a little more speed. Mostly looking for more strength in the motor as I use the cart to pull a sled trailer around the yard and drive it out to the hunting spot a few times a year.

I was thinking the exact same thing with the pulse line, A brass fitting and JB Weld. Good pointer on with the grease. I think if I go nice and slow, it shouldn't be an issue, and with it being aluminum, it should drill nice and easy.
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Old 02-22-2014, 12:11 PM   #7
stuff4mason
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Default Re: Polaris Trail Boss motor into Yamaha G2

Quote:
Originally Posted by XxMertxX View Post
The back side of the clutch also serves as somewhat of a turbine, so i think im going to try to find a way to fabricate a cover around the clutch and exhaust it onto the motor to help cool it, sort of like it was when in the ATV. Otherwise I may look for a way to install a fan in front of it, which might actually be easier. Something to ponder as things progress.

Was your carb fed gas through a fuel pump, or gravity fed? Im still trying to resolve the issue of fuel supply.
No, my pump runs off pressure line on the carb. You might ask pitbull joe - I think he's had to deal with that on his. Not sure.
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Old 02-22-2014, 03:11 PM   #8
XxMertxX
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Default Re: Polaris Trail Boss motor into Yamaha G2

Pulled the wiring harness and all electrical parts not needed for the new motor. Pulled brake lines and all cables connected to the swing arm. Easily dropped the swing arm using my sled lift!



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Old 02-23-2014, 11:16 AM   #9
smallblock450sl
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Default Re: Polaris Trail Boss motor into Yamaha G2

Need a closer/better picture of the secondary clutch, something looks wrong, maybe just the picture though.
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Old 02-23-2014, 11:56 AM   #10
XxMertxX
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Default Re: Polaris Trail Boss motor into Yamaha G2

Im gonna pull the secondary and go through it. It's in pretty rough shape, ramp shoe's are gone, so im thinking i may need a new helix. I'll dig into it and take some pictures for a better assessment.
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