Clone Install and Pics!

spudd001

I blew the stock motor on a Yamaha G14 and decided to do a clone build instead of rebuilding the stock motor. This turned out to be cheaper and there is significant hp and torque gain. I spent a little over $750 in parts to be able to complete the Duromax 16hp electric start engine swap. I am super happy what the outcome. Tons more torque and GPS shows to top out at 32mph.
Below is the parts list I used to complete my build.
-Clutch and shipping (cartpartsplus.com) – $347.50
-Duromax 16HP and shipping (maxtool.com) – $289.00
-4' of 1/4'' tubing and hose clamps for fuel and pulse line (AutoZone) – $4.50
-1/4'' barb fitting for pulse line (Lowe's) – $2.50
-JB Weld to seal barb fitting – $6.00
-1-3/4 x 1/4 Flat Bar motor bracket (Lowe's) – $10.00
-8 – Spring Bushings for motor bracket vibration dampeners (AutoZone) – $10.00
-Briggs & Stratton Fuel Pump #808656 (local small engine shop) – $25.00
-Drive Belt; IMC 11059, 1-3/16'' X 47-1/25'' O.D. (groovycarts.com) – $35.00
-35' roll of 18 AWG Stranded Wire to extend wiring harness (Radio Shack) – $8.00
-18 AWG Butt-Spice Connectors to extend wiring harness (Radio Shack) – $2.50
-4 – 1/4’’ bolts and nuts to mount full pump – $.89
-8 – 3/8''-16 x 3'' Bolts & Stop Nuts for motor bracket and engine mount – $2.00
-4 – 3/8 Lock Washers for motor bracket and engine mount – $.60
-8 – 3/8 Fender and Regular Washers for motor bracket and engine mount – $2.00
-3/8''-24 x 5'' Grade 8 Bolt and Washer for engine crankshaft – $10.00
-Loctite for all nuts – $5.00

- The motor bracket is made of 1-3/4’’ x 1/4’’ flat bar. The motor mounts on my cart were shot so instead of spending $100 on new ones, I decided to mount the rear motor bracket directly to the frame. The front motor bracket mounts to the rear motor bracket and the front frame which is separated by spring bushings to act as vibration dampeners. It took some serious time to get the perfect spacing and height of the engine. Seems to be a fine line in getting the drive belt just right.
- I removed the gravity fed fuel tank from the Duromax motor and I am using the stock Yamaha tank. I drilled through the top the valve cover and inserted a ¼’’ barb fitting for the pulse line. For some reason the Yamaha fuel pump would not pull fuel so I bought a Briggs & Stratton fuel pump from a local small engine shop and it seems to be working perfectly. I mounted the fuel pump to the old gas tank hole.
- Throttle set up was pretty simple. I ended up eliminating the governor because it would give me more top end speed (need to watch rpm’s) and it was just the easiest way to hook it up. Pics will explain better.
- Choke is a little different. I disconnected the spring from the throttle controls (red handle) so it would not have anything to do with the throttle at all. I drilled a hole through the red handle along with the choke handle. I connected the two with a zip tie and attached a return spring from the frame of the cart to the choke handle. I attached the stock Yamaha pull choke from the cart to the inner part of the Duromax throttle lever. This way the travel is perfect when I pull the choke out to be able to obtain full choke. Pics will explain better.
- I am using the stock muffler but I added tail pipe to it so the exhaust won’t release under the seat but rather discharges out of the back of the cart. This certainly helps with the noise while driving/riding the cart. I connected a piece of flat bar from the differential mounting bolt to the bottom of the tail pipe to help support and keep the pipe from bouncing all over the place and damaging anything.
- I extended the wiring harness to the dash with 18 AWG stranded wire and butt-splices. The blue wire connects to the blade fitting on the solenoid, the ring connector connects to the positive terminal (front stud) of the solenoid, connected all other like colors together, and attached the small yellow/green wire to ground.

BGW

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spudd001

Shoot... forgot the pics at the house. Will upload those tonight or tomorrow.

spudd001

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spudd001

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spudd001

I also want to thank all the great folks on here that helped me get through my build.

Black Thunder

Looks great! Nice install.
Did you have to adjust the carb much i.e jetting?

spudd001

Thanks. I left the motor stock for the time being.

jackel440

Nice job! Looks well thought out.
I am curious about how you are starting it and shutting it off?
do shift gears then start it or are you able to change gears with it idling?
once again awesome job

spudd001

I removed all the iginition stuff from the little blue box and extended the harness to the dash. Took some while but I was able to get the wiring figured out so I can start it and shut it off when the key. I am able to change gears with it idling. It was a little time consuming to get the spacin just right. The first could times the belt was too tight and the cart wanted to roll not to mention it was hard on the gears because the belt was pulling. Second to last adjustment created too much slack in the belt and it wasnt all that fast. Then Finally the last adjustment was perfect. I can start it without needing to apply the brake, no roll and changing gears is fine as well.

tenaciousj

How loud is that exhaust setup like that? I was thinking of running a piece of pipe off mine kind of like you and then maybe adding another muffler to the end of that depending on how loud it was but wasn't sure if it would kill power either though.