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Old 03-30-2014, 09:22 PM   #31
XxMertxX
Not Yet Wild
Yamaha
 
Join Date: Oct 2013
Location: Minnesota
Posts: 38
Default Re: Polaris Trail Boss motor into Yamaha G2

Hey guys, thought I would drop in and give a little update on the project I am now calling the YamaBoss 250.
Been really busy with work lately, but I try to fuss with it a little in the evenings and on the weekends.
Im gonna give a quick rundown of some of the problems i've encountered along the way without being to long winded.
1. after all vital electrical components were hooked up, i discovered I had no spark. Using my multimeter i tested for open circuits throughout the system and still struggled to track down the issue. I was almost sure it had to do with the black 'kill' wire. Nope. Realizing I broke the important troubleshooting rule of 'start at the source and work your way back', i soon discovered I had a bad ground on the coil. (shame on me!)
2. After getting spark I was pretty confident I should at least get the motor to pop off...or try to start. Not the case. Motor just turned over with no signs of starting. Long story short, cleaned the carb, adjust fuel line sizes for the feed and return and now im getting it to start with either choking the carb with my hand or using starting fluid. I think with a little more fussing with the carb and things will start to work out.
3. The worst issue of them all so far. I must have mis measured/miscalculated/wasntthinkingstraight when i did the motor mounts because the belt is way to tight, not allowing the clutch to spin freely during idle. the way I fabricated the mounts, i can move the motor forward by adding a few washers or spacers, but I can't move it backwards at all. So i may have to pull the motor out and make some adjustments to the rear mount to allow the motor to move back a half an inch or so.

Besides all of that, other things I need to look forward to are:
- Modifying the stock exhaust so it fits under the seat and exhausts down below the cart
- Run all the wiring for accessories (headlights, tail lights, reverse lights, aux charging port, radio, ect.
- Mount air cleaner within the swing arm assembly
- Mount oil rez(this is a 2 stroke motor) (or take out rez and just pre-mix)
- Fine tune throttle pedal

I'll get some pictures posted of how i chose to run some of the wiring and linkages soon.
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Old 03-30-2014, 09:26 PM   #32
XxMertxX
Not Yet Wild
Yamaha
 
Join Date: Oct 2013
Location: Minnesota
Posts: 38
Default Re: Polaris Trail Boss motor into Yamaha G2

Also, if anybody is interested, im selling the Yamaha motor I pulled out of the cart. Also have the starter/generator, muffler, ignitor, wiring harness, and solenoid. PM me with any offers.
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Old 03-31-2014, 08:46 AM   #33
tbirder
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Location: O'Fallon IL....for now....
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Default Re: Polaris Trail Boss motor into Yamaha G2

can't wait for the pictures!
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Old 04-02-2014, 09:08 PM   #34
XxMertxX
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Yamaha
 
Join Date: Oct 2013
Location: Minnesota
Posts: 38
Default Re: Polaris Trail Boss motor into Yamaha G2

Thought I would post a picture of my wiring mess. Its starting to get a bit more organized, hopefully will he nice and clean looking this weekend.
Also was able to get the motor to start with the eoectric start, bit now I'm having troible keeping it running and once it kills, it won't start until it sits for a while. Getting closer, just needs more tinkering.

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Old 04-03-2014, 06:02 AM   #35
tbirder
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Default Re: Polaris Trail Boss motor into Yamaha G2

I wouldn't consider that too much of a mess. It actually looks a lot better than the "finished" jobs on most of my buddies carts. I bet a couple hours, some tape and some wire loom and you'll have it all detailed in no time.
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Old 04-03-2014, 07:31 AM   #36
XxMertxX
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Yamaha
 
Join Date: Oct 2013
Location: Minnesota
Posts: 38
Default Re: Polaris Trail Boss motor into Yamaha G2

Yeah, I'm pretty particular about how it looks, guess is all part of the enjoyment of the build. It was actually a lot worse before yesterday.
I've soldered and heat strinked any splices I made. Kinda wish I would have soldered all the female blade ends too, instead of crimping them because they don't hold nearly as well.
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Old 04-20-2014, 11:31 AM   #37
XxMertxX
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Yamaha
 
Join Date: Oct 2013
Location: Minnesota
Posts: 38
Default Re: Polaris Trail Boss motor into Yamaha G2

Well after a lot of fussing around I was able to adjust my motor mounts and get the belt tension set just right. Once I got all the electric components plugged back in and stock exhaust mocked up, I was able to get the motor running and the primary clutch spinning without any drag of the belt while sitting in park!
I temporarily tied down the oil rez on the back end of the cart and secured the exhaust with some wire, now it was time to see if it would actually work.
First time out, had problems with the motor back firing like crazy, but man does the cart have a ton of torque! Especially with my heavier gauge primary spring. I swapped that with the stock for now though, not in need of that much power yet.
Anyway, found that the rubber boot between the carb and the motor was leaking really bad, so I fabricated my own with the pieces from the exsisting boot and some PVC I had laying around. Now that boot is more rigid and doesn't let the carb bounce around as much. Wish I would have gotten some pictures of how I created it, but in moment of ideas, i didn't think of it.
After the carb boot problem was resolved I took it out again and it ran great! No backfiring, just lots of power! The only issue im having now is it won't start on a consistent basis..Im having to play with the choke a lot to get it to fire and sometimes it wont idle very well until it gets warmed up. Im sure its just some fine tuning with the starting circuit in the carb, ill get to the bottom of it eventually.

Thinking of just sticking with the stock exhaust. I wasn't too keen on the idea of having to cut a large hole in the rear shroud of cart and having it stick out, but I realized with my setup, it will hardly be visible. I have a 'bed' that I made that extends past the rear of the cart a few inches, so it should be a little inconspicuous under that...Guess we will see.
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