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Old 02-29-2012, 08:55 PM   #1
Not Yet Wild
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Join Date: Apr 2011
Location: Holland NY
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Default Club Car hybrid starting system?

I read all the clone threads and couldnt find one that mentioned this idea. I bought a manual start Lifan from HD last week and have begun to install it in my 89 Club Car. In order to get the engine to fit I need to move the black box along with all the wiring from the drivers side. My other option I was considering was to hook up the CC S/G as others have but get rid of the black box and all the wiring. I would wire it up to key start and shut off and still get plenty of charging for the battery. This seems to be a pretty easy way to go since I have a manual start engine. I also dont mind shutting it off to go in reverse. Anyone have any pros or cons? Thanks Jason
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Old 02-29-2012, 10:39 PM   #2
2nd clone crazed
 
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Yamaha
 
Join Date: Jun 2009
Location: West MI
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Default Re: Club Car hybrid starting system?

Problem with clones is even the electric start ones barely charge the battery and can't run any accessories. That is why its a good idea to keep the gen or mount an alternator on them. You can just not use the pedal switch and it will run with the key on with most carts. Just set the idle on the engine to idle really slow, many carts have the idle shut off on the carb. I don't know what all the wiring is on that, in the G9 I did I left all the factory wiring in there, was just a couple plugs anyway so I taped them together. The gen needs a voltage regulator to charge. You need a clutch with the pulley.
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Old 03-01-2012, 04:22 PM   #3
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Default Re: Club Car hybrid starting system?

Thanks SHO, my other option would be to move the blck box with the switches and throttle cable but it seems like a real pain. I would have to drill 2 holes in the cross member, 1 for wiring and 1 for gas pedal rod. Then I would have to extend or replace all the wiring as the box would be on the other side of the frame. If I removed all that stuff I could probably even get it to shift running as my drive clutch has the roller in the center of it.
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Old 03-02-2012, 01:04 AM   #4
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Default Re: Club Car hybrid starting system?

Quote:
Originally Posted by Jaythor1974 View Post
I read all the clone threads and couldnt find one that mentioned this idea. I bought a manual start Lifan from HD last week and have begun to install it in my 89 Club Car. In order to get the engine to fit I need to move the black box along with all the wiring from the drivers side. My other option I was considering was to hook up the CC S/G as others have but get rid of the black box and all the wiring. I would wire it up to key start and shut off and still get plenty of charging for the battery. This seems to be a pretty easy way to go since I have a manual start engine. I also dont mind shutting it off to go in reverse. Anyone have any pros or cons? Thanks Jason
Your CC S/G will bolt right up to the clone Jason. You will need a 1/8" washer to offset the pulley on the starter for alignment and also file the washer to fit over the woodruffe key. Ten minutes easy work. On my clone I also added a pair of bracing brackets to connect to the front lugs on the clone motor since I have heard of breakage when just using the rear lugs. I always figure overkill does'nt hurt in these situations. Now you can start, charge your system and shift to reverse with no issues.
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Old 03-02-2012, 01:19 PM   #5
2nd clone crazed
 
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Default Re: Club Car hybrid starting system?

The one I looked at was a carryall, there is plenty of room in that for a clone without touching the box of stuff. Yours must be different.
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Old 03-02-2012, 08:25 PM   #6
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Default Re: Club Car hybrid starting system?

Thanks guys, made a motor mount plate today at work brcause the factory one was shot. It had egg shaped holes worn in the plate and all the bolts were worn half through. I also cut the crankshaft and attached my old clutch with the adapter. Nex up is the S/G mount and barb in the valve cover. I am just going to remount the black box to retain the solenoid and throttle cable as it hit the carb on the clone. Too bad the throttle cable kit I ordered from AGK is on back order or I might have been tryin it out this weekend. Thanks again for the help and this site, would have never thought to do this instead of rebuilding the weak KF 82. Jason
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Old 03-04-2012, 11:33 AM   #7
2nd clone crazed
 
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Default Re: Club Car hybrid starting system?

The 420 clone will have you grinning ear to ear with the power. I hear the 390cc is not that much slower it actually revs a little higher but must lose a little torque. This 420 has a pile of power at takeoff it just does not rev that high about like stock G9 (w/no governors)
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