G9 clone swap

beachcart22

After 2 years i'm finally going to fix the g9 i've had sitting in the yard, Just picked up a 420cc from harbor freight ($310 out the door with 1 year warranty) I've been scouring the posts here trying to gather all the information I'm gonna need to do this right, heres what i've come up with so far:
-remove governor arm shaft, thread and fit bolt into hole
-break governor gear and remove
-drill with 29/64 to shaft shoulder depth
-Cut shaft to 1'1/8" in front of shoulder
-tap with 1/2-20 hand tap
-taper adapter
-put barb for gas pump pulse through both layers of OHV cover
-remove air filter and replace with pvc/flexible tubing to filter.
-wire start/kill switch box to front of cart
-rig up the throttle using the governor arm similar to how a couple guys on here have done it
I'm still trying to figure out the best way to do a mount (currently don't have a means by which to weld), i also have a yoshimura motorcycle exhaust i got a yard sale for $5 that i would love to put on this if it would work. Any advice is appreciated, and did I miss anything major?

BGW

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sho305

In my clone I ran a standard 3/8" tap part way down the governor shaft hole to thread it, then put in a set screw or use a bolt, I put teflon tape on it. Be very careful to keep any metal chips out of the engine I greased the tap to collect them, used rags, etc.

I'd recommend you put a 4-6 degree advance key in the flywheel, lap the wheel a little, and put HD valve springs in, then you can run no governor with no problems long as you don't try to blow it up, and you keep rpm down to break it in. But that stuff is easier to do out of the cart.

You can buy the mount at Vegas carts. You can make one but bolting may take some time. I had bars welded in and all done in a couple hours at most. I used the stock mounts with bars attaching them, a tube across the front to drop the front to level the engine better with my lift.

beachcart22

I see vegas carts sells an 8 degree advance key they recommend for any cart, would that work?

jackman08

do you have to get a longer belt that drives the primary clutch? Looks like there is no way to mount the clone close enough to the read end to use the belt that was on cart. If you do, where would I find one? Thanks

beachcart22

I was under the impression the stock belt would work. Sho, what do you mean by lap the wheel?


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sho305

The stock belt works if you keep the distance the same. I had to grind a notch in the block on mine it was rubbing the shifter bolt on the trans....due to me using stock mounts the engine moves around. Just look at McMasters there are many sizes for 1 3/16 or 1 1/4 wide belts.

The timing key is great but depends on if you cut the head and what gas you use. I have .050 cut and 4 degree and can still run regular fuel its far as I can go without premium. Maybe you can run 8 degree with no head cut and its ok, just verify it.

Its a good idea to put valve lap compound on the crank and turn the flywheel on it to lap them together. Clean it off and install the key. Some have had the flywheel slip and shear the key. Racers lap them and run with no key, so we know that helps grip a lot.

beachcart22

I don't have a head cutting tool, so is a timing advance key pointless on these without cutting the head?


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sho305

No you machine the head down at the gasket surface to increase compression. You tend to want more timing with less compression, advance will start the fire early and build compression sooner sort of making it higher. 8 might be good just find out if you can run regular if you are worried about it. Too much advance and you have to run premium or it knocks and can damage it after a while. I can only run 4 degree key with .050 cut off the head, you should be able to run more I just don't know how much more.

Lawn engines are pretty retarded from factory because they don't know how it will be used, they only run to 3600rpm, and they might use substandard fuel in them in some places. When you rev it higher you need more advance, you want more power you need more.

beachcart22

Got an email back from Geoff at Vegas carts and he said I can install the 8 degree key but have to use premium gas.


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sho305

That is what I was thinking. If you have a clutch that engages higher rpm you might be able to run regular. Colder temps you might run regular also.