Club Car DS Predator 420 Engine Swap - Budget Build
This video goes over a recent build we just finished up installing a Predator 420 engine into a 1995 Club Car DS golf cart. We built this cart on a pretty low budget and couldn't be happier with how it turned out. Check out the links below to all the parts we used and some of the other Predator swaps we have done. Thanks for watching!
Check out our website here - powerequipmentman.com/
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Parts used on this build:
Club Car DS LED Light Kit shown here - amzn.to/2KdeFbU
Light kit with turn signals - amzn.to/3DhG3MX
Predator 420 engine - amzn.to/3tI2Bnl
Jet Kit - amzn.to/3OzQj8U
780 primary clutch - amzn.to/33hGzNR
780 secondary clutch - these are hard to find, the comet part number is 301940A - this might be another option but we have not ordered one to test - beltpalace.com/comet300782c.html - another place to check with is Vegas Carts.
muffler - amzn.to/3K9tNkX
exhaust flange - amzn.to/3DEJiPu
engine mount plate - amzn.to/3qpG0u7
1.25" square tubing - amzn.to/3H2gaSX
belt - vegascarts.com/products/ezgo-...
intake insulator with pulse fitting - amzn.to/3noB06W or amzn.to/3LNSzXT or amzn.to/3nwtpmC
pulse fuel pump - amzn.to/3rjyLTE
1/4 fuel line - amzn.to/3zY9guY
3/16 pulse line - amzn.to/3FpnQNu
1/4 fuel filters - amzn.to/3DgPoVV
pod air filter adapter - amzn.to/3KlltPx
uni pod air filter - amzn.to/3trOkvk
uni crank case breather - amzn.to/3qyKqiB
valve springs -
remote choke cable plate - amzn.to/3no5dmU
choke cable - amzn.to/33wHiuu
brake cables - amzn.to/3I0Bet5
front bumper - amzn.to/33kvpb3
rear bumper - amzn.to/3no4jGZ
seat bottom - ebay.us/gzpK5k
sound and heat suppressor liner under seat- amzn.to/34DnR3t
seat back - ebay.us/2vPDmH
seat back cover - ebay.us/BpF5IE
box bed brackets - amzn.to/3Lh1DEy
tires 20x10x10 - amzn.to/412yxC5
hub caps - amzn.to/3zY6E0v
front lift block - amzn.to/3FlnG9D
leaf spring bushings - amzn.to/3zWa9o0
front wheel bearings - amzn.to/3fmHMpv
side rub rail inserts - ebay.us/RxEmAy
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#clubcards #clubcarbuild #predatorswap
Is the 1-inch extension enough for a 20-inch tire? I ask for example when I am loaded with weight (people) it does not wear out between the tire and the body while jumping?
Whooooo nice work!
Thanks for watching!
I just discovered your channel and am working my way through your videos! Great content! It's occurred to me that maybe I can immediately ask you for information after ever so briefly throwing you a single compliment! Hopefully I'm right! lol. I'm working on a installing a Scorpion 440cc engine in a Yamaha G9 and have nearly completed building a jackshaft mount. I have sprockets set with a 1:2.4 ration to counter the factory 12:1 in the differential, giving me an overall 5:1 reduction in my drivetrain, retaining the CVT with stock G9 engagement RPM's. The engine is rated for a minimum of 40hp. Do you think I'll have any issues with acceleration? I've designed this jackshaft and the cart's input shaft adapter with taper lock hubs so I can change my sprockets to whatever work best but I'm not sure if my starting point seems realistic? To clarify, my goal isn't to achieve awesome donuts, burnout, and wheelies. My goal is to hit 40MPH without being at full throttle, coupled with enough torque for some 2X4 trail riding.
Sorry, but I don't have any experience with the type of setup you are working on. Good luck!
Do you have to buy the secondary clutch to make that Amazon primary clutch work? Says online it’s for a 1-3/16” belt which is different from the vegas carts one
Yes, you have to buy a 780 secondary clutch to match a standard 780 primary. The factory club car clutches use a narrower belt than the 780.
What belt are you guys using seem stock size is to small?
What pelt are you using u have a part number thanks
Your link on the secondary clutch doesn't work anymore and will the same clutch for a Yamaha G2 work on a G1? I have a Hyundai HGG-1 and I think it is the same as a Yamaha G2. PS - Awesome job. It actually gave me a renewed sense of actually being able to accomplish this job.
