90% complete Yamaha G2 7" lift 50hp ex500 cart

[cfherrman]

Hello, I recently got this cart from my brother who did the motor conversion and the black paint for a tank of diesel. He picked this cart up for $500 with the hill billy 7" lift and new 22 x 11 x 10 tires. In his area, north manhatten kansas, there is a lot of hills including his sand road streets so the factory 8hp motor plus the tires didn't cut it for him so he put in a 1st gen ninja ex500 motor. I had my reservations about it but its a clean job that needs a little touching up. About 10 months ago he picked up a cheap china side by side and that was a get in and go so he stopped driving this. Fast forward to a week ago he decided to buy a big polaris crew 900 side by side and with my help getting it the 2.5 hours away to him he gave me his project.

With a gallon of gas and a jumper pack we drove it on the trailer and away i went. Most of the work is done just some refinements and tuning is left.

question and to do list:

1. The front end floats, badly, it does not have much weight on it so i want to either put a heavy bumper on it or skinny tires on front. I just lowered the springs one notch to see if that will help.

2. Cooling, right now it will idle to 200 degrees and start to vapor lock, i will get some scrap aluminum and heat sheild the tank and perhaps insulate the fuel line. We think the radiator might not be big enough, will have to drive it more and see.

3. Gas tank vent leaks and will fall off, any suggestions?

4. Roll bar, if anybody knows of a bolt on id like to know, otherwise i will probably buy a harbor freight pipe bender and make one.

5. Lights, i will add some head and tail lights.

6. Appearance upgrades, he gave me more diamond plate to put on the sides.

7. Safety checks, make sure mounting is done correctly.

8. Skid plate and off road protection of components.

9. Gauges, i have a free temp on there now, would like to get a triple with temp oil and volts along with a big rpm and speed.

10. Megasquirt, in the winter if i get all this done i might try this for fun and learning.

Thanks! Pics in next post.

[cfherrman]

Seems you have to wait to post a link. Sorry

[coolpool]

Sounds like an interesting rig. Hope you can post pics soon!

[cfherrman]

Havent had the time to link the pictures, lets see if this link works to my album

https://picasaweb.google.com/m/viewe...19720347677921

[taz79]

doesn't seem to work

[cfherrman]

Ok here is a video, sorry i hit a button when driving

Watch "G2 with 50 hp ex500 and 7" lift" on YouTube
https://www.youtube.com/watch?v=AvPKU-l-R1o

[bikerjoe]

bigger fan with shroud and switch

[Tonka329]

Looks good

[93yellowclubcar]

That's really cool!!

Front tires are backwards, swapping them side to side will fix em.

[cfherrman]

Yeah i know they are backwards, havent got around to swap them, dont think it will fix the high danger this thing has. I havent had any extra money to throw at this thing yet, been fixing up my truck and some 150cc 4 wheelers. When i get some money im thinking a much bigger radiator and fan along with changing the exhaust will help the heat. I have been thinking of doing diy double a arms by finding a second set of g2 a arms and then custom making the spindle mount things, however jakes has a 7" lift doible a arm for front and rear for 400 that would solve that and the weak hillbilly rear lift that i plan on redoing. My brother informed me a few days ago that one of the motor mount is not strong enough so add that to the list.