1993 EZGO Electric to Gas Budget Build 6.5hp GX200 Clone

carolinasled

Hey Guys, Time for another build. About 2 months ago I picked up a 93 marathon with a bad set of batteries, a good controller and Charger for $325. So I knew that I wanted to do a gas conversion with a gx200 clone 6.5hp engine. so the first thing I have done is scrapped the batteries and motor for $95 Sold the Controller on Ebay for $100 and Sold the Charger on Craigslist for $100. The cart also came with a light bumper for the front that was never installed, so I sold it for $60 on craigslist.

I will post build pictures tonight, Until then here is a Youtube video.

BGW

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carolinasled

So as with most builds planning is the most important step of the build and trying to figure out how to make things work together. I guess I have searched this site over and over for the 19 spline 21mm shaft sticking out of the rear end. So I couldnt find much here other than rear axle swaps. I know a couple guys on youtube have welded a sprocket to the splined shaft. I was wanting something alittle more stable. So I found a 13/16 3/4" axle sprocket hub @ surplycenter.com. I did not know how the rear end was geared so I ordered a 40/41 size 13t sprocket. I have heard the rear ends are gear low, but how true that is I'm not sure.

The main goal with the cart was to build a neighborhood cruiser/mild trail riding vehicle. Not Mudding or Jumping or anything seriously Fun. Just Really something for the kids and wife if we went camping with friends. So with this being said, I purchased a GX200 Clone 6.5HP Engine. These engines are notorious for hop ups, modifications and have alot of knowledge across the web. I bought the electric start version off ebay so pull starting was only a last resort.

I also bought a Hilliard Extreme Duty Clutch.

carolinasled

So the cart Runs, I have the motor mounted (electrics not installed yet), The Clutch is ok for riding around the neighborhood. The Top end is ok, Not The best but aint bad with what I'm working with. The Engine is Completely Stock, I have not removed the govenor yet and unsure if i'm gonna do it with the stock connecting rod in it.

I used the Stock Accelerator pedal, rod and Hinge system that was used for the potentiometer and welded a mount to use it for the throttle system on the engine. I have not made a throttle cable mount, Still in the testing stage of the build (Not Completely Done).

AirJunky

Saw this & the first thing I thought was the cart was going to be waaaay underpowered. And it still may very well be. But watching the videos you've done & the gearing is low enough to get those carts moving pretty good. Looks like maybe the top speed is around 10 or 12 mph?

Using a chain drive on a sparky rear end too.... good stuff. I think your the first guy I've seen pull this off. Makes me think a chain drive from a big block to a sparky rear would be a FUN ride. Seems like sitting at an idle would be next to impossible. Maybe incorporating the pedal electric start would get past that though.

carolinasled

From Parting off the stock electrics from the cart to buying the new conversion pieces, I have about $350 in the total project as it sits. However I'm ordering a TAV2 Torque Converter to replace the Clutch. So Hopefully that will be in this weekend or the beginning of next week.

Still need to:
- Mount the electric start module on the dash and run wires
- Add Rubber cushions between motor mount and sub frame
- Buy Battery and weld Battery box in
- Modify Seat mounting / modify exhaust and tank to fit under seat
- buy starter generator for electric reverse and mount it

Etc etc. Pictures will come soon of different parts of the build.

carolinasled

From what I have seen on other 6.5 conversion videos on youtube, I hope its not. But building something that has not been done a whole lot is risky and I understand if its not that fast. Tonight I will get a test shot from 0-full speed to get an idea of it. Hopefully when the TAV2 gets here it will have better bottom end as the clutch is just a single speed.

Here is a guy with a 6.5hp on his cart on youtube.

http://www.youtube.com/watch?v=-nOHW...lBySaPQZmhg%3D

carolinasled

So Last night was late getting home after T-ball practice and all but I GPS'd with my Phone and you hit it on the head. It maxed out at 12mph. I have ordered a CVT Tav2 for it. I'll test it again after that.

AirJunky

[quote=carolinasled;700800]Probably good for some who may have kids driving their carts or if you want to use it on the course. But for someone like myself, who is the primary driver & doesn't have much more than my wife or a buddy driving very often, and wants to really get around, well, I'm gonna need a bit more power.
But I'm pretty surprised to see the cart do so well with less horsepower than stock, and using the sparky rear diff. I guess your next task to overcome may be a reverse gear?

kgsc

Just a question but aren't most stock electric motors under 4 hp ? I know it doesn't have the torque but makes ya think... Got a dead sparky, drop in a 13hp clone and a chain. I like it..

sho305

That thing is an awesome conversion, a sparky to gas clone, I love it! Yeah 6.5hp is kinda small the CVT should help you a lot, but you can get about 8hp out of them by not doing that much at all check out AGK tips section and some forums. Some have made a short pipe for larger clones and put the stock muffler back on the pipe dropped lower is all and aimed down. Hey you can always get a minibike or gokart for that and buy a 13/15hp clone they will move the cart much better. For a long time they sold those 6.5 for $99 at harbor freight on sale I wanted one bad lol, for something not sure what.

I wonder if you used a car starter motor with a sprocket on it, mount it on a lever that came down on the chain (or up) with a spring to keep it away. When you stop pull it down and have a switch to activate it and back up. Let the engine idle. Just an idea.