Sorry, but I don't have any info on G1 and G2 clutches as we only deal with the newer Yamahas. Good luck with your project!
Ive got a 2002 ds gas. Came with a small shop i just purchased. The engine is shelled but the seats clutches etc etc are in decent shape Harbor Freight has a predator 420 on sale for 369 in my area until Halloween. How much fabrication do you think would be necessary for just the engine swap and clutch replacement? I've got some stock and a MIG but I'm a horrible welder LOL turn the head and splash well things. I would love to get this thing running my kids and wife would have a blast with it I appreciate your video you got a sub and a plus one for me. Any other tips for somebody about to try this? Should I even?
Depends on what is actually wrong with your engine and the condition of the rest of your components. If your engine can be easily rebuilt and your clutches, starter/generator, and muffler are all still usable, it would be cheaper, easier, and more reliable to get your engine rebuilt. In our case, everything was shot, so the predator swap was the better option.
Did you guys do any tuneing to the primary? Mine seems to be closing a little too fast.
No we did not. It takes some time to get the idle set right, just high enough that it doesn't die, but low enough you can still shift gears. Make sure the engine is completely up to temp before you make any adjustments. Thanks for watching
Perhaps I missed it, but if we plan to run stock size tires there is no lift kit required? I know for the 22 hp predator you have to install a 4-6" lift.
No, you do NOT need a lift kit to install a Predator 420 or 459. If you wanted to do the Predator 670, you do have to have a lift kit.
Greetings. Converting a 1996 G-16 with the 420. Do you know if i should hook throttle cable to the engine directly, or leave it attached at differential and use that cable (from the old set up) to the new engine? THANKS!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!1
You would probably just want to connect the throttle cable directly to the carb.
With this swap do you have to put the cart in reverse to go forward? If so will that slow it down. I have a 2001 club car ds
The 1995 and older models engine spin the opposite direction of the newer engines. So for this cart, the engine rotation was correct for forward and reverse. On a 2001, your forward and reverse will be backwards. I do not know for sure if gearing is different between forward and reverse to effect your speed.
Forward is 12:1 and reverse is 15:1
Got everything installed like yours but wanted ask why when u give it a lot throttle at dead stop it squeals like heck but if u go easy don't squeal do i néed to put power spring in that 780 secondary clutch I am using one put in description
Sounds like you may have a belt alignment or tension adjustment issue. The belt has to be perfectly straight and should have around 1" of deflection. We did not change weights or springs in either clutch.
I live in a beach community and lookijng to fix and upgrade carts for people. I have autobody skills including paint and welding. Do you think it could be a profitable endeavor?
Since the pandemic, every Joe Blow out there thinks they can flip carts and make money. Some do very well with it, others just do a terrible job and sell stuff for too cheap which hurts the market for everyone. I have been building carts for over 20 years and enjoy doing it. The best way to be successful at it is to get setup with a couple of the cart distributors to be able to buy multiple carts at a good price. You have to make your money on the front end, not the back end (if that makes sense), and the only way that is going to happen is buying in volume (6 to 25 carts at a time). We have actually been making more money lately just selling basic carts, usually just tires/wheels and nice seats. Make sure they are fully serviced and ready to go. Less work and dollars in parts, and we make more money and they sell faster at the lower price point. Trying to do custom builds like the cart in this video is a BAD idea for making money. Way too much labor and very limited market of people willing to buy something like this. Buy carts that are running and just need serviced and cleaned up with very minor repairs needed. Like fleets that are coming off leases (this is where the distributors/brokers come in). Hope this helps. Good luck!
@PowerEquipmentMan wow. Thanks for the advice. I have been flipping cars and have a mechanic and autobody background so i am good to go there. I also live in a beach community. I see carts online that look like i could flip with some paint, epolstry, and a good service. But i will look into picking up a lot of carts if i can locally. Thanks for the help
I put thenew jets you recomended into my prediator 420.. I believe it was a .041 and put pod style air felter on the carb. I got it to idle ok but when I I push the gas it seems to want to die. I can ease on the gas sometimes and it will go but not all the time. please advise.
I would recommend calling someone like Go Power Sports that specializes in Predator engine performance. I am sure they can get you fixed up.
Did you have to adjust the clutches at all or are they adjustable? I'm having slipping issues taking off
Clutches are adjustable with different springs and weights, but we did not have to make any changes on this build. Are you running the correct size belt and is it adjusted properly and aligned?
