My second G9 clone BB

sho305 · 07-29-2012, 09:11 PM

Got rolling on this project this weekend, will get some pics loaded in next day or two. I pulled the motor this weekend after I drove around minus the rear body and muffler, what a loud thing. I got everything removed and welded in a new motor mount similar to the last one I did. Its a 1.5 tubing 6.5" long welded under the gen mount, under the engine holes. Leave it out about 1/8th inch on the driver side and flush with the back of it. Then I weld a 2" piece of 1.5" angle on the rear mount passenger side to make the mount plate longer. I cut two bars 2x3/8" to 11.5" long. This time I used 1.75" wide because it was there. I clamp one bar .5" in from the driver side on bottom of new tube and it should come out about even with rear of rear mount for length. Then I clamp rear and use a small square to get it even with the cradle tube. But then you have to even out the mounts, they sag when you take the engine out. I level the top of the mount above the rubber to the cradle, and on that angle I tack weld the rear of it only. Put the pass side bar in and make it 6" outside to outside for the bars and weld the rear of that one make sure its lightly clamped to front bar and parallel. This is by memory could be a mistake in it. So then you move the front mount up/down and get it level like the rear and tack the front of the bars. Weld them up. This cart is lifted so the whole cradle is angled, the mounts should be about that same angle or look at the bolting pads on the stock engine.

I spent half a day rebuilding my clutch out of pieces and making new bushings. I tell you, oil all the pins on your clutch once a year or something what a pain! Then again I can't complain too much about a 21 year old clutch. I mic'ed it and only about 10 thou thicker than another clutch that had holes worn in it, so the sheave does not have much left in it. But hey it will say me 3 bills for a year or two if it works that long. I made bushings out of a bic pen cap lol. The weights were blowing out and lucky I caught that they were loose. We had some extra pieces from other G9 clutches we had rebuilt and managed to duct tape it together one more time.

Before that I had finished buttoning up the engine, removed the airbox stud and reworked the choke to move easily via rod. Cut the crank to just over 1" long and fit the adapter, drilled and tapped it 1/2-20 the stock G9 bolt size. It is ready to install.

Before this weekend I had worked on the engine some to address weak spots on the stock install I did. So I put a 4 degree advance key in it, had the head ported and cut .050, added gx200 springs inside the stock ones, removed the governor, loctited the side cover back on after double checking factory torque on the rod. The first clone I did remove the governor of course. I also installed the pulse in the OHV cover instead of the intake, the intake has caused problems for me with fuel overflow using the stock G9 pump. I will be swapping the first clone to this and have bought this style airbox for it also. In a G9 you have no room in front of the carb so the overhead airbox is the way to go. You can slap a hose on it for a remote filter easily. The first engine had a square box on the end of the carb we had to rebuild, wasted a lot of time on it and is still not a nice setup. I also popped the plug off the idle mix screw and found a real screw in this one, sweet.

On top of that I cut down the tired stock clutch in the center to push the belt up top again it is so worn. Might be good for a little top speed not sure. Brought the secondary home going to have that cut it seems to be of good thickness yet. It will be cut like the ones you buy for a lower gear, I put one on the other clone when it had a stock engine and I really like it. Still has the stock spring in it.

Soon as I get time to unload my camera I will get some picks on here.

sho305 · 07-31-2012, 10:29 PM

Ok lets try to get some pics on here.

Here is the clone ready to go with the adapter on and pulse fitting, the pulse fitting close up, cart ready for engine mount. I got the mount in but had to leave no time for a pic.

G1-G9 · 08-01-2012, 06:08 AM

Why did you run your pulse fitting out that side? I have mine running out the other side away from the muffler. I got my next clone project out of the box last night and sitting on the bench. I filled it with oil and i plan on letting it run for a couple of hours before i take it apart. I already have the motor mount built.

G1-G9 · 08-02-2012, 02:02 PM

Sho could you get me a better pic of your air cleaner? Im trying to make a little more room. Thanks

sho305 · 08-02-2012, 05:29 PM

What pic do you want? This is the cyclone (honda called it) type aircleaner, it sits above the carb next to the muffler. I just bought another one for the other clone for $20 off ebay. I only use the lower section that goes on the carb, I busted the long stud out of the top and will put a 90 rubber elbow on it to a remote filter.

