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Old 06-22-2021, 08:50 AM   #1
Renarderickson
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Default Yamaha g22a/honda 200sx swap.

Well I decided I may as well do a build thread. Hopefully it'll help some one out in the future. My little yami motor is burning oil like crazy. I mostly use this as a chase rig while the kids are out on there four wheelers. I've got a 5 yo that just got her first quad so she needs a little help. The kids don't want me to drive around with them due to the constant smoke screen. Wife won't drive it either, so I decided to look for a older Honda swap. There was a couple key needs, 5 speed auto, electric start, and reverse if I decide to go to a live axle. For now I'm using the golf cart axle so reverse is a mute point, but the option is there. Found a well used 200sx locally at a fair price, motor is a fine runner. I employed the use of a porta band to unbuild the Honda, kinda sacrilegious. I had one of these when I was a kid, lots of good times had. I was going to use the front a arms off the 200 but that's hardly a upgrade, so my buddy gave me a 400ex minus the motor. My plan is to wrap up the motor swap before the 4th of July (we shall see) then tackle the front end swap. I got the motor pulled and hopefully this evening I'll have time to build a adjustable cradle for it.
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Old 06-22-2021, 10:09 AM   #2
crash12888
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Default Re: Yamaha g22a/honda 200sx swap.

200cc motor? what HP is that?
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Old 06-22-2021, 11:12 AM   #3
Renarderickson
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Default Re: Yamaha g22a/honda 200sx swap.

Not 100% sure, somewhere in the 12-15 range I've read. Should be just about perfect for my needs. I can't got to crazy on the power or no one but me and my friends will use it. Right now my 12yo son and my wife use it, or at least they'd like to. This swap has been done several times and it seems to be a good motor for it.
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Old 06-23-2021, 06:32 AM   #4
crash12888
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Default Re: Yamaha g22a/honda 200sx swap.

Stock Yamaha runs in the neighborhood of 350CC @ 11 HP so hope it works out for you. Post lots of pics.
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Old 06-23-2021, 08:10 AM   #5
Renarderickson
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Default Re: Yamaha g22a/honda 200sx swap.

If stock yami was 11 then I should be just fine. The yami motors don't Rev very high (I think in the 4k range) where the little Honda is 8500 or so. That and the addition of 5 speeds should work out perfectly. Yesterday I got the Honda motor all cleaned up and ready to install. I pulled the golf cart motor and spent some time pressure washing the crap out of the engine bay. I set the Honda motor in just to see what was working with. This motor fits very nicely in the cart. After looking and brain storming it was clear that there's no way in hell I'm trying to do this swap with the golf cart intact. Either I could remove the body, which means I'm still working on the ground, or pull the rear swing arm/axle and throw it up on the table. Seen as I'll be cutting the center mount and lowering it 2-3 inches it's just easier to remove the whole rear swing arm/axle. I started to make a cradle, it's cut out of 1/4" and then I'll use 1/8" to make the motor mounts. Everything looks really good thus far. Two major issues are the sprocket for the Spicer axle's input, and exhuast. I going to attempt to re-use the Yamaha muffler, which I believe is adequate and should keep things quiet. I've drilled one of my 13t ktm sprockets to fit just over the splines, more for mock up purposes but worst case I'll weld that sucker on there. I should have the motor mount made today.
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Old 06-23-2021, 09:17 AM   #6
Renarderickson
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Default Re: Yamaha g22a/honda 200sx swap.

While I drank my morning coffee I whipped up a plate for the rear motor mount.
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Old 07-04-2021, 08:16 PM   #7
taz79
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Default Re: Yamaha g22a/honda 200sx swap.

Thats some nice fab work
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Old 09-20-2021, 11:15 PM   #8
DocMcStuffins
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Default Re: Yamaha g22a/honda 200sx swap.

Any more progress???
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Old 10-20-2021, 05:49 PM   #9
Renarderickson
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Default Re: Yamaha g22a/honda 200sx swap.

Yes! I got busy with other projects. The golf cart went to the back burner. Last I was using the Yamaha rear, that doesn't work. Or I wasn't willing to mess with it anyway. The gearing is SO low it isn't really worth doing. A friend had a 400 ex minus the motor. I took the rear axle/swingarm/shock and the front end to put into my cart. A friend came over all ambitious to help work on it so we dove in. We mounted the motor, the seat barely fits but it'll work perfect. The 400 swingarm is simply to long to use without pushing the motor forward and cutting the seat box. The sand guys have been building there own extended swing arms for years, so finding a carrier housing was easy, thus I built my own (or in the process of, waiting on some .25 wall dom tube and bushings) which let me put the axle right where I wanted it. I swapped the axle temporarily just to see how it'd work out, looks to be real good. After I finish the swingarm, I'll build a upper shock mount. And side supports for the engine cradle/swing arm mount. While I was stuck on the rear, I started on the front end. What a PITA. I intended to cut the front end off the 400 leaving the front of the frame with the A arm mounts and everything. That won't work or atleast it will make hooking up steering extremely tough. I had hopes to use the carts steering rack, so I ended up splitting the 400 frame thus being able to spread the A arm mounts out and allowing the rack to A. fit and B line up with the steer shaft so I'll essentially have the carts factory steering. Lot AND LOTS of measuring later I got the front mounted. I've got the shock mount cut and ready to weld on. There alot more gussets I've still gotta make. I'm hoping to have it rolling and steering in the next day or so. I'm really digging it!
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Old 10-21-2021, 06:29 AM   #10
crash12888
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Default Re: Yamaha g22a/honda 200sx swap.

Looking good so far, I enjoy seeing people take the time to fabricate style into their brackets.
Can you tell me a little more about the blue jack stands? If thats what they are?
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