@@PowerEquipmentMan my main issue is it is a harsh shift and then at top speed it will act like it is slipping and if I let off it aggressively slows me down.
@@xsavage136x8 I would guess that you either have an alignment issue and/or the belt tension isn't correct. Are you using an 1 3/16" wide belt? For clutch alignment the belt has to be perfectly straight and centered in the clutches. We had to use spacers on the transmission input shaft to get the secondary clutch aligned. Then for belt tension you should have about 1" of belt deflection when the belt is cold.
What Spacer Did U Use On The Secondary Clutch? Didnt Put It In Description
@@PowerEquipmentMan you don't happen to have a pic of the mount plate finished do ya?
What's the button you guys put under the throttle pedal? Starting? Thanks
Or is that a bolt to stop from pulling the cable too much now that I look at it more ?
Yes, it is just a bolt for a throttle stop.
I am having issues switching into reverse or Forward while running. It grinds and most of the time will not get out of the gear its in. I have to kill it and move it and restart. I tried toning down carb and looking the belt. It helps but still having issues.
The idle has to be set VERY low, just high enough the engine doesn't die every time you come to a stop. Make sure your engine is hot when you adjust your idle.
Did you use the original engine cradle?
Yes, just added the square tubing and engine mount plate.
The 420 runs the opposite direction of the old club car engine , without changing gears in the rear-end, is there a way to stop it from going forward whens it's in reverse and vise versa when it's in forward,?
I believe '97 was when they changed the engine rotation. So anything before that (like our 1995) the engine rotation will be the same as the predator. If you have a DS that is newer then that, then your rotation will be backwards. No, I do not know of any easy way to correct that.
@@PowerEquipmentMan I've been told the 88 thru mid 1996 FE 290 models had CCW rotation, which is the case with my 1992 model. After 1996, the engines were made with CW rotation. I assume the Predators have a CW rotation??
@@k.lindsey3529 just did a predator 420 swap on my 1991 club car ds. It spins the same direction as the old engine.
@@ronniereaver2815 In the counter clockwise position? I need to know because I'm thinking of doing the same thing. My 1992 FE290 turns counter clockwise
Does this engine still start and stop every time you step on the pedal. And how did you do it?
No. It is just key start.
@@PowerEquipmentMan can you do my cart like this I just need a engine swap cart is in perfect condition
@@jonathanwimberly7058 Sorry but we are not doing any customer builds at this time.
is the new secondary overall OD wider than the original stock secondary?
Sorry I did not compare the two. The 780s do use a wider belt then the factory clutches, so you can not mix a 780 with a stock clutch.
@@PowerEquipmentMan i have the 780 series clutch with my stock secondary. Yes the 780 takes a wider belt. they say min of 1 3/16". The stock belt width is a 1". Mine is working just fine.
Ronnie reaver so are you using the 780 clutch on the 420 and using the stock clutch on the transaxle?
Nice vid. Where are you guys out of?
South central Kansas
@@PowerEquipmentMan nice. Are you guys selling swap kits or something to that affect? Not many if any shops by me that are doing this. I have a old club cart that I would like a new motor in
@@Jaydayallday No, we are not doing any work for customers at this time. Just our own builds.
@@PowerEquipmentMan got ya. Thanks
i ordered the valve springs from the parts list but they are significantly smaller than the oem springs. are these correct?
It looks like they may have changed the listing as they are now showing those valve springs for a 212 engine. You might check out Go Power Sports to see what options they have for valve springs. Sorry about that.
@@PowerEquipmentMan no problem! Would you recommend the 50 lb springs from go powersports?
@@ASDCustoms 50 lb springs are probably overkill. I would shoot for the 20 to 30 lb range.
Does this swap retain the pedal start feature?
It is possible to install the oem starter generator on these engines with some fabrication and wiring skills, but we did not do that on this build. Our starter generator was junk and they are pretty expensive to replace.
I swapped my club car engine with a predator 420. when I put in drive or reverse it automatically starts moving in that direction without pushing gas. is that normal or is there something I need to do?
Start with turning down the idle screw on the carb as low as you possibly can without the engine dieing every time you let off the gas. The engine needs to be hot while making this adjustment. You should be able to get it down around 1100-1200 RPM. If it is still trying to creep, then you may need to adjust belt tension. You only want about 1 inch of belt deflection, but you may have to do a little more to keep it from creeping at idle.