Since the G2/9 have the rear shock right there, this is ideal.

IIRC that was the only place the inner and outer valve cover was pressed together as one and easy to drill. My exhaust will come out and go down/back it should not be an issue. I will fab a little heat shield if I need to.

pachanga90 · 08-02-2012, 08:09 PM

When we raced Go-Karts,we would fill them with standard-grade oil,idle them up a bit and let them run about an hour or so,then run some moderate-speed laps under-load.Shut it down,drain the oil,put in Synthetic,run about 5 moderate laps,then turn it loose.Never lost an engine.Since you are bench-running it,let it run about 1hr at a high idle,then tear it down,pull the gov,etc..refill with standard oil,and give it a decnt break-in run,then dump the oil and Violate It!!

G1-G9 · 08-16-2012, 02:38 PM

Sho what is up with this? When are we going to get some updates?

sho305 · 08-17-2012, 07:44 PM

Getting killed with work here, I wanted a 3 day weekend to work on it and got a 1 day weekend! Hard to complain about OT but messed up my plans big time. I got the exhaust for it from Robertson, got the walker quiet flow muffler also sitting here. Posted pics *here*. Didn't get my clutch machined yet all the cnc machines are full of work.

Cart is at family's welding shop, not here at home. Still need to get an airbox for it, don't think I need much else except odds and ends like some pvc pipe I can add later. I have a roll of cool clear blue fuel line. Also now that the drought is over and it rains like crazy here, I have to mow the grass every 3-4 days. I guess it is making up for lost growth or something. I like my big lawnmower but jeez...

I have not run it, in fact I need to buy some oil for it since it is empty. It took about half the summer to break the first clone in, though it was not taken on any trail trips until most of the bugs were ironed out of it. I really don't want to hook fuel/muffler/etc back up to it and it has no governor on it to hold higher rpm. It needs my foot pressing on a cart pedal to make it run.....but OT means I can buy more parts for it lol....what do ya do.

sho305 · 08-26-2012, 07:54 PM

I did get to work on it this weekend, turns out somehow the engine mount was just a hair too short even though same size as the other clone. Had to weld 3/8" pieces on the end of the bars lol, doh. So got the engine mounted and all aligned, bolted in. After that worked on the exhaust and got the custom exhaust all welded together. Not the best welds that welder has larger wire in it, but not bad. Still have to get some hangars for the muffler but I think it will work well and muffler can hang from the frame not the cradle. If it breaks the pipe off I'll know it was a bad idea. Put the walker quiet flow muffler on it but can't run it yet, I pulled it over with the recoil a few times and it has a little thump to it....but not conclusive. Also no tailpipe at all on it yet. Will post pics soon as I get the camera unloaded.

Did have to rework some of the exhaust pipes, but could be from the bends being close to the ends. Some ends were egg shape had to dolley them out round again so they fit.

Should have it going next time long as I can find an airbox from the right car. I can hook up the stock airbox if I really have to. All that is left is building the throttle linkages and I found the material for it already. Then mounting the gen back in and have to make a tension adjuster for it but that is not a big deal. Then have to find the relay I have here someplace to kill the ignition. Should be able to toss in the fuel tank and fire it up then

I could not get my secondary machined they were too busy have to do that later, but have the larger cogged belt to try on it. I ground the primary myself to see if it adds any speed, though I will not be taching it up high for break in so may be hard to tell how that works.

Managed to do a burnout on the gravel road with the old clone man that is fun to run. Held the brake for a few seconds and floored it, both tires spun some for 10 foot or something.

sho305 · 08-27-2012, 08:27 PM

Ok, I know you all are ignoring me because I'm so slow....but here are the pics. Photo of the motor mount from the top, note the tiny additions on the rear. Have no idea how it turned out 1/4 inch short must be the angle the mounts are different or something, took some extra time to add on to them. That is where the engine has to be in order to use stock belt, iirc it was 2.5" (or a hair over) between the clutches outer sheaves and 2.65" offset between the non-movable sheaves. I clamped a bar behind the primary and measured to the outer edge of secondary fixed sheave at front and rear.

