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Old 10-04-2017, 09:23 PM   #1
Docpr
Getting Wild
Yamaha
 
Join Date: Sep 2017
Location: Cowtown, Texas
Posts: 76
Default My G2 Clone Swap

Thought I better start my own thread, been posting on Justwondering's.
Thank you. Have been Lurking, Lurking, Lurking.
A great site, So Dang much knowledge.
Bought a 90 G2, pretty good deal, 4" lift, good tires, bad engine.

IMG_4829A.jpg

Could not make up my mind which way to go, So I read dang near every thread on here. Finally decided to go with the VC 460. Ordered the engine and the kit last Monday. Part of it, maybe all of it will be here tomorrow.
Got the old engine out, cleaned everything up getting ready.

IMG_4880A.jpg

Going to be a good weekend, I hope.

So, this afternoon I'm looking at the old cart and think, HMMM, I need to get the driven clutch off there so I can put the pretty new one from Vegas Carts on when it gets here.
Besides, How Bad can it be???

Well Dangit, that rascal was on there!!!!
I have every tool/puller known to man AT my business shop. I didn't want to wait until tomorrow of course. Too easy...
Got the nut off, no problem. Soaked everything in my Secret Sauce.
Tap, Tap, Tap.....Nothing. Pried, cried, cussed and bled.....
Soaked it some more, more of all the above. Nothing.
Finally broke the inside sheave, CRAP, luckily a new one is on the way.
Finally retapped the holes in the outside sheave put heavy pressure on the puller, more secret sauce and tapping and off it came. Whew!!!

IMG_4882.jpg

IMG_4884.jpg

It's gonna be fun, Thanks to all the pros on here for the great advice so far.
I'm sure I will need lots more of it.....

To be continued...........
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Old 10-04-2017, 09:32 PM   #2
raydhd
VC 460 CLONE GONE WILD
 
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Yamaha
 
Join Date: Oct 2014
Location: Ray BY The Bay NJ
Posts: 10,593
Default Re: My G2 Clone Swap

They sell a puller made just for the yamaha secondary that works well. You may want to invest in one in case you find that your initial spring setting doesn't work out just right.
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Old 10-04-2017, 09:39 PM   #3
Docpr
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Posts: 76
Default Re: My G2 Clone Swap

Pretty sure that would be a good investment.....
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Old 10-05-2017, 11:58 AM   #4
AaronW
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E-Z-GO
 
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Location: Las Vegas
Posts: 281
Default Re: My G2 Clone Swap

Quote:
Originally Posted by raydhd View Post
They sell a puller made just for the yamaha secondary that works well. You may want to invest in one in case you find that your initial spring setting doesn't work out just right.
That might be the best thing I've read all week. The right tool for the right job. Hopefully the new clutch isn't married so well to the shaft. After 27 years I'm not surprised the clutch didn't want to come off.

I'd EXTRA clean that shaft and those splines.
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Old 10-05-2017, 05:57 PM   #5
Docpr
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Yamaha
 
Join Date: Sep 2017
Location: Cowtown, Texas
Posts: 76
Default Re: My G2 Clone Swap

Yep, Shaft is getting a super clean!!!
My weld shop will be building a puller next week
Received the first box today, I looked like my Grandkids at Christmas.
What spring setting would ya;ll recommend to start with.
Mostly a general purpose/work cart, with the occasional run up..
Not many hills on the place, mostly just flat running to the fish pond
and carrying tools and feed.
Thanks, Pat..........
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Old 10-05-2017, 06:21 PM   #6
raydhd
VC 460 CLONE GONE WILD
 
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Yamaha
 
Join Date: Oct 2014
Location: Ray BY The Bay NJ
Posts: 10,593
Default Re: My G2 Clone Swap

Before you reinstall the secondary you need to get rid of that circlip on the input shaft and put in the yamaha spacer part # J55-46322-09
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Old 10-05-2017, 06:31 PM   #7
Docpr
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Yamaha
 
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Location: Cowtown, Texas
Posts: 76
Default Re: My G2 Clone Swap

Yes Sir, clip is gone. VC sent a new spacer with the installation kit.
Cleaning and removing rust from the splines now.
Just didn't know what numbered hole to put the spring in to start off.
Thanks.....
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Old 10-05-2017, 06:40 PM   #8
raydhd
VC 460 CLONE GONE WILD
 
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Yamaha
 
Join Date: Oct 2014
Location: Ray BY The Bay NJ
Posts: 10,593
Default Re: My G2 Clone Swap

I have a umaxx spring set on B 1. If you have the stock spring I would still start with B 1. The VC 460 has got plenty of oomph.
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Old 10-05-2017, 06:42 PM   #9
Docpr
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Default Re: My G2 Clone Swap

Thanks Ray, I will bet it does....
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Old 10-05-2017, 08:16 PM   #10
Docpr
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Yamaha
 
Join Date: Sep 2017
Location: Cowtown, Texas
Posts: 76
Default Re: My G2 Clone Swap

Made some progress tonight. Getting ready for the engine.

Got everything cleaned up and the driven clutch on.
New engine mounts on.
Changed the oil in the rear end.

DSC04563A.jpg

DSC04564A.jpg

More tomorrow. Enjoying this.....
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