87 Yamaha G2 Engine swap

keith4128

I want to ask all of you experienced engine swappers out there what is the preferred engine to use on an 87 G2, I just got this thing and the engine started blowing lots of blue smoke. I want to have more power and torque to be used around the farm and also taken with us on the as we go to different campsites that allow carts. I was looking at the Predator Hemi, and Duromax 16 and 18HP, with electric start. I am curious if I can use the original Primary clutch on any of these engines, do you recomend that I remove the governor? Is there enough shaft to use the original generator pulley, or do I need to add another coil for charging (if that is possible). What are your opinions of some of the performance kits that are available? Any advice on this matter is greatly appreciated, I have not started dismantling any of my kart yet, so I don't even know what the stock shaft size is yet.
Thanks

BGW

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jclark138

Welcome !
I have a VC 460 in an EZGO, but both of our 87 G2’s are still stock. Looking forward to seeing what is recommended by those more familiar with this swap. I really like everything about the old Yamaha, but if I could get more power, without sacrificing noise level, ride etc , that would worth looking into!

raydhd

If you are handy I would get the DIY Vegascarts VC 460 that has a lot of performance upgrades for just a few $'s more than the engines you mentioned.

Shepard

sI agree with Ray -- if you have any mechanical skills - buy the 460cc engine kit. This is better then any over the counter engine by a mile. 25hp - lots of torque - and the quality of the parts are great - billet rod - hi torque cam grind. You doing the build, you can check all tolerances and end play. And in the end you'll have a custom built Vegas Carts 460cc engine. Go for it -- you won't be disappointed. I own 2 of them and there the best small engine I've ever owned.

Shepard

As far as the clutch goes, its internals parts are in the same shape as the engine. You have to use an adapter and cut the crankshaft off to a usable length, doing this makes it hard to upgrade cause you'll have to replace the crankshaft. I would recommend the comet 780 with a one inch bore - I have 3 of them and they work fantastic

AaronW

Like Shepard said, the C780R is a good well known clutch. We have since gone with a CVTech Series 6 clutch for all Yamaha's and have had good success with them. Like the C780R they install very easily and you can still retain your pedal start with them.

What do you do with your cart? Do you want pedal start or key start? Is it lifted? Can you fabricate and build or is it not worth your time?

-Aaron

keith4128

Thanks for all of the insight, My cart will be used around the farm, hauling kids, going hunting, pulling a driveway drag, Up and down hills, Pull sleds in winter, Generally having fun. I am looking at the Tillotson 212 Elec start, And I dont care if I have pedal or foot start. Any thoughts on that motor with a 265 cam and a little head work?

AaronW

IS that 212cc? Doesn't your stock engine come with 301cc? Wouldn't that mean you are technically going with a smaller engine than it came with? Kinda seems like going backwards. What makes you want to use such a small engine?

Shepard

The guys from cars and cameras little truck goes around 300lbs. A G2 weighs in at 660lbs dry - 600 without the engine. I don't think you'll have must success with the little 212cc engine. Like you said - its a go kart engine. I would suggest something like a 420 Predator or more. We'll be watching to see your progress.

sho305

It depends on what you want to spend and what you need. You can put a stock clone in like a harbor freight 420, home depot 420, etc. About 300 you will have to modify the exhaust and make or get a mount from Vegas. There is tons of info here. This is cheapest and is about double the power of an old tired engine, I have one it runs great on 22 tires you can spin in the dirt. You can use the adapter to run the stock clutch but if the clutch is worn out you should replace. You need a pulley on or behind the clutch to use the starter/gen which I would recommend because it charges 15A and for yard work stuff its much easier to operate. The clones only charge 3A, unless you get a special one like the 18A charge home depot is only one I know of. 3A does not charge battery much unless you run it for hour every start and no accessory use.

Next step up is the Vegas 460 it has HD block and cam/rod its a built up 420 and 460 actual size. This has more power and revs, your cart will go much faster top speed. It is basically same family as any other 390/420/440/460 clone and all parts work, there are a lot of performance parts out there for these honda gx390 clones. After that you can go 625 Vegas its a larger engine with more torque, which moves these carts very well. That is why a 212cc will not do well it has much less torque. 600cc range engines are big most are twins other than the 625, but the 625 is low profile and fits in carts easier. After that you go to twins the cheapest is the harbor freight 22hp and better is the vanguard which can be modded for more performance but it costs more. The clones and vanguard are raced a lot, many parts out there. Some twins can pull wheelies if the clutches are set up right. The stock 420 I have will wheelie up a steep hill with two guys on it and valve floats at 31mph but gets there much faster than stock. The 420 with 460 parts in it and head mods I hit 41mph gps on a road, it has more power than stock 420 at higher rpm. The stock 420 is just like a stock G9 it just has about twice the get up and go. It takes work to make the exhaust quiet though.

He jumped the gun in the race but watch this and see how the clone 420 all stock just pulls away no matter. Green cart is stock 420 other than jetting and exhaust/airbox to fit in the cart. Camera cart is stock G9 with modded airbox and jetted for it, both have no governors. I hit gas only few second after he did but stock cart is quieter, 420 just takes off that much quicker. Note G2/G9 are same cart with detail differences.
https://www.youtube.com/watch?v=y55ouqdV5Rs