G1 & G2/G9 LT Kit? Need opinions

slonomo

I am seeing a demand for DIY long travel suspension kits for the Yamaha G1. There isn't one on the market, but I see a lot of these carts still alive and being restored/modified. The older Yamaha carts seem to have a large following because of their durability, low cost, and full frame construction. This was the reason that I went with the G1 model.

In the last 12 months I have been diligently working on perfecting my atv long travel front suspension. I can sat that I finally have worked out what I feel are all the bugs with this setup. It's my opinion that this front end is the best golf cart front suspension that I've seen and driven. It's based on an actual atv suspension, so the parts are proven off road, and plentiful in the used and new parts market. It's amazing how much better this suspension is than the standard "lifted" single a arm setup.

The Concept:
Bolt-in subframe designed for Yamaha G1, G2, and G9 gas models, possibly electric if the mounts are identical. The subframe is setup for use with off the shelf new/or used a arms, spindles, rack and pinion unit, and steering column. For best parts availability, the Yamaha Warrior atv was selected as the donor vehicle for the suspension parts. These parts are plentiful in the used market, and there are lots of new, upgraded parts on the market such as long travel a-arms and shocks. The builder would gather all the needed parts (listed below), buy the subframe and kit, and start assembling the front suspension based on the specs provided. Most DIY builders should be able to be completed, with painting, in a weekend, which all depends on the builder's skill level and access to tools, etc. On a scale of 1-10, I'd put the difficulty rating at a 6, because there will be some small fabwork/drilling involved.

The Specs:
Base width = 46" (center/center of tire)
Weight = approx 50 lbs (without tires)
Travel = 7.9" stock a arms / 10-12" long travel a arms
Turning radius = 12 feet (very tight)

The Benefits:
*Much longer suspension travel for off roading, 2-3 times as much as stock.
*NO CAMBER CHANGE, this means superb handing and feel on any surface.
*Much softer ride than stock, absorbs bumps and smooths out the ride.
*NO BUMPSTEER, this makes the steering more accurate and much safer.
*Proven off road design, donor parts from a common Yamaha atv.
*Mostly bolt on design, very little drilling, measurements and specs provided.
*Disc brakes available from donor atv; requires fabwork and mastercylinder.

Donor/Used Parts Needed:
*Yamaha Warrior atv front upper/lower a arms
*Yamaha Warrior atv spindles
*Yamaha Warrior front wheels/tires OR *4/156 to 4/4 wheel adapters
*EZGO TXT 4 bolt style steering column w/u joint shaft and steering wheel

New Parts Needed:
*14" Sand Rail type rack and pinion unit
*Tie Rods/Heim Ends with hardware and misalignment spacers
*Misc. Grade 5 (or better) hardware

My idea is to have the base subframe unit made to match the specs on my "experimental" piece, but made out of thick walled square tubing, fully mig welded, finished in primer. The donor/used parts can be sourced by the builder, and I can source/provide the new parts needed.

I know for the G2/G9 I'd be competing with the a couple well known brands, but I'm confident this kit will be equal in fit/finish, and better in quality and durability. Just a different twist on the same idea, but I feel this would be much better for serious off road driving because it's a proven platform. Not taking away anything from the other kits out there, just think there's room for improvement there. Plus I think there is a possibility that the cost could be less once you figure in the disc brakes, and the other kits don't offer any true long travel options for serious dune riding etc.

For the G1, there isn't any LT kits out there. So no competition. The question here is, would the G1 crowd pay the extra money for the better suspension, compared to the single a arm lifts that are available. I think once someone "test drives" a cart with this suspension on there, they will feel the difference and the cost will be justified.

With all that said, this would not be aimed at the "BUDGET LIFT" crowd.

Opinions? Ideas?

You can read about my suspension project here: http://www.buggiesgonewild.com/lifte...sion-done.html

BGW

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slonomo

For those of you who haven't seen my thread....

Here are some photos of my "test" setup. Keep in mind this was an experimental project that evolved over the last 12-18 months. It doesn't look like much in the photo, I realize that. But the project still isn't "finished" by any means because I'm still doing some tweaking to the design. As far as function, it is nearly perfect in the way it works, but I feel there is still room for improvement. This is why I am confident about what I have here.

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slonomo

More....

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slonomo

More....

Here's a couple videos to show the suspension in action during development.


Higher speed runs the suspension is very stable and goes where you point it, no bump steer, very predictable and smooth. This run is about 22 mph.


It's so easy to steer, even a 6 year old can do it.


It's good in the snow, the thinner front tires make steering in deep snow easy.

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slonomo

Here's a video of some woods riding, coming down a big steep hill, then going over some rough atv trails, following a 4x4 Grizzly atv and a Ranger 4x4.


The suspension action off road is outstanding, although the stock Warrior shocks are a little too soft and bottom out on large bumps. They since have been upgraded.

pachanga90

Go for it!!! I would offer it as the installation-kit only,let the consumer locate the parts,that way you don't have come-backs on all those extras.G1 gas/electric are the same,G2/9 gas/electric are the same,so you would only need 2-kits.With it being the the frame-kit only,you can price it competitively,even if some extras are included.

Jd62

Really nice job slonomo and nice video !!!!!

slonomo

Thanks for the good words of advice Pachanga! I know you speak from experience.

slonomo

Thanks man. What do you think of this idea? If it was priced competitively, would you buy one? Give me your thoughts?

pachanga90

I think the market would be good for the G1.Its a tough cart,very popular,and really hard to lift easily,due to steering-issues.A complete upgraded front-clip would eliminate those issues.The G2/G9-group would have another alternative now.