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Unread 07-05-2011, 02:57 PM   #1
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Join Date: Nov 2007
Location: Leduc
Posts: 300
Default My G9 build

Hey guys!!
Its been a long while since I have been on the site, sold my last cart almost a year ago and been missing it since… Came across a steal of a deal on Kijiji and couldn’t pass it up… $200 for a running G9 that needed a little bit of TLC.
The goal of this project is to take the stock engine and make it perform like a champion, I am a strong believer that these engines are far more capable of putting out more than most of us think and I am wanting to set out to prove that
I am on a limited budget so I’ll be looking to save money where ever I can, but make this thing capable and making some bigger purchases where needed.
I already posted a question about the new pistons I ordered for my new to me G9, so I'll leave that all in that thread.

First off here are the immediate plans for the old girl:

-New paint –paint is peeling in man spots and is full of runs
-Weight loss – the previous owner added about 250lbs in additions
-Remove previous owners "modifications" if that’s what you want to call it
-New front bumper – the front end of this thing is a tank, the current bumper prob weighs 35-45lbs
-Winch… because I plan on getting stuck
-New pistons & rings… currently is burning oil (from B/U)
-Timing advance key- hope to give this old girl a little more pep (from Plowmans)
-New valves, intake & exhaust figured I should replace while I have the engine apart for the above
-New gaskets- head gasket is leaking bad
-Aftermarket Air filter - my custom "cold air kit" *let the engine take in some deep breaths*
-New jetting … find some hidden power
-Custom high flow exhaust *let this thing fart a little more*
-Hitch receiver …for towing stuff
-power spring to give her some low end grunt (from B/U)
-new battery **already installed
-New spark plug **already installed
-redo accessory wiring…. It’s a mess under there!

Some of my future plans:
-New front suspension out of a Suzuki “Qaudracer” that I have laying around
Long travel, way better than any stock golf cart suspension and geometry
-has front disc brakes, so that will be a much greater improvement over stock braking, which we all know can get scary some time
Some things that I want to sort out first before taking the plunge into new front suspension
-how to make the steering work with stock steering box and the new front end
-how to use the front hydraulic brakes & stock rear drums. Or should I ditch the rear drums all together, should I swap out the rear drums for rear discs? I know 75% of the braking force come effectively from the rear end, so is this enough to worry about having rear brakes at all??
-Rear Suspension If I make the above changes, what should I do with the rear suspension, just upgrade the shocks to the same performance level and make sure that I lift the cart enough to make it level. Or should I make a whole new rear swing arms and make it a bit more of a long travel type.

I have a GSX-R engine and exhaust, I could use the rear suspension out of the quad and that motor and have a wild ride, but that would defeat the purpose of building up the stock motor to its best and full potential…

Questions
Jetting- Does anyone have any experience re-jetting these engines? Anyone have a starting point that I should look at after I modify the air intake and exhaust – making them both more breathable.

Exhaust- What have you guys used for silencers in the past? I want this to be high flow but I also want some sound deadening… no need to piss anyone off from a loud golf cart. I was thinking I would shorten the Vance & Haine’s street bike exhaust and use that, but then I will be experimenting with a perfectly good silencer that might not end up working in the end. But at the same time it is a performance pipe for a four cylinder four stroke street bike… I was thinking that I’ll just loose 75% of the silencer and that should be good enough for my tiny one cylinder golf cart….

Timing Advance Key- this one is from Plowman’s Carts, has anyone used it before? Anyone have good results? If not I will post on here.
Port and Polish- Has anyone done their own on these engines? Any tips? I am going to go in there and smoothing things out a bit but that’s about it unless someone else has some tips of what to do and where to take out some metal.

Is there anything that I am missing (other than removing the governor)??

**Pic’s to follow in the next few days**
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Unread 07-05-2011, 10:03 PM   #2
Getting Wild
 
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Join Date: May 2011
Location: North Central Vermont
Posts: 97
Thumbs up Re: My G9 build

Trick and Treat for cheap? Sounds like my kind of build. I will be watching this one. I would like to say that I have a Yamaha cart lined up for for a low price build, but I think it just went out of reach. Oh well, I will keep looking for a different build if I don't get a Yamaha.
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Unread 07-06-2011, 11:03 AM   #3
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Join Date: Jul 2011
Posts: 19
Default Re: My G9 build

Are you a snowmobiler?
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Unread 07-08-2011, 01:07 PM   #4
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Join Date: Nov 2007
Location: Leduc
Posts: 300
Default Re: My G9 build

Quote:
Originally Posted by superdrag73 View Post
Are you a snowmobiler?
Sure am!

Ride an Arctic Cat... you?
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Unread 07-09-2011, 04:39 AM   #5
Not Yet Wild
 
Join Date: Jul 2011
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Default Re: My G9 build

Quote:
Originally Posted by turnagainhardcore View Post
Sure am!

Ride an Arctic Cat... you?
Thought so, I'm familier with the turnagainhardcore DVD's. I ride an 800cc summit.
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Unread 07-11-2011, 11:50 AM   #6
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Join Date: Nov 2007
Location: Leduc
Posts: 300
Default Re: My G9 build

Good to see some fellow riders on here!!
Back to the build! As promised there are pic’s!!
I spend 4 hours on Sat going through the cart and making some of the changes that I have plan/outlined above… I took the cart out between each change to see what made the biggest difference, what I did was timed each run between two markers, then recorded the average time after doing several runs on the “notes” section of my Blackberry…. However my Blackberry stopped working (just the keys) and I can’t get to the notes I made….
This is what I was able to get done:
Remove “roll bar”… this seriously took off about 50lbs of steal from the cart..The previous owner seriously over engineered this.
Removed governor & adjusted to achieve WOT
Cleaned out the Carb – solvent was seriously dark and gross.. This baby needed it.
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Unread 07-11-2011, 11:58 AM   #7
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Default Re: My G9 build

Then I removed stock air filter and replaced it with my own contraption!
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Unread 07-11-2011, 12:18 PM   #8
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Posts: 300
Default Re: My G9 build

Next I removed the exhaust & welded up a new one – this thing sounds exactly like a 350cc-550cc work quad, just the sound I was looking for, might still shove a bit of steel wool into the exhaust to quiet things down a bit, but I am going to see what it sounds like out around the yard first before do this.

I took this genaric brand small engine muffler that was rated up to 10hp,drilled two small holes to improve the exhaust flow (as you can see in pic #2)... cut off the first section of the stock exhaust and welded the two together, and this was the end result... my favorite part of the whole deal is that I was able to retain the stock heat shield to protect the seat bottom from being melted.

I am considering using some of the exhaust wrapping that they use on race headers to help keep under hood temps down and hope that improves the long term performance....

This took a good 10lbs off the Cart
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Unread 07-11-2011, 12:22 PM   #9
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Default Re: My G9 build

More Pic's of the new exhaust...
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Unread 07-11-2011, 12:35 PM   #10
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Join Date: Nov 2007
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Posts: 300
Default Re: My G9 build

Last but not least, I added a hitch receiver to the foot area of the rear seat. This way I can launch the jet ski into the lake, pull boat/empty boat trailer around the yard when we need to move it to cut the grass and such… the best part is I will be able to pull the cart out to where ever I am riding/working unload the cart then hook up the trailer to the cart and work away!!
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