Upgrade Your Golf Cart with EZGO Workhorse 1200 Starter Generator!

Table of Contents

1. Introduction
2. Mounting the Engine
3. Installing the Starter Generator
4. Throttle Control and Choke
5. On/Off Switch
6. Wiring the Starter Generator
7. Fabricating the Bracket
8. Securing the Bracket
9. Finding the Right Belt
10. Conclusion

Introduction

Hey guys, it's Henry from Mowers and Blowers. Today, I'm out on the golf course working on my latest project - a repower for my Workhorse 1200 Easy Go. I recently replaced the engine with a Honda GX340, and now I'm in the process of mounting the engine and installing the starter generator. In this article, I'll take you step by step through the process and share my thoughts along the way. Let's get started!

Mounting the Engine

The first step in this repower project is to mount the engine permanently. Currently, the engine is loose on the cart, but it seems to align well with the transmission. I want to make sure the engine is secure before moving on to other tasks like installing the starter generator. I'll need to fabricate a new bracket to accommodate the Honda engine, as it sits further forward than the previous engine. Once I have the bracket in place, I can bolt the engine down securely and move on to the next step.

Installing the Starter Generator

The starter generator is a crucial component in this repower project. It acts as both a starter and a generator, providing power to the engine and charging the battery. I need to find a way to affix the starter generator to the engine and ensure that it lines up with the pulley system. I plan on using the existing bracket but drilling a couple of new holes to accommodate the Honda engine's placement. Once the starter generator is securely mounted, I can connect the wiring and test it out.

Throttle Control and Choke

One of the key elements missing from the Honda engine is throttle control and choke control. These features are essential for easy starting and controlling the engine's speed. I'll need to find a suitable solution to add throttle and choke control to the engine. This may involve purchasing additional components or fabricating custom parts.

On/Off Switch

In addition to throttle and choke control, I also need to install an on/off switch for convenience. Pull-starting the engine every time can be tedious and inconvenient, especially when accessing the engine requires removing the back bed and lifting the seat. I want to have the option to start the engine with a simple switch, making the process much more user-friendly.

Wiring the Starter Generator

Once the starter generator is mounted and the throttle control, choke control, and on/off switch are in place, I'll need to connect the wiring. This is where I might need to refer back to my previous videos or consult the engine's manual to ensure the proper connections. I have wires everywhere right now, so it's crucial to get this step right to avoid any future issues.

Fabricating the Bracket

To mount the starter generator, I'll need to fabricate a bracket that can accommodate its size and weight. The original bracket is not sufficient, so I plan on using it as a base for a new bracket. I'll drill new holes and make any necessary adjustments to ensure a secure and stable mount for the starter generator.

Securing the Bracket

After fabricating the bracket, the next step is to secure it to the designated area on the cart's frame. I'll need to drill holes and use bolts that can withstand the weight and vibrations of the starter generator. It's essential to ensure that the bracket is solid and doesn't pivot or move once installed.

Finding the Right Belt

With the starter generator mounted and everything wired correctly, it's time to find the right belt. The original belt is too short, and the available options do not fit the setup correctly. I need to find a belt that is the right length and properly aligned with the pulleys. It may take some trial and error, but finding the right belt is crucial for the engine to start and run smoothly.

Conclusion

In conclusion, this repower project for my Workhorse 1200 Easy Go is a complex endeavor with many steps involved. From mounting the engine to installing the starter generator and finding the right belt, there are various challenges to overcome. However, the end result will be worth it, as I'll have a cart with improved performance and functionality. Stay tuned for more updates on this project and other exciting content from Mowers and Blowers!

Highlights

• Repowering the Workhorse 1200 Easy Go
• Mounting the Honda GX340 engine
• Installing the starter generator
• Adding throttle control and choke
• On/off switch for convenient starting
• Wiring the starter generator correctly
• Fabricating a custom bracket for stability
• Securing the bracket to prevent movement
• Finding the right belt for proper engine operation

FAQ

Q: How long does it take to complete this repower project? A: It's a long-term project that requires extensive fabrication and modification. There is no set timeframe as it depends on various factors.

Q: Can I use a different engine for this repower project? A: Yes, you can use a different engine, but it may require additional modifications to fit correctly.

Q: Is the starter generator necessary for the engine's operation? A: Yes, the starter generator is essential for starting the engine and charging the battery.

Q: Where can I find the components and parts mentioned in the article? A: You can find the necessary components at hardware stores, online retailers, or specialized automotive shops.

Q: Are there any specific tools required for this repower project? A: Basic tools such as drills, wrenches, and sockets will be needed. Depending on the customization and fabrication, additional tools may be required.