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Unread 02-15-2016, 09:57 PM   #1
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Default 500 cc 2 stroke ez go

I pulled the engine out of my white cart to get it ready for the street bike engine and decided to build a dune cart with it to generate some money to get back on the white cart. I am using the blue cart I was going to use for the track cart build. So far I have welded the rear and hope to have the engine mocked up in the next few hours.
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Unread 02-16-2016, 11:24 PM   #2
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Default Re: 500 cc 2 stroke ez go

I finally got the engine mount done. Now the plan is to get the exhaust and crabs mounted since they have to be solid to the swing arm. I also added 6" to the swing arm, I hope to be able to get about 12" of travel in the rear. I don't know if I am going to like the front being so much lower than the rear. I will update what I get done tonight.
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Unread 02-17-2016, 03:32 AM   #3
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Default Re: 500 cc 2 stroke ez go

I didn't get much farther but I did get the intake and carbs on and the exhaust header shortened. Now I need to change some angles on the expansion pipe and mount it and the muffler, figure out how to mount the starter generator, then it should be ready to go back under the cart. Wondering how much more cutting I will have to do to make it fit?
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Unread 02-18-2016, 04:51 AM   #4
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Default Re: 500 cc 2 stroke ez go

I got the pedals back on and everthing I cut off when I was going to turn this cart into a tracked cart, I cut the old spring perches off, and started playing around with the rear suspension. After about 10 different set ups I have it down to two ways that I like. I used a single coil over shock off of a Polaris 4wheeler which gave me the ride height that I want, but it didn't have the travel (6") or plushness that I am looking for. With two shorter rear shocks off of a Kawasaki bayou, I was able to move them to in front of the engine which gave me more travel and made it a lot softer. I still didn't get my 12" of travel but I am flirting with 11", now I need to decide on which way would be better. In the pictures I have the suspension fully extended with 11.5" between the tire and fender and ride height with 8" between the tire and fender, fully compressed I can barely get my fingers between them. The last picture is to show where I put the shocks. The u bolts are temporary to test the set up.
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Unread 02-19-2016, 11:30 PM   #5
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Default Re: 500 cc 2 stroke ez go

On her own feet! Now the last two big things on the list are steering and exhaust, and several little things; starter, fuel tank, wheel adapters, and wireing. Anybody have a way to make wheel adapters? The machine shop I usually use are about a month behind.
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Unread 03-30-2016, 05:31 PM   #6
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Default Re: 500 cc 2 stroke ez go

A couple of new projects. 88 electric club car and a mid 80's G1 gas. I need to sell the rear end and motor from the club car. The G1 is in running shape. When I got it, I was told that it didn't have enough compression to suck gas to the fuel pump, I found a hole in between the pump and tank. Runs good. I was impressed that i could power slide and do donuts in my driveway. Now to get it sold.
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Unread 04-12-2016, 08:49 PM   #7
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Default Re: 500 cc 2 stroke ez go

it"s alive
I finally got to work on the cart again, I got all the wiring hooked up, sat a gas tank in and it started right up. I put two 4 wheeler shocks on the back and took the 4 shock setup off for now and put some atv dirt tires on it for testing purposes. Hopefully this weekend I will be able to hook up the fan, put in a battery, connect the brakes, throttle, build brackets to hold the seat backs, and make a fan shroud. getting down to the skinny list
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Unread 04-15-2016, 02:43 AM   #8
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Default Re: 500 cc 2 stroke ez go

I couldn't sleep last night so I went to the shop and started working. I hooked up the throttle, rear brakes, and over heating light. My daughter and I drove it around for an hour or better. Not as fast as I wanted it to be, but it will light the tires up at any speed. My wife has a three day weekend so I hope to finish the last few things and get it up for sale. I did add a few things that I didn't need to, but wanted to. I put in a battery, voltage regulator, and two relays to kill the engine and run the fan. So now this cart is an ezgo+Kawasaki bayou front end+Polaris wheels and voltage regulator+Artic Cat engine+Yamaha battery=FRANKENSTEIN

I'll try to make a video this weekend
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Unread 04-15-2016, 05:56 AM   #9
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Default Re: 500 cc 2 stroke ez go

cant wait to see video
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Unread 04-19-2016, 11:02 PM   #10
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Default Re: 500 cc 2 stroke ez go

Here is a video of this cart in action. I still have some work to do on it. I starts missing after half throttle, make a new seat bottom, and clean up the wiring so it looks nice.

https://www.youtube.com/watch?v=fO4URVgGV3g
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