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Old 02-22-2012, 04:45 PM   #11
Not Yet Wild
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Default Re: wanting to install gx390 in my yamaha g2

Thanks mike never thought of changing the clutch spring. Hmm guess that would just mean cutting the shaft and using the tapered adapter.
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Old 02-22-2012, 05:32 PM   #12
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Default Re: wanting to install gx390 in my yamaha g2

G2/9 does not have a spring in the primary. Why don't you just keep the generator and have it start like a stock cart? I bought my G9 from a golf course in '99 and to this day have never touched the generator. The clones only charge 3A some people have to charge the battery once in a while and forget running lights/etc for long. The gen charges 15A some keep it just to charge with. You can likely idle with stock clutch you just can't shift gears with it running. You can lower the comp release rpm if you loosen the valve lash, iirc it is on the intake valve. From what I find you need to get a used honda gx390 with the larger charging system to change it over, because you need the flywheel and coils and rectifier/vr, and a new engine cost less than the parts. I was told you can add another coil to the clone and double it so 6A charging but don't know of anyone doing it yet. Some put a pulley and alternator on them. If you use a comet use a 94C, CPP used to have them, they come in taper shaft replacements and in 1" shaft. If comet is back in business now. They use the common 1 3/16 belt like a stock yamaha does, the other comets I believe use smaller belts. Far as I know only CC uses a weird 1" anyway.

If old people were using it I'd make it work like stock, but I don't know your situation. I will be making my cart start like stock too why screw with a key all the time (when I clone it). I'd never get rid of the gen unless I only trail rode it and used it for nothing else. Plus you are just wasting gas when it is made hybrid to stop when the cart is not being used. I don't mean to tell anyone what to do, just saying I don't understand why people want it to idle unless you only trail ride it for long runs. My cart stock will idle long as I keep my foot on the pedal, so will the clone I put in, if I want it to idle for some reason. The only time I ever found myself do that is mushroom hunting from on the cart, or looking for lost item, or if I am going to move again in the next 10 seconds. You can put a switch to bypass the pedal and it will keep running long as the switch is on and still stop/run with the key, but it is pointless really. My gen is 21 years old and never touched, it has been run every summer since birth. Not very common to rebuild them the most I see is people put brushes in once in a while. Failure is very uncommon in yamahas. And with a clone you then don't have to worry about charging. Also note only the stock and stock replacement taper shaft clutches have the generator pulley on the clutch.

The clone I put in a G9 kind of starts in this page. Lost the photos but I just re-posted them at the very end of this thread.
The CLONE engine setup & specs thread
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Old 02-22-2012, 06:29 PM   #13
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Default Re: wanting to install gx390 in my yamaha g2

Sho This cart is used on a small farm by my parents. Both have an extremely bad habit of only running it at cranking speed for long periods of time which kills the battery and I have even seen the cables smoke from them doing this and Ive had to go jump start many times. They are older and just dont run it like it needs to be. I just feel that this would be easier on the battery ect. and safer for the both of them. I know the fuel cost might go up but These deep cycle/start batteries arent cheap either lol. Id just feel safer if they could set the park brake and leave it idle when they are making these really short move and stop things that they do with it. Not fun when its in the middle of the barn with a dead battery lol. Thanks for the reply greatly appreciated
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Old 02-22-2012, 09:03 PM   #14
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Default Re: wanting to install gx390 in my yamaha g2

Set the engine to idle just above the starter speed. It can never run on the starter unless the engine runs out of gas/etc. I had a guy do that same thing until I reset the idle. G1 yamaha were that way then they stopped saying that in the manuals. My cart is that way it starts and runs but does not move until I step on the gas more. When it starts creeping at idle I know it is time to grease the clutches again.

In this video I touch the pedal and it starts but no throttle, and it idles. It idles in gear slower because of the belt drag, but note how fast it fires and runs they start faster with a working idle. At .26 it idles again. I have the clone set up exactly like this, can't go too low on idle on that or it hits the comp release.
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Old 02-23-2012, 07:35 PM   #15
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Default Re: wanting to install gx390 in my yamaha g2

am i correct in assuming that is in neutral?
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Old 02-24-2012, 06:30 AM   #16
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Default Re: wanting to install gx390 in my yamaha g2

yes looked like it was in neutral since the rear clutch was rotating and the cart wasnt moving.

I found a clutch I believe it is a cvtech series 06 the set it up to engage and reach highest gear at the rpms you ask them to. and it takes the same 1 3/16 belt that yamaha uses on the g2.

Pulled the old motor yesterday and got measurements to make mounts to keep new engine level, and get an idea of how throttle cables, exhaust, and that kind of stuff will have to be re rerouted and mounted. Going to order the clutch today. along with a few other things. Gonna take the tank exhaust and air breather off the honda engine today pull the flywheel and get ready to install the electric starter and charging kit when it gets here.


Oh by the way guys the reason I couldnt get my clutch to release at idle or cranking speed is that it had worn through one of the arms that attaches to the rollers.
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Old 02-24-2012, 12:57 PM   #17
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Default Re: wanting to install gx390 in my yamaha g2

Yes it is in neutral I made the video to show how the clutches shift, if they are broken they will not move like that. It idles a little slower in gear and the clutch on the trans can't turn.

Just wanted to explain that I know some people I would not want to have a cart that idled for safety reasons. They already hit stuff with them now. Some of them are old and others drink. I'll assume you don't have that situation, wish I didn't.
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Old 02-24-2012, 01:23 PM   #18
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Default Re: wanting to install gx390 in my yamaha g2

Sho I understand your situation and if I were in it I would feel the same as you do. This cart will only be used by my parents on the farm. Great video by the way it shows how the clutches work very well.

I have another question for you. Where is the best place to install the vacuum line for the fuel pump. I looked at my carb and it looks like I can drill it and put a nipple on it right where it bolts on to the engine. Ill have to take it off and make sure it wont interfere with anything before drilling though.
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Old 02-24-2012, 01:59 PM   #19
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Default Re: wanting to install gx390 in my yamaha g2

Get an 1/8npt to barb fitting for the hose, most are 1/4npt and its too big. Then drill it this way in the rocker cover:
lyfan swap?

I did one in the intake using a spacer from AGK, though you can make one if you have a little piece of brake line or something. It causes problems it makes the carb overflow at idle. That is using the stock pump maybe a gokart pump that is smaller would be ok. Anyway I'd not use the intake for this reason the crank signal is better it increases with rpm and the intake increases with vacuum....so it has the most at idle and less at WOT. We had to put a return line on it finally, and I plan to change it back to the crank case at some point. One day the return line came off and blew gas all over the ground so IMO it can be unsafe as well. I bought a parker brass fitting on amazon-- "Parker 4-2 B2HF-B Brass Barbed Connector To Male Pipe 1/4" Hose Barb X 1/8" Male NPT"
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Old 02-24-2012, 06:46 PM   #20
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Default Re: wanting to install gx390 in my yamaha g2

Ive got some barbed fittings in my tool box that should work. I asked that question then I read and found out not to install in the intake. And I wasnt sure if I could get the right pulse through the valve cover or not. Sure enough thats where I will put it though. Got the muffler off today and air cleaner to make a little extra space. Had some old plastic tubing laying around off of some mowers found one that was angled so I drilled it for the hold down stud on the carb and but a sponge type filter on it. Cut the flange off of the yamaha muffler cut and turned the pipe a little to get the angle for a piece of tube and muffler on later once I get it in. So far everything is going smoother than I thought. Will have to get some line of course and maybe a longer choke cable.
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