Another pic is my new Robertson torque tube exhaust he made for me. I might have to fab a little sheet metal guard under the edge of the bagwell its about 2" from it and likely ok but not big deal to toss in there. I have to pick up some rubber mounts for the muffler yet. Note the cool coupling off the engine that allows it to rotate so I can hang the muffler on the frame. Hoping I can get it running next weekend and jet the carb. I could have got a 30 degree bend there to move the pipe down but looks like it will work this way. The pipes were 60 total with one hangar, but I might use automotive hangars anyway. The muffler was $30 via amazon shipped and is a walker quiet flow 22266 for an acura lol. It has 1.5" ends, I had the pipe made for 2" and ended up chopping it down and welding it in. Cut the muffler pipe off too for more room.

Check out the <.5" I have to the lift mount on the rear shock, well at least it fits lol. This is the problem area in G2/9 carts. Best to get this type of aircleaner so you can use the elbow there to get out of the shock area. I will have to pull the lift mount to get the carb off, hope to make an intake at some point and fit a different carb anyway. I will angle it towards the rear.

07-29-2012, 09:11 PM	#1
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,443	My second G9 clone BB Got rolling on this project this weekend, will get some pics loaded in next day or two. I pulled the motor this weekend after I drove around minus the rear body and muffler, what a loud thing. I got everything removed and welded in a new motor mount similar to the last one I did. Its a 1.5 tubing 6.5" long welded under the gen mount, under the engine holes. Leave it out about 1/8th inch on the driver side and flush with the back of it. Then I weld a 2" piece of 1.5" angle on the rear mount passenger side to make the mount plate longer. I cut two bars 2x3/8" to 11.5" long. This time I used 1.75" wide because it was there. I clamp one bar .5" in from the driver side on bottom of new tube and it should come out about even with rear of rear mount for length. Then I clamp rear and use a small square to get it even with the cradle tube. But then you have to even out the mounts, they sag when you take the engine out. I level the top of the mount above the rubber to the cradle, and on that angle I tack weld the rear of it only. Put the pass side bar in and make it 6" outside to outside for the bars and weld the rear of that one make sure its lightly clamped to front bar and parallel. This is by memory could be a mistake in it. So then you move the front mount up/down and get it level like the rear and tack the front of the bars. Weld them up. This cart is lifted so the whole cradle is angled, the mounts should be about that same angle or look at the bolting pads on the stock engine. I spent half a day rebuilding my clutch out of pieces and making new bushings. I tell you, oil all the pins on your clutch once a year or something what a pain! Then again I can't complain too much about a 21 year old clutch. I mic'ed it and only about 10 thou thicker than another clutch that had holes worn in it, so the sheave does not have much left in it. But hey it will say me 3 bills for a year or two if it works that long. I made bushings out of a bic pen cap lol. The weights were blowing out and lucky I caught that they were loose. We had some extra pieces from other G9 clutches we had rebuilt and managed to duct tape it together one more time. Before that I had finished buttoning up the engine, removed the airbox stud and reworked the choke to move easily via rod. Cut the crank to just over 1" long and fit the adapter, drilled and tapped it 1/2-20 the stock G9 bolt size. It is ready to install. Before this weekend I had worked on the engine some to address weak spots on the stock install I did. So I put a 4 degree advance key in it, had the head ported and cut .050, added gx200 springs inside the stock ones, removed the governor, loctited the side cover back on after double checking factory torque on the rod. The first clone I did remove the governor of course. I also installed the pulse in the OHV cover instead of the intake, the intake has caused problems for me with fuel overflow using the stock G9 pump. I will be swapping the first clone to this and have bought this style airbox for it also. In a G9 you have no room in front of the carb so the overhead airbox is the way to go. You can slap a hose on it for a remote filter easily. The first engine had a square box on the end of the carb we had to rebuild, wasted a lot of time on it and is still not a nice setup. I also popped the plug off the idle mix screw and found a real screw in this one, sweet. On top of that I cut down the tired stock clutch in the center to push the belt up top again it is so worn. Might be good for a little top speed not sure. Brought the secondary home going to have that cut it seems to be of good thickness yet. It will be cut like the ones you buy for a lower gear, I put one on the other clone when it had a stock engine and I really like it. Still has the stock spring in it. Soon as I get time to unload my camera I will get some picks on here.

