Yamaha G22E electric cart high speed gear

itstheburns327

Does anyone know how to remove the drive gear (or primary gear) from the rear end of a Yamaha G22E electric cart? i am trying to install a high speed gearset into this cart and this is where i am stumped. i have pictures of inside the gearbox of the gear i need to remove. on the outside, there are 2 rubber covers, one on each side of the case that cover the gear. any help will be appreciated!

Kevin

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BGW

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smallblock450sl

Don't know about being rubber, but those are plugs (simular to freeze plugs in an engine block). I always just drilled a 1/8 hole in the center (just need to go thru the metal) and then use a screw to pop them out (the screw will touch the shaft, so damage will not incure). Now the fun part....behind the plug you will have circlips that hold the bearings in, take them off..now the really fun part, tap the shaft (from the input shaft side) from the bearing race, use a bearing removal puller to get the bearing out. Repeat procedure on the other side bearing. Then pull out the shaft and gears. Install new gear, install bearings in reverse remove procedure, might want to lube/grease the orings, install new plugs or if not to damaged, reuse old ones and silcone the hole really well. Install the new ring gear,make shure to put the bolts back in the direction they were before and torque to 40 ft lbs. torque diff bearing caps to 40 ft lbs also. Hoped that helped.

itstheburns327

Well! Yes that did help. Unfortunatly i had figured it out prior to receiving the reply lol. It was very simple. The hardest part was removing the old gear off the input shaft. i had to go to my machine shop and press it out and press the new gear in. this was a simple install. I was told that this will require special tools and isn't possible to do by any average Joe... well i think the average person could pull this off, just as long as they know a little something about bearings. This cart went from a stock 14-16mph to 25-29 mph! I am going to upgrade the controller, battery cables, and eventually the motor.

smallblock450sl

Good for you (I forgot you have to press on the new gear) The stock controller (300 amp) can handle the gears unless your trying to climb hills. Keep us posted and lets see some pic' of your cart.