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This winter, I decided to take on a project. I've had this golf cart since '98. I lifted it about a week after I got it. I knew the stock 9 hp engine would be underpowered with the 22" tires and stock gearing, but I figured I would just put a larger engine in it when the original one crapped out. Well, 14 years later and a lot of utility/offroad abuse, that stock Kawasaki FE290 is still going strong. So, I decided I would put a motorcycle engine in it.

First and foremost, I wanted to keep the cart usable around the farm, not just have a 100 mph screamer like so many others. With that said, I decided to keep the original transaxle so I would have reverse. The motorcycle engine needed to be on the smaller size so it wouldn't overpower the transaxle. I wanted liquid cooling for obvious reasons. I went with a 2004 Ninja 250.

Now for the fun part, since the input shaft on the transaxle rotates in a counter-clockwise direction, the engine has to be mounted backwards. I could have mounted it facing forward and simply shifted into reverse to go forward and forward to go backwards, however the gear ratios are different. I installed a counter shaft that connects to the engine output sprocket via a short chain, then another sprocket on that shaft connects to the transaxle input shaft via a longer chain. Right now I have it geared for about 40-45 mph at 6k-7k rpm. Hehehe, that Ninja 250 is factory redlined at 13k, but I don't plan on ever spinning it that fast. If I do a high speed gear set for the transaxle, it should do 60-70 mph.

I think I will mount the radiator up front, but I haven't got that far. At this point, I'm still welding my axle brackets. But I used up my last tip tonight and will have to get more tomorrow. Here are some pics I shot tonight, I'll try to keep this thread updated as I make progress.

I got a little more done today, finished welding on the transaxle and input shaft support bracket. Also I got the radiator mounted. It is up front, over the tie rod and should be well protected when offroad. I think it will get enough air flow, but we'll see the first time I try it out.

Sorry, no pics today.

Got a few pics of what I accomplished this weekend.

I am certainly impressed...

Why thank you. :smile:

I only had a couple of hours last Saturday to work on the project, so needless to say I didn't get much done. I got all of the cabling off the bike and attached to the engine, but they are all too short and somehow I knew they would be. I started stripping out the wiring that I'll need to make the engine run. I didn't realize just how much wiring there would be on a little 250cc street bike. I pretty well have everything separated out and labeled up to the steering neck where the ignition switch is located. I don't intend to use the ignition switch, and I didn't intend on using the fuse block. However, after thinking about it for a couple of days, I think it would be easier to use it than to build a new one. I have a muffler on order, just waiting for it to arrive. Once it does, then I'll be able to start fabbing up the exhaust system. I'm not sure where I will find the four cables I need, anyone have a suggestion?

Man I can't wait to fire this baby up!!!

Well crap, I didn't get to play with the cart any at all this weekend!! :thumbdown: I have this week off, so I'm hoping I can get some shop time in after Christmas.

Darn flu!!!! I got sick Christmas day and am just now beginning to feel like doing something again. I won't get much of an opportunity this weekend either, darned family obligations. Don't get me wrong, I'm blessed to have a family and even more blessed to be in a position to help when I can. I'm going to try to work on it some either the 31st or 1st as I have those two days off as well. Hopefully I'll be able to post some pics then.

Hope everyone had a great Christmas and have a wonderful New Year!!

Very nice job, you know what your doing, plus looks like you have the proper tools.:thumbsup:

Thank you for the complement. But, as for knowing what I'm doing, well that won't be determined until I live through the trial run. :laughing:

Finally got to work on the cart some today. I didn't get much done, but any progress is a step forward. I had to add a brace to one of the counter shaft brackets as it flexed a little during some informal stress testing. I got the ignition coils, shifter linkage, thermostat housing and radiator overflow tank mounted. I did some work on the throttle cable mechanism, but finishing it will have to wait until next weekend.

Lookin good, keep up the hard work & keep us informed. :thumbsup:

IT'S ALIVE!!!!!!!!! I got to work on "Frankencart" today, finally. I got the throttle linkage completed, and also hooked up the cooling system, crankcase breather and began working on the clutch. I got the clutch pedal fabbed up and mounted, but now I need to actually connect the clutch pedal and cable. However, I did get the wiring harness out of the bike and made enough connections to make it run. Since I don't have any coolant in it just yet, I didn't let it run for very long, only about 10 seconds or so. I know it won't overheat in that short of a time frame, I don't want to ruin the water pump. Here are a few pics I took today just before I called it quits. Still looking kinda rough, but at least I'm making progress.

