G2 Rebuild

The old carpet was in bad shape and was moldy, so I went to the Home Depot and bought new utility carpet and cut it out to fit using the old carpet as a template. It looked and worked great! Before, original carpet After, new carpet I also replaced the gas pedal because the old one broke while replacing the throttle cable. Oh, I also replaced the windscreen cause the old one had fallen apart. The windscreen could fold down in the middle and was held together with a rubber seam in the middle, but that had deteriorated. I also installed a new rear view mirror on the top of the windscreen and a cool Ducati logo. Cal finished the motor installation. As mentioned, the motor retrofit took 40 hours, much more than the original 4 hours quoted. Cal builds bikes for a living; hes legitimate and I believed him. It was a lot of money, but oh well. I drove up to Leavenworth to pick up a trailer and pick up the cart. We took it out for a test ride and man was it fast, and LOUD. I was g

The engine needed some work, it was sluggish and I felt it could be better. I replaced the ignition coil, spark plug, crankcase breather, adjusted the valves, installed a new battery, new fuel filter, and changed the gear oil. The gear oil probably hadnt been changed in decades; it looked like grey mud. Gear oil is very heavy weight and is a golden color like cooking oil when its clean. Next I decided to replace the secondary clutch spring with the performance spring which had higher tension and was supposed to add more torque. I didnt notice it, but I did notice a reduction in top end speed. The new spring is in the center. Pain the ass to replace. I also replaced the carburetor, removed the governor so the cart could go faster, replaced the throttle cable, and fuel line. While doing this, the fuel filter came apart so I ordered a new one, which was a piece of shit and fell apart right away. I sent it back for a replacement and this time ordered something legitimate from

During the original rebuild, I tossed out the factory wire loom and created a new one. I ditched the factory lights and installed new tail lights with integrated turn signals and replaced the headlights with halogen driving lights. I installed a blade fusebox for the wiring under the dash and LED turn signal indicators in the dash also. That worked fine, but it wasn't practical because you had to reach way down and flip a toggle switch to activate the turn signals. I decided to order a turn signal lever designed for golf carts with a four-way flasher function that mounted to the steering column. For the headlights, I kept the toggle switch mounted to the dash, and then relocated the blade fusebox closer to the dash access doors. I also improved the wiring and added higher amperage fuses. I also installed higher wattage halogen bulbs for the headlights, but since they weren't street legal I had to order them online. Factory bulbs are 55watt, and the ones I order

After my parents bailed again to their winter home in Tucson for the winter of 2016-2017, I towed the cart back from Bellingham to Seattle for some tear down and rebuild work. When I do projects, I rarely work from formal plans. I loath structured work like that and prefer to do it as I go with an informal plan in my head. I had decided what I wanted to do was replace the front suspension, resolve the steering shakiness, replace the secondary (rear axle) clutch spring with a higher tension spring which delivered more torque, upgraded exhaust system, improved electrical system, higher wattage headlight bulbs, connect the horn, and some additional engine work. I started with the front suspension by ordering some 11 inch coil over springs that I bought on eBay I think. They were basically motorcycle shocks and much more rigid than the original 30 year old ones. They also looked cool. The first problem I discovered was the metal sleeve inside the bushing of each shock was too smal