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Unread 08-01-2016, 08:05 AM   #1
Not Yet Wild
 
Join Date: Dec 2015
Location: Syracuse Indiana
Posts: 22
Default Hyundai 420 clone build

This is the start of my beater Hyundai golf cart HF 420 engine swap. While I may not always have the pics in perfect order or always have proper syntax- I'm throwing it out there for the world to see! Don't be afraid to throw your adlibs or info in either.
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Unread 08-01-2016, 08:20 AM   #2
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Join Date: Dec 2015
Location: Syracuse Indiana
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Default Re: Hyundai 420 clone build

Here are a few pics of my cart and some parts too.

pic 1- $6 steering wheel from ebay.

pic 2- The Hyundai.

pic 3- 63 amp Premium Bosch rebuilt alternator- ebay- $50.

pic 4- alt- I think they sent me the premium alt by mistake and didn't want it back

pic 5- China made ArcticCat fuel pump from China. Its for a 660 sidexside-$11

Alternator is for a 1978 Impala. The pigtail for the 2 prong hookup and rubber cover for the main 12 volt hookup were from ebay
for a few bucks.
Attached Images
File Type: jpg New cart steering wheel 5 2016.jpg (144.2 KB, 0 views)
File Type: jpg Photo2308 Hyundai cart.jpg (195.3 KB, 0 views)
File Type: jpg Photo2324 63 amp alt.jpg (161.6 KB, 0 views)
File Type: jpg Photo2325 63 amp alt.jpg (150.0 KB, 0 views)
File Type: jpg Photo2375 China made artic cat 600 SxS pump.jpg (149.0 KB, 0 views)
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Unread 08-01-2016, 08:25 AM   #3
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Default Re: Hyundai 420 clone build

Just getting started with engine/ electrical removal, and start the planning.
Attached Images
File Type: jpg Photo2302 cart.jpg (210.2 KB, 0 views)
File Type: jpg Photo2303 cart.jpg (201.4 KB, 0 views)
File Type: jpg Photo2304 cart.jpg (203.4 KB, 0 views)
File Type: jpg Photo2305 cart.jpg (199.1 KB, 0 views)
File Type: jpg Photo2306 cart.jpg (189.4 KB, 0 views)
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Unread 08-01-2016, 08:27 AM   #4
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Default Re: Hyundai 420 clone build

Starting on Harbor Freight 420 mods though I know it wont be all of them at this point.
Attached Images
File Type: jpg Photo2307 cart.jpg (186.1 KB, 0 views)
File Type: jpg Photo2369 Gaining access for mods..jpg (116.5 KB, 0 views)
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Unread 08-01-2016, 08:38 AM   #5
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Default Re: Hyundai 420 clone build

I decided to run my fuel pump pulse from the carb spacer. I just happen to have had a nipple laying around. ( I'm a hoarder/scrounge) to use for this. 5/16" hole and red thread locker.
At this point is where I figured out why the throttle was binding and rough to operate-NO LUBE ON ANYTHING!
The spacer nylon washers under the throttle lever were just thrown in there with no lube. I restacked them for non binding operation and lubed them with silicone grease.
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Unread 08-01-2016, 08:45 AM   #6
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Default Re: Hyundai 420 clone build

After I got the fuel pump pulse nipple installed I noticed a major restriction caused by the carb gasket. Just carefully trim the excess that is outlined by the throat of the carb. Used a pencil to trace the carb throat if needed to keep from removing too much gasket material. You just want to unblock any restriction.
Hmmmm, the garb gasket material is made in the USA! Who could've guessed?
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Unread 08-01-2016, 08:50 AM   #7
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Default Re: Hyundai 420 clone build

The engine had waaay too much fuel line installed that it was running uphill and was restricted above the carb. Fixed that.
Second pic is of the throttle pivot bolt after taking it apart, restacking the washers properly ,lube, install lever and red threadlocker on the threads of the bolt/nut. Operates perfectly now.
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Unread 08-01-2016, 08:59 AM   #8
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Default Re: Hyundai 420 clone build

I wanted to be able to operate the choke easily and dependable. I drilled a hole in the lever for choke cable hookup later.
Had to lube before reinstall.
I also trimmed the choke lever stop away for smooth operation after the breather assembly was reinstalled(next pics).
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Unread 08-01-2016, 09:04 AM   #9
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Default Re: Hyundai 420 clone build

Choke stop was then removed for smooth operation with a cable.
Yellow hose is for the fuel pump pulse to be used later.
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Unread 08-01-2016, 09:08 AM   #10
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Default Re: Hyundai 420 clone build

I decided to change the manual start housing clocking in case I needed to pull start the engine. That way if you had to pull start the engine it would be in a straight up motion.
Attached Images
File Type: jpg Photo2392 pull start rotate to up.jpg (155.9 KB, 0 views)
File Type: jpg Photo2393 pull start clocking to upright..jpg (157.4 KB, 0 views)
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