I can't wait to see this done!

Gotta say, I am more impressed everytime you report more progress.

Thanks guys, I can't wait to see it done either. At this point I need to connect the clutch cable to the pedal assembly, fab up an exhaust system and clean up/mod the wiring harness. Once that is done, the rear body will go back on so I can fab up a shifter and linkage and build an instrument panel. I'm sure I have forgotten something.....

I didn't get any time to work on Frankencart this weekend, I had too many other things that had to get done. Maybe next weekend. :ashamed:

Yet again I didn't get to work on Frankencart very much. I did get the clutch connected and functioning, but now I'm working on the exhaust system. Running a pair of straight pipes out each side or the back would be the easiest by far, and would save myself a lot of head scratching and fabrication, but it would be soooo loud and I don't want that. I want it to be quiet, I know it won't be golf cart quiet, but I don't want it any louder than the bike was when new. I know I will need some really tight radius bends in the tubing, and I may need a smaller muffler. I guess if all else fails, and against my cheaper judgement, I may just have to finish the build and take it to a muffler shop for some custom tubing.

Ugh, I am so ready to get this thing done!!

mullins87 said:

Yet again I didn't get to work on Frankencart very much. I did get the clutch connected and functioning, but now I'm working on the exhaust system. Running a pair of straight pipes out each side or the back would be the easiest by far, and would save myself a lot of head scratching and fabrication, but it would be soooo loud and I don't want that. I want it to be quiet, I know it won't be golf cart quiet, but I don't want it any louder than the bike was when new. I know I will need some really tight radius bends in the tubing, and I may need a smaller muffler. I guess if all else fails, and against my cheaper judgement, I may just have to finish the build and take it to a muffler shop for some custom tubing.

Ugh, I am so ready to get this thing done!!

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Sounds like you know what your doing.
When doing the exhaust remember both pipes need to be as close to the same as you can get them.
Built a go kart a few years ago with the engine off of a cb 350. Was crazy fast.

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Carscw said:

Sounds like you know what your doing.
When doing the exhaust remember both pipes need to be as close to the same as you can get them.
Built a go kart a few years ago with the engine off of a cb 350. Was crazy fast.

Sent from my iPhone using LMF

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I've never been fortunate enough to get to drive one, but I've seen some shifter carts that were absolutely wicked on the track. They look like way too much fun. I bet you had a lot of fun with yours. My sons have a two seater off-road cart that has a sad, sad 6.5 hp Tecumseh on it...........I better get Frankencart finished before I even start thinking about their cart!

mullins87 said:

I've never been fortunate enough to get to drive one, but I've seen some shifter carts that were absolutely wicked on the track. They look like way too much fun. I bet you had a lot of fun with yours. My sons have a two seater off-road cart that has a sad, sad 6.5 hp Tecumseh on it...........I better get Frankencart finished before I even start thinking about their cart!

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Don't know how old your sons are my youngest is 13. I think maybe a 80cc or maybe a 125 would be fun. With a seatbelt and helmet.

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My boys are 16 and 12. Obviously the oldest is more interested in my Jeep right now, however I think he might get interested if the cart was capable of near highway speeds!!! You're right, just about any dirt bike engine would be perfect.

I got to work on Frankencart this weekend!!! All of the electrical is done with the exception of physical installation of the gauges, they are already wired up, and the installation of a starter switch. The switch will just have to wait until I can reinstall the body. I'm still having issues with the exhaust, I can't seem to make myself give up on that one. I was brainstorming yesterday afternoon and I think I may have a solution, but it will be a last ditch effort on my part. If it doesn't work, then I'll have to back up and start over. Eventhough I still can't crank it just yet, it is nice to turn the key and see the dash light up again.

Hey, got to work on the cart today!!!! I have spent roughly the last month getting ready for a mission trip to Louisiana last week. So, now that's over and I can get back to Frankencart. Today I got the exhaust system installed!! WooHoo!!!! Next weekend the body will go back on so I can fab up a shifter handle and linkage. Sometime before then I'll also pick up a metal hole saw so I can install the gauges. Sorry fellas, no pictures today of the exhaust.

