VC EZGO Build ...

BrewCityMusic

Well I finally got some open shop time, and I'm on my way towards getting the first VC build together, so far the 8:1's are installed in the rear end, the cradle, engine, etc are "in" but not fully aligned, etc ... Picked the whole shebang up for $2k from a buddy who bought the kit from VC this spring and then found out he was gonna be a Daddy so I figure at the price for the lifted cart, VC kit, gearset, brand new factory EZGO body, brand new seats, and new rims and tires I couldn't go wrong LOL ....

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I'm sure as I go along I'll be needing some advice and picking a brain or two, the kit he bought has the Walker muffler so I'm assuming I won't be using that (need this one to be quiet) and there are a few other silly ideas I'm bouncing around in my head already - the wiring harness was stripped from the cart with the exception of the pedal micro so I'm going to have to design a few changes along the way I'm sure ....

BGW

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sho305

Wow, that has to be the biggest Vegas swap kit ever!

AaronW

Looks like you forgot the Starter Generator tensioner and the throttle cable bracket off. Gonna need those before you head down the road.

BrewCityMusic

The starter is just sitting there "test-fit" in the pic, I haven't gotten that far yet (need another set of hands to get the engine aligned and positioned perfectly) - and the darn throttle bracket is the only part that was missing from the whole mess but I think I'm going to change a couple of things when I fab one up, I don't like how long the throttle cable is and how it loops around the way it sits (and for that matter, I also think I may modify the whole shift linkage thing too for similar reasons) ...

What's everyones honest opinion on key-vs-pedal starting? Are these engines reliable and easy enough to start when hot OR cold that a pedal-start setup really works well? I'm hoping to get the wiring harness designed and laid out / completed tonight but I really have reservations about doing a pedal-start setup (even though I would greatly prefer it) ...

Lastly, how important is it to have these engines relatively level? I have the cradle set in the middle mounting hole now so it's at a bit of an angle, I know that VC recommends a lower hole for a lifted setup but I really REALLY don't like the front of the cradle hanging so low just waiting to get hung up on something. Worst case, for my own peace of mind I could fab up a skid plate or something to help protect it but with the whole drivetrain and whatnot held in front by a simple Heim, I would be apprehensive that a good hit from below could cause everything to part ways and create a real problem, LOL. Opinions?

sho305

I love the pedal start, I also leave slack at the idle part of the pedal so I can hold my foot on it and idle. I had to move the pedal back a notch on the spline to get more travel though (did that long ago). People run pedal start on v twins no problem, long as the comp release works. They are very reliable. But if you only trail ride you may not like it as well, depends on your use. I use my cart for any and everything including yard and utility work and its awesome for that and not really a problem on trails. You can also wire a bypass switch to the pedal, so it stays running if the key is on. Only issue is some of the stock clutches drag the belt and you can't shift that well or the cart wants to creep, but those issues can be solved.

I dropped my front mount about 1.5" I think, its in my build thread in clones here. I put a tube across under the generator and ran bars off that to the rear mount (in a yamaha, but you get the idea. I was worried about going up hills and getting a really huge angle on the engine, so now its tilted forward just a little. A lift tilts it back if you do nothing on a G9.

Another related issue is the low oil sensor some disconnect it, I have not. It can go off on hills I guess but I only had it go off when my oil was low anyway and then it comes back on (and I was turning on a side hill).

BrewCityMusic

So it lives .... Fired it up tonight for the first time and WOW, loud isn't the word, LOL ... The good news is the pedal stuff all went well once I made a few changes to the kit (new bracket for the cable, etc) and she's starting great and charging right at 14.4 like she should with zero drain when she's off (so the electrical was a success) ...

NOW onto the things that DIDN'T go so well, I managed to crack the starter bracket meaning I had to replace the starter - had a new one laying around anyhow but I'm going to rethink the whole assembly before I break this one too. The stock mount from the kit had the starter almost 3/4" too far to the passenger side, a couple of spacers picked up the slack as well as a little creative bending of the tensioner arm - I think before I tear it apart and replace the starter I'm going to cut a spacer to keep the factory bracket from bending inwards and it should be fine. Also, I have the single-cable shift on this cart, and the relocation brackets that came with the kit had the cable smashed into the head so I had to space that off to the drivers side about 5/8".

Lastly (well, so far anyhow) there has GOT to be a way to quiet this thing down, even with the Walker - I have a bunch of different mufflers from my bike stash laying around so I'm hoping to get on that after the Holiday weekend (got about 400-500 miles of riding here and there planned over the next couple of days so other than in the AM I'm not going to have a ton of time for the cart - I'm just glad the worst is over and she's at least running and behaving as it should) ... Gonna at least get a rear body and bottom seat on it in the AM (oh yeah, and the brakes, LOL) and see how she rolls down the road. More to come ...

BrewCityMusic

SO .... After a long list of tweaks and changes, it looks like the project is almost done. Had to go pick up a longer 3/8" starter belt to relocate the starter back a bit to allow dipstick access (also, the pulley that came w the kit was FAR too narrow for the supplied 1/2" belt, at 4500rpm or so it would constantly jump ship) - found a relatively acceptable place to mount the Walker so it didn't look ridiculous and could be suspended correctly to keep it from cracking too.

Had an issue w the driven clutch sticking, so that was a fast disassemble, clean, lube, etc (it's a brand new 28, but evidently was on the shelf *just* long enough to need a little tweaking before it wanted to cooperate) - also I still have to get the toe-in adjusted because at speeds, it gets a little hairy - OH, speaking of speeds, here's a screenshot of a 100yd run I did from a stop:

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When I hit my beer-can 100yd marker I was at around 5100rpm or so and as much as I really wanted to stay on it and see where the GPS maxed out, that's going to wait until after the first oil change, LOL. I can see 45 happening all day, maybe even a touch more so I'm definitely happy with the whole project so far.

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Today is the wiring, I have to install the LED's, Stereo System, Lights, relays, etc as well as get all the body trim on the cart, adjust the toe, etc - hopefully the rain stops by the time I wrap up this afternoon and I can get some riding in, see how the whole enchilada comes together - more pics to come soon!

2000-? EZGO TXT
VC Big Block Kit
6" Axle Lift 23" Tires
28Deg Clutch - 8:1 Geared Rear End
Speed from Stop at 100yds 40mph

BrewCityMusic

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Just a couple more photos of the install in progress

raydhd

Nice Install! P.S. Want more top end ? Add ported head and 1.3 rocker arms.

BrewCityMusic

^ That's likely to happen if You keep bringing it up, so SHHHHHHH !!!! ^



Anyhow, the rain hit this afternoon so I managed to get into the frame and run basically the harness I needed for some of the "Extras" - all set up for LED head and Taillights, Brake and signal, etc ... 9W Led "Cabin Lighting" as well as underbody LED's, 400W Kenwood Bluetooth system with a set of 8" Wakeboard Cans, got the Equis Tach mounted permanently and wired up the right way - it's "Beer-Thirty" here in the Northwoods so I'm leaving the rest of the body trim, flares, etc for Monday afternoon (BIG Toy Run Tomorrow, that's gonna cost a day) ..... All in all, it's starting to come together pretty nicely !!!

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