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Unread 02-07-2016, 11:53 AM   #1
Getting Wild
 
hardway's Avatar
Yamaha
 
Join Date: Jan 2016
Location: Illinois
Posts: 134
Default what i've done so far

Replaced tension cable, drilled out exhaust studs and re tapped, updated helix to a g8 model, put on Plowman clutch, rejetted carb, and drank a few adult beverages. That was yesterday.
Old clutch plates looked fine to me, I probably only needed a helix , spring, and belt. Saving old clutch plates cause who knows what my cart future is.
Helix was a must. So was tension cable. Changed oil, smelt like gas, now I need to work on that. Drained fuel tank to replace fuel filter. Found my fuel gauge. Too cloudy to read easily,never knew it was even there.
Cart was running 12mph when we started, now it doesn't run.
Plowmans does not include gaskets so now we have to wait for another delivery.
Could not have got this far without help from members here and an thumbs up to my son for help.
Bought a cart to have fun with friends and family, so far so good.
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Unread 02-07-2016, 12:07 PM   #2
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Yamaha
 
Join Date: Sep 2012
Location: Missouri
Posts: 2,756
Default Re: what i've done so far

Waiting is the hard part. But it looks like your heading the right direction with the build.

Continue to post updates with pictures. Some of us are like little kids.... We can't read without pictures.
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Unread 02-07-2016, 12:10 PM   #3
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Default Re: what i've done so far

What gasket are you missing? Did you get exhaust and modify air box or just secondary clutch kit?
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Unread 02-07-2016, 12:17 PM   #4
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Location: Illinois
Posts: 134
Default Re: what i've done so far

Got Plowman muffler and it did not include gasket. Also pulled carb to clean and rejet, so I need that gasket also. I drained fuel so I could check fuel filter and it was rough, so I ordered 1 of those also.
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Unread 02-07-2016, 12:34 PM   #5
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Default Re: what i've done so far

Quote:
Originally Posted by hardway View Post
Got Plowman muffler and it did not include gasket. Also pulled carb to clean and rejet, so I need that gasket also. I drained fuel so I could check fuel filter and it was rough, so I ordered 1 of those also.
Should be able to reuse old exhaust gasket,did you get a Yamaha fuel filter?just curious many people say the aftermarket ones leak you can just cut filter off and use inline filter on line to carbthat's what many have donealso did you figure out the oil leak? Is it leaking from the primary clutch side seal? If so that's a simple repair alsogonna be a blast next time you ride it! I was impressed with the performance gains from the plowmans kitand if you have questions they will help you!
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Unread 02-07-2016, 01:55 PM   #6
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Location: Illinois
Posts: 134
Default Re: what i've done so far

The oil is blowing into the air box. It has apparently done this for some time. A previous owner drilled out the bottom off air box and tray it sits on. I need to keep gas out off oil (obviously). When I changed oil I jacked up the back to level pan off to get all oil out, refilled and now I will notch dip stick so I know where true full is. If I continue to get blowback I will take another approach.
Once I figure it out I will seal bottom of box.
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Unread 02-07-2016, 01:55 PM   #7
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Location: AZ
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Default Re: what i've done so far

I agree, gut the old filter & add an inline filter for easier future service...
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Unread 02-07-2016, 06:10 PM   #8
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Default Re: what i've done so far

Quote:
Originally Posted by hardway View Post
The oil is blowing into the air box. It has apparently done this for some time. A previous owner drilled out the bottom off air box and tray it sits on. I need to keep gas out off oil (obviously). When I changed oil I jacked up the back to level pan off to get all oil out, refilled and now I will notch dip stick so I know where true full is. If I continue to get blowback I will take another approach.
Once I figure it out I will seal bottom of box.
If you are getting fuel in the airbox check your needle and seat in the carb the little rubber tip of it mine looked like a pez dispenser good luck
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Unread 02-08-2016, 03:46 AM   #9
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Yamaha
 
Join Date: Jun 2009
Location: Phoenix
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Default Re: what i've done so far

Order 2 carb/intake gaskets and I'd order 2 exhaust gaskets, (having an extra one never hurts. There is a gasket on each side of the carb intake manifold (plastic spacer). Need to make sure the plastic spacer is not cracked and that the studs in it are still tight. New gaskets are soft and seal much better than old ones that have been hot. So you don't have to sinch down the nuts and screws as tight!!

I would seal the hole in the air box, even if it's with duct tape. Air box needs a good tight seal for car to run right!!

You may find that the new filter/cap, at gas tank, leaks at the threads, so hold on the the old one!!
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Unread 02-08-2016, 10:20 PM   #10
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Yamaha
 
Join Date: Jun 2009
Location: West MI
Posts: 13,809
Default Re: what i've done so far

I bought a new filter and it didn't have the big o ring in it. The old filter looked good to me, I put it back in and put a clear inline near the carb. It has worked fine for years and now with the clone in it.

Lot of people do zero work on carts, you get things working right you will have a big grin! And you will know what you have.
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