Yamaha G1 Clutch Questions

1946J3Cub

Both drive and secondary clutches came off my G1 easily. Bought a puller for the primary, made homemade one for the secondary. Should I polish the sheaves smooth and shiny or not?

Ramps on secondary are slightly scored, grooved sort of like the rotors on disc brakes get. Should I have a machine shop smooth their surfaces? Put another way; are the ramp surfaces smooth when new? I figured that if they should be smoothed I'd have a machine shop do it due to their slight spiral.

Lastly, any pointers for removal/replacement of the ramp pucks/shoes? Pucks in relatively decent shape but because clutch is apart and they're rather cheap figured I'd replace them. Perhaps grooves on ramps are because the pucks weren't replaced in a timely fashion?

Because the cart is: My first cart and new to me I figured I'd familiarize myself with it by removing, cleaning, refurbishing the clutches (original as far as I can tell) and replace the crank seals for starters.

Must say I'm glad I held out for a G1 which is what I wanted. It's been fun tinkering in the two weeks I've owned it.

Thanks,

Tom

BGW

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Lochlin

Yes, those clutch faces should be smooth. I never knew a machine shops could do that. If true that's a real money saver.

Are you sure you want to monkey with the clutch weights and ramps? The pucks don't go bad and I can't imagine the grooves having any impact on performance unless they were burred or something.

1946J3Cub

Actually, I didn't plan on messing with the weights (which I believe are on the primary/drive clutch). It's the ramps on the secondary/driven clutch that are grooved. I think I'll check with a machine shop to see if the grooves can be smoothed a little. If not I'll just put on new pucks and be done with it. Thanks for your reply. Think I'll get the surface rust off one of the sheaves and smooth them all up a bit.

Tom

mikeasis

post pics of the sheaves if you can.

I replaced half the ramp shoes on my g1 (for forward) and what a PITA
you want to do it while the secondary is apart as a small punch knocks them out from the small hole below them.

I had such a hard time i thought of installing my spare secondary clutch which has the black shoes. of the 6 shoes i had i was able to get in the 3 for forward and broke the rest.

After searching ebay the black shoes are shorter, don't know why but after comparing with my spare clutch i belive the black ones will fit better and be easier to install. i think the black ones are intended to be for the G2. Now i cant swear to this but when i can I'm ordering a set and taking apart the secondary and trying them out.

Big Bopper

On the primary clutch there are 4 fingers in the clutch held in with 2 Phillips screws each. Should I grease the shafts or just clean them?

Spicyunicorn

Clean them is fine no grease the grease will collect dirt and gum up over time

Big Bopper

Thank you for responding so quickly

sho305

It would be 3d programming in a CNC mill, a lathe could do it easier but still some work. You have to measure it and then program to it. I just sanded my old one before I bought a new one. When they get worn through from the belt you have to buy one anyway, that dish also makes them shift poorly. Another issue is if you cut them down (the ramps) you are shortening the length from the sheave, this can change how it shifts a little.

I'd like to machine mine to a different angle, but it looks pretty involved and I'd have to weld them up higher or something. Its a project I don't have time for. I did do that to my old one but only the slow speed part, it worked well. IMO the ramps are not proper angle for our lifted cart use.

Molon Labe

I bought new plastic ramps from ebay for less than $10.