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Unread 01-18-2018, 04:07 PM   #1
Not Yet Wild
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Default 1989 G1 Rear axle bearing replacement

Hi all,

I am the caretaker of a 1989 Yamaha G1 2 stroke golf cart for an older lady that is not well off and she uses it for the feeding and care of her horses and boarding horses (oh did I mention she also has serious mobility issues). My daughters take riding lessons with her and while the girls are riding, I am fixing things around the farm.... of which the golf cart is but one. I got it running great last year with replacement crank seals and butterfly valves. The cart has been problem free until now. So, got a call yesterday stating the golf cart runs fine but won't move. Get over there and the whole wheel is about 3-4 inches out from the side of the cart. Come to find out the rear wheel/axle bearing had failed allowing the axle shaft to move out of the transmission, thus no movement. It appears no damage other than the failed bearing. Got a new bearing but for the life of me can't find any how to's on the internet on procedures for removing the old and replacing with the new... Any pointers?

Read some of the other threads on here, and does not appear to have welded collars. Not sure if bearing is pressed from the transmission end on or if the hub end is a press interference fit that needs heat on hub and cold on shaft to separate... Looking closely at the shaft, it appears to have a shoulder on the axle on the transmission side of the bearing which would prohibit pressing off in that direction. Hopefully the shaft is not welded to the hub. If it is, what are my options? Seems silly to have to get a whole new axle shaft assembly (including bearing) for a simple bearing replacement...
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Last edited by tom.robson; 01-18-2018 at 05:10 PM.. Reason: pictures and more detail
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Unread 01-18-2018, 06:02 PM   #2
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Default re: 1989 G1 Rear axle bearing replacement

Those bearings were installed before the hub flange was welded on the end, thus making bearing replacement nearly impossible after the hub is welded on. 2 options, find a different axle shaft to pop in there. Or, remove the welds holding the hub on, so the hub can be removed, then bearing race can be removed. Both are bad options, but it's all you got. You can see the weld on picture 2, at the center of the hub. Maybe you could drill and tap a hole in the end of the axle shaft to use a bolt to retain the hub for reassembly.
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Unread 01-18-2018, 09:10 PM   #3
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Default re: 1989 G1 Rear axle bearing replacement

Thanks cgtech. Was figuring that. I have a metal lathe in the garage so I will try and machine the weld off and see if I can get it separated. Should be easy to get back together with a spot weld and on each side to lock it in place.
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Unread 01-19-2018, 03:25 PM   #4
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Default Re: 1989 G1 Rear axle bearing replacement - Success

Successfully separated the hub and axle. Replaced the bearing and had the hub welded back on. Total cost $30 including the bearing. 6205-RS was the original bearing and it crossed to a 205-F from National Bearings/Federal Mogul. Looked at the cost for a replacement axle assembly initially and the least expensive of unknown quality was $75 used. New was over $170

I had to grind the weld off the end of the axle/hub and then beat the snot out of it to separate the two. Was going to try and machine it off with my lathe but the axle was too long to fit. Finally got it apart and discovered that it is just a press fit with no splines to stop rotation. The welded end of the axle is the only mechanism that stops rotation between the axle and hub. Reassembled the axle by putting the bearing on first using a deep socket and a vise to press it into place, next the spacer then the 4 bolt retaining plate and then the hub. Don't forget the retaining plate. It will ruin your day if you do. The only way to get it on is with the hub removed. Took the axle assembly to the local muffler shop and gave them $10 to run a bead or two around the end of the axle where it comes out of the hub. Pictures are worth a thousand words so here you go!
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Unread 01-19-2018, 06:16 PM   #5
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Default re: 1989 G1 Rear axle bearing replacement

RIGHT ON! Most everyone seems to shy away from the project when the necessary steps are described. $30 bucks for whole job too! SWEET.
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Unread 01-19-2018, 09:28 PM   #6
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Default re: 1989 G1 Rear axle bearing replacement

Great info and pictures. I never would have believed they would make the shaft with the step like that. Some have reported pressed collars, welded collars, and this later model looks different yet with no collar and a machined step. This thread would be great to link in the G1 axle bearing replacement sticky for reference.
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Unread 01-20-2018, 08:00 AM   #7
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Default re: 1989 G1 Rear axle bearing replacement

Nice job Might have opted for a sealed bearing on both sides.
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Unread 01-20-2018, 01:58 PM   #8
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Default re: 1989 G1 Rear axle bearing replacement

Yeah, thought about getting sealed bearing, but the inside is protected by the axle tube and also a secondary source of lubricant in the transmission lube also figured the original is identical to what I put back in and that lasted 28 years
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Unread 01-21-2018, 08:00 AM   #9
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Default Re: 1989 G1 Rear axle bearing replacement

Bearing part number corrected, and added to the Stickies! (Great fix!)
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Unread 01-22-2018, 07:08 PM   #10
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Default Re: 1989 G1 Rear axle bearing replacement

Went out to the farm to install the repaired axle today and took a closer look down the axle tube. Saw some debris from the destruction of the bearing and decided to pull the axle tube to clean it out. Unbolted the six 14mm bolts on the axle tube at the transmission and the four 15mm bolts at the axle tube support and removed it from the cart. Discovered the axle shaft seal was chewed up from the shaft disengaging itself from the transmission. Tried to source one locally to no avail using the part number on the seal. Finally pulled up the national seal dimensions chart and discovered the axle shaft transmission seal at the inboard end of the axle tube is identical to a National seal 222238 and is readily available from online suppliers. Was unable to get it locally without a 3 day delay plus shipping costs. Nobody carried it (NAPA, Advance Auto, Autozone, Oreilly's) but could order it. Seal pictures attached. I will post some more to this thread on Thursday after getting the new seal and installing it, the axle tube and axle shaft. Wish I had pulled the axle tube the same day I removed the axle. Would have had the seal in hand by now... Ah well, lesson learned
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Last edited by tom.robson; 01-22-2018 at 07:20 PM.. Reason: Pictures and more detail
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