08-01-2012, 06:08 AM	#3
G1-G9 LIFE IS TAKING FOREVER Join Date: Apr 2010 Location: DANSVILLE NY Posts: 5,327	Re: My second G9 clone BB Why did you run your pulse fitting out that side? I have mine running out the other side away from the muffler. I got my next clone project out of the box last night and sitting on the bench. I filled it with oil and i plan on letting it run for a couple of hours before i take it apart. I already have the motor mount built.

08-02-2012, 02:02 PM	#4
G1-G9 LIFE IS TAKING FOREVER Join Date: Apr 2010 Location: DANSVILLE NY Posts: 5,327	Re: My second G9 clone BB Sho could you get me a better pic of your air cleaner? Im trying to make a little more room. Thanks

08-02-2012, 08:09 PM	#6
pachanga90 I Refuse To Get Stuck!!! Join Date: Jun 2010 Location: Hilton,NY Posts: 5,427	Re: My second G9 clone BB When we raced Go-Karts,we would fill them with standard-grade oil,idle them up a bit and let them run about an hour or so,then run some moderate-speed laps under-load.Shut it down,drain the oil,put in Synthetic,run about 5 moderate laps,then turn it loose.Never lost an engine.Since you are bench-running it,let it run about 1hr at a high idle,then tear it down,pull the gov,etc..refill with standard oil,and give it a decnt break-in run,then dump the oil and Violate It!!

08-16-2012, 02:38 PM	#7
G1-G9 LIFE IS TAKING FOREVER Join Date: Apr 2010 Location: DANSVILLE NY Posts: 5,327	Re: My second G9 clone BB Sho what is up with this? When are we going to get some updates?

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08-17-2012, 07:44 PM	#8
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,443	Re: My second G9 clone BB Getting killed with work here, I wanted a 3 day weekend to work on it and got a 1 day weekend! Hard to complain about OT but messed up my plans big time. I got the exhaust for it from Robertson, got the walker quiet flow muffler also sitting here. Posted pics here. Didn't get my clutch machined yet all the cnc machines are full of work. Cart is at family's welding shop, not here at home. Still need to get an airbox for it, don't think I need much else except odds and ends like some pvc pipe I can add later. I have a roll of cool clear blue fuel line. Also now that the drought is over and it rains like crazy here, I have to mow the grass every 3-4 days. I guess it is making up for lost growth or something. I like my big lawnmower but jeez... I have not run it, in fact I need to buy some oil for it since it is empty. It took about half the summer to break the first clone in, though it was not taken on any trail trips until most of the bugs were ironed out of it. I really don't want to hook fuel/muffler/etc back up to it and it has no governor on it to hold higher rpm. It needs my foot pressing on a cart pedal to make it run.....but OT means I can buy more parts for it lol....what do ya do.

08-26-2012, 07:54 PM	#9
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,443	Re: My second G9 clone BB I did get to work on it this weekend, turns out somehow the engine mount was just a hair too short even though same size as the other clone. Had to weld 3/8" pieces on the end of the bars lol, doh. So got the engine mounted and all aligned, bolted in. After that worked on the exhaust and got the custom exhaust all welded together. Not the best welds that welder has larger wire in it, but not bad. Still have to get some hangars for the muffler but I think it will work well and muffler can hang from the frame not the cradle. If it breaks the pipe off I'll know it was a bad idea. Put the walker quiet flow muffler on it but can't run it yet, I pulled it over with the recoil a few times and it has a little thump to it....but not conclusive. Also no tailpipe at all on it yet. Will post pics soon as I get the camera unloaded. Did have to rework some of the exhaust pipes, but could be from the bends being close to the ends. Some ends were egg shape had to dolley them out round again so they fit. Should have it going next time long as I can find an airbox from the right car. I can hook up the stock airbox if I really have to. All that is left is building the throttle linkages and I found the material for it already. Then mounting the gen back in and have to make a tension adjuster for it but that is not a big deal. Then have to find the relay I have here someplace to kill the ignition. Should be able to toss in the fuel tank and fire it up then I could not get my secondary machined they were too busy have to do that later, but have the larger cogged belt to try on it. I ground the primary myself to see if it adds any speed, though I will not be taching it up high for break in so may be hard to tell how that works. Managed to do a burnout on the gravel road with the old clone man that is fun to run. Held the brake for a few seconds and floored it, both tires spun some for 10 foot or something.

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