Keep up the good work, it just takes time. :thumbsup:

Frankencart is alive and kicking!!!! I got the shifter and linkage fabbed up today for the final time, and it works great. In said "for the final time" as it took a couple of failed attempts to get it right. The exhaust turned out exactly as I wanted, it is quieter than the bike was when new. I don't think I'll have any overheating problems, but then again I only had it out for about 20 minutes. Then chain drive is noisier than what I was expecting, but that may just be a minor alignment issue with the sprockets.

I have learned something about motorcycle engines and transmissions. I have been riding motorcycles for 35 years, but I didn't know until this past weekend that a motorcycle transmission input shaft rotates at 1/2 to 1/3 the speed of the crankshaft. I have always dealt with automotive transmissions where the input shaft rotates at crankshaft speed. In essence, if the transmission ratio is 1:1 and the engine is turning 3,500 rpms, then the output shaft of the transmission is also turning at 3,500 rpms. The ratio for 6th gear in this motorcycle transmission is 0.89:1, so I assumed the output shaft of the transmission would be turning faster than the crankshaft. Well, we know what happens when we assume things. Frankencart is slow!!! I put a wrench on the end of the crankshaft and made a mark on the transmission output shaft and starting counting revolutions. I was not expecting to find the crankshaft rotates 2.625 times for every one full rotation of the output shaft in 6th gear. Long story short, I have new sprockets on order that I hope will give me an overall gear ratio that I can live with.

Here are some pictures that I snapped today.







Don't look too closely at the welds on the exhaust system....you may find out I'm not very good at welding thin walled tubing!

:thumbsup::thumbsup: Very nice job, we learn as we go don't we? It will be just what you wanted soon & all the hard work will be worth it.

I got the new sprockets installed, and boy what a difference!! I got a new 10 tooth sprocket to go along with the 14 tooth on the transmission, and a 14 tooth to go along with the 23 tooth on the counter shaft. Before taking into account the 12:1 rear axle ratio, this new combination gives me a final drive ratio of approximately 2.25:1, which means the input shaft on the rear axle is spinning at nearly the same speed as the crankshaft. I am very satisfied with the speed of the cart, first gear is a slow walk at roughly 1,500 rpms, while sixth gear gives me a "sane" speed of about 30-35 mph around 6,000 rpms. To date I've been too chicken to see just how fast it will go. Thing is, with this little engine, 6,000 rpm is just getting into the meat of the torque curve, it wants to go!!!

Wow that is impressive. You may want to install a ROPS, a couple seat belts and helmets if you plan on reving it up. Nice job and ingenuity.:thumbsup:

I've already thought of that!! :biggrin: Buggies Unlimited has a complete front disk brake kit that works in conjunction with the factory rear brakes, and they have a high speed gear set for the rear axle that changes the rear end ratio from 12:1 to 8:1!! With those gears, Frankencart would be capable of getting a speeding ticket on any interstate. The front brakes, better wheels and tires, new bushings and tie rod ends for the front end, a full roll cage, a pair of racing seats with 5 point harnesses and a helmet are a necessity if I go that route. I really don't think I'll be going that route.

As a side note: If the rear axle had a locker, I do believe it would carry the front tires on a good hard launch. :laughing:

I haven't been around in quite a while. Life and work has been less than easy these past two years. Anyway, I received a PM from a new member "Dobbz21" about this project of mine from nearly three years ago. He is building an EZ-Go with a 900cc motorcycle engine. I don't know how he found this thread. I have done numerous searches and have never seen this thread show up in the results. The pics for this build are located in my album titled "Winter Project 2012".

Came across this build. I am in the process of building a Yamaha g2 cart with a Kawasaki 250cc swap. Was curious on how fast yours ended up going? And were you happy with a 250cc? Got a lot of good ideas from your build! Just started mine, can't wait till its done!

Thanks!

I have been happy with the build overall. I don't like the very noisy chain drive, and the engine is adequate. I chose the 250cc liquid cooled engine for its compact size, but it doesn't have a lot of low end torque. I should have thought about my engine choice a little longer. As far as top speed, I don't know. I've had it up into the 50's and it had a lot more left. On paper it's geared for 80-90 mph. If I were to rebuild it, I would rethink the chain drive and put in a larger engine.

Thanks! You said it doesn't have much low end torque. How does it do for just "putting" around in 1st or 2nd gear?