96 EZGO VC625 Conversion

Rooster59

The beast is in and a few brief 35 degree foggy test runs done. Power is awesome. The throttle could be a bit longer throw but it would still be a brute just off idle. Have to get adjusted to the abrupt power when starting out in a tight spot.

Sound is a bit ear splitting but that is due to no muffler. It was damaged in shipment and Aaron sent a Walker 22022 as a replacement. I will have to visit my country exhaust expert later this week to get it adapted and installed. The header stay is about 1/4" too short from what I can tell. Will have to fab a different one.

It idles easily as low as 675rpm. Any lower and you have to press the accelerator to start it and run it for a minute. Shifts into gear easily when idling. It is hard to shift out of gear though. The clutch isn't engaged at that rpm. The belt has about 1.5-2.0" of deflection but I may try loosening it a bit. The filter almost touches the cradle drop bracket where I have it now.

Installed the tach and turned on my DigiHUD phone app on the first test run. Ran it up to 28mph for a second or two. Exhaust noise kept me from going higher. Couldn't believe I had my tach set right when it showed 2600+/- rpm at 28 mph. Unless this engine times the ignition off the cam the tach has to be set right. Same as the 295 Robin. One spark for every revolution? If that is right I can't imagine running it to 4000rpm. I backed it down to about 1950rpm and it churned uphill at 19-20mph.

BGW

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Rooster59

Just read VC's description for oversize drive belts. They state clearly the belt should be significantly more loose for engines using the built in starter to allow shifting an idling cart. Guess I better get out the 9/16" wrench tonight and give the belt more slack.

BLACK DEATH

***... I may have to get this for my g29 cart... I like that speed you all are getting

AaronW

If we sent you the Walker 22022, that is wrong. You should have been sent the lunch box looking OEM muffler. I believe that one is on the way. That should be more quiet and easier to install.

Rooster59

Thanks Aaron. We'll find out tomorrow when the Fedex man arrives.

Rooster59

Is there a downside to using the Walker 22022? Your expertise is trusted when you say it may be louder than the stock muffler. Not that I want louder but decibel level isn't quite as critical for my use. I live in the country with houses at least 250-300 yards apart and I don't hammer it at any time. Obviously it would require slight modification to work but not much.

The 22022, or something like the 22229, would accomodate adding a longer tailpipe for when I use the full enclosure. The 22022 is even smaller in diameter to fit crossways behind the rear axle and under the bagwell. Just thinking out loud here while I have time.

AaronW

[QUOTE=Rooster59;1466752]Is there a downside to using the Walker 22022? ]

We tested it earlier in the R and D phase and preferred the lunch box over 22022. It was more quiet and didn't notice a power difference.

Rooster59

[quote=AaronW;1466825]That's good enough for me.

This weekend a friend and I will "reclock" the header near where it passes by the valve cover to raise the muffler mounting flange. The header positions the muffler perfectly for a non-lifted cart. Since mine is lifted 5" the muffler could be raised quite a bit and still not contact or overheat the bag well recess. That will also keep the short tailpipe extension more horizontal and closer to the rear bumper. Immediately after the muffler exit the tailpipe will be 2" OD. The intention is to minimize any effect the tailpipe may have on engine tune "as delivered".

One section of the extension will be permanent to reach the rear bumper. The second section removable to get past the winter enclosure. That section will be removed when the enclosure comes off. Using one of those stainless steel band clamps with offset should make that a simple task.

In order to better support the muffler and added weight of the tailpipe extension we will weld a bolt to that heavy metal tab on the inlet side of the muffler wall. It looks like it might be intended to be used as additional support.

Rooster59

AaronW,
Muffler arrived a few minutes ago. Thanks for taking care of this so quickly. Really appreciate your attention to the matter.

Rooster59

The lunch box muffler works pretty well. Now the 625 only makes one of my dogs nervous. [emoji3]