What drive clutch are you using. If you are using a stock golf cart clutch, it will do this. You will need to upgrade to a 780 series drive clutch. Mine did the exact same thing. One other thing is you may have the belt too tight.
I see that you had the secondary clutch is backwards. What's the reason for that?
I was asking because I just bought both 780 clutches and did not want to put them on wrong.
The secondary is right for the direction of rotation and the spring that is in it. It is different from how the factory clutch is installed if that is what you are referring to?
@Power Equipment Man so you can just fill the driven clutch around like that an have it mount up and work? I wasn't sure if one would because of how the stock one sits inside in casing a bit. What did you all do to make it fit? Long bolt and spacer? And would that also work for my 06 club car ds? Thank you
What about reverse is it all controlled from the differential?
Yes. Just about any gas golf cart from the early 90s and newer with a 4 stroke engine will have a transaxle with forward and reverse. Only the old 2 stroke carts would run the engine backwards to go in reverse.
@@bryanraykovics2843 The belt was a 45 inch from Vegas carts. I would recommend measuring your setup once you get it installed to verify what belt length you need. Vegas Carts should be able to tell you how to measure.
@@PowerEquipmentMan thank you!
Where do I find a driven pulley with 7/8” that uses 1-3/16 “ belt
All the links are in the description. ebay.us/VoOThM
Gates belts are the best they have every possible size
What is the distance from the center of the shaft on your differential to the center of the shaft on your engine? I'm wondering so I can get the proper spacing for the belt between the two clutches.
Sorry I don't have that measurement and we already sold that cart. Vegas carts has belts of all different lengths and could help you figure out which length you need.
@@PowerEquipmentMan ok thank you
Did that build mean you had to run the trans in reverse to make it go forward
On the earlier DS models, like this one, the engine ran counter-clockwise. So with the Predator engine, forward and reverse were still the same. I believe they changed it in 1995. So if your cart is newer than that, you would have to run your cart in reverse to go forwards.
I put the predator 420 into my clubcar ds. I got 780 clutches and put the carb filter and choke kit. The only way I can get it to start is with the choke on. Any ideas? Do I need to put a bigger jet in the carb? Help.
The 420s are pretty notorious for always needing the choke on to start. But if you added a pod style air filter then you most likely do need to rejet it to run right. Try these jets - amzn.to/3OzQj8U
Let me clarify. It will not idle unless choke is atleast half way ingaged.
PLEASE HELP . I am having that issue as well. It is only idling when choked.
@@PowerEquipmentMan Yes is the pod style filter like on you list. Not only need choke to start but to idle after it is warmed up.
I don't know alot about it do I need to use the .041 or .042 jet in the kit? with using the choke I can get it to idle but clutches are still ingaging.
Hey how can I get yall to do the engine on my Cart engine only
Sorry, but we are not doing any customer jobs at this time.
I'm looking to pick up a 85 club cart would this swap be pretty similar?
Sorry I am not familiar with the older models.
What did you do about charging?
Just using the charging coil that comes on the 420. It only puts out a couple amps so you can't run much with it, but it should be enough to recharge the battery.
Do the clutches you have listed allow the cart to shift in gear while the engine is running?
@@airfox023 Yes it shifts no problem while running.
Thank you for all the info!
How many horde power is the stock motor I needed to know for a friend that has the exact same motor
The stock 290 engine is around 9hp.
@@PowerEquipmentMan thanks
Is this for sale? If so how much?
Yes is it currently for sale. facebook.com/marketplace/item/378238567464714
What was the top speed?
Around 28 mph if I remember correctly.
I dont see where i can find parts
The parts list is in the video description.
Why 780 clutches and not 40 series
A golf cart is too heavy for 40 series. You would just burn up belts all the time.
Make a bolt in kit.
Why not show the build?
We did this build over a 6 month period as we got time to work on it and parts became available. Almost all of it we just had to figure it out as we went along. It is pretty tough to film a build like that, so we just decided to do one video when it was completed that explained everything we did.
This dudes way off for budget style build.
Considering the last cart we built was over $18,000 when it was done, this cart was just pocket change. To do a Predator 420 swap for $1000 is CHEAP!
I love my remote choke adapter for my predator honda part # 16590-ze2-812
Thanks for watching