G1 No Spark

troutbum

I have a G1 Gas cart and am having an issue. Here is the back story, I use my cart on a hunting lease and the thing is amazing. The ATV guys are always giving me a hard time saying that thing won't go here or there and it always does. So Saturday, we were turkey hunting and tried to cross a big mud hole. Unknown to us it had a bunch of logs in it and we slipped of into a rut high centering on a log. Me and my son them proceeded to spend 2 hours trying to get it out. Finally had to call a buddy & have him pull me out. after the cart wouldn't run so had to be towed back to camp. Cart ran fine even while we were stuck but finally won't fire, turns over but not firing.

Checked it Sunday and it doesn't have any spark. Replaced Plug to be safe. Can someone in layman's terms, I not a mechanic can fix stuff but ignition is my weak point, explain where the spark for the plug is initiated? I am assuming it is generated by the rotation on the flywheel but where is that located? Main question is could I have gotten mud/dirty water in the flywheel where that would prevent it from sparking? Or could us cycling the engine on and off trying to get unstuck worn out the CDI? I know this is kind of long winded but, need to get this fixed been without her for a day and already missing her LOL.

BGW

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Spicyunicorn

I'd start with checking all fuses then on the passenger side back corner there is four wires coming out of the motor check those connections of the four wires iv seen them unplugg

Lochlin

How deep was the cart submerged? If it was over the engine for a couple of hours then you probably have some work to do.

Here is a repair manual:

http://www.buggiesgonewild.com/garag...ir-manual.html

You'll see electrical in CH 7. If that thing was submerged you are probably going to need, at minimum, a CDI and coil as those are somewhat frail components. The magento (under the flywheel) solenoids and voltage regulator are a little more hardy and if there were allowed to dry they might be ok.

Just to make sure, your cart is turning over so the starter / generator is spinning? Some people equate no spark with not turning over at all. In reality those are two different things.

troutbum

Thanks, it was not submerged in the water. The water was being thrown up on the engine by the tires. It was sitting on the frame and the water was just up to the bottom of the frame, wasn't even up to the center of the wheel hubs.

I think it's either that dirt got up in the fly wheel and gummed up that, or the CDI just went bad. I'm going to look at it this weekend again. I got a cheaper used CDI to test it with. I'm planning on wash it up real good and will keep everyone updated.

Thanks for the input.

troutbum

Thanks for the repair manual, its been very helpful.

Its been a heck of a couple of weeks for the little cart that could. We went down Saturday to get it from Hunting camp, so we could bring it home and work on it. On the way home it broke the front strap, looks like sharp edge cut strap. It came off the trailer at 50 mph. It traveled down the road about a 1/4 of mile before driving off the shoulder down a steep bank and smashing into tree, lucky it was on a back country road with no traffic, thank God. Its a sinking feeling when you hear a thud look in your side mirror and see your golf cart driving down the road behind you. It really did a pretty good job as a self driving cart, until it used a tree to apply the brakes.

Anyway, when it applied the tree brakes, it bent front bumper into the body and rim on left side, bending the rim, blowing out the tire and pushing on the body. Tree brake was applied so abruptly, that it ripped the back of the bench seat off and slung it out into the woods. As a self driver it did good gotta work on the stopping part. It looked like the little cart was done, almost made me want to cry.

But, when people say you cant kill these things it true. I Got it home, we removed front bumper and fixed rim with a chisel and hammer. It broke one side of the tie-rod mount, but we were able to reattach it, think if I weld on a couple of grad 8 washers top and bottom it will be as good as new. Bent the rear of aluminum body where it fell off trailer but, have been able to pound out most of the damage. It bent side panel/ cover along drivers side and supports that hold the body, should be able to repair this too. It cracked the body around the cupholders and steering wheel. But, it didn't bend the frame or anything that will make it go down the road cattywampus, that a technical term for out of alignment. It did break the drive belt guess its not meant to travel 50 mph, which concerned me, but it rolls fine, trust me I know had to push it up a the steep shoulder and load it back on the trailer. Therefore, I am assuming the differential is fine.

After removing the bumper, I think that its gonna be fine. Anyone who ever says there cart is tougher than a Yamaha G1, just ask them if it will survive falling off a trailer at 50 mph and still work. If not then it can't be as tough as this little cart.

Good news is, we were able to get it running, it was just debris on the Magneto/Flywheel. Anybody have any experience pulling the flywheel off. I removed the fan and was able to get some gunk out of it but, would like to remove it and clean it out properly. I know I need a way to hold the flywheel, so it cant turn, when I'm removing the nut. However, do I need a puller to get the flywheel off? Is there suppose to be any kind of grease in the flywheel, mine is caked up with some funky looking stuff, of course I doubt this has been off since it was put together in Japan. Again I can only see it through the holes in the flywheel. I would like to clean it up right, any help would be greatly appreciated. I have ordered a new belt and will keep everyone updated on the progress.

CP241

sounds to me like it was trying to escape so it chewed through the strap and made a run for it. Like one of my dogs when it's bath time... Almost made it too, if only that tree didn't feel like it had to jump in front of it, could have been a clean getaway.

lol sorry to hear all that sounds like quite the event.

I'd make sure to soak the bolt real well with penetrating oil. If there's that much mud in there i'm sure won't come off nicely... but you should be able to use the harmonic balancer puller at harbor freight. they work for pretty much anything

Spicyunicorn

Impact is best to remove it but if you don't have one make sure Piston is about half way up it's stroke (you want the ports closed up) then feed clean rope into the hole until you can get anymore in it and the Piston will come up and smash the rope and allow you to get the nut off if you don't have a impact and use this same method when going back together make sure to torque the nut to 52 ft/lbs

troutbum

Your dog sounds like my dog. I'm just curious how they know your going to give them a bath. I take a shower everyday but as soon as I start think about sticking him in there he runs and hides under the bed.

Thanks guys, surprisingly that area was clean. Its just seems to be inside the fly wheel itself and really appears to be just a combination of 35 years of dust, dirt and grease mixed together. Kind of has the consistency of dirty drier Vaseline. May just keep doing what I'm doing, just cleaning out a little at a time by spraying part cleaner in there, or its running so maybe just let it be. I did find a small pulley holding tool at Northern Tool today but its for smaller pulleys. I didn't think about a harmonic puller.

Spicyunicorn, I've got a dewalt cordless impact wrench. But, more than anything, thanks for explaining the rope thing. I saw that on a post and for the life of me couldn't figure out what the heck to do with the rope lol. Learn something new everyday.

Spicyunicorn

If it's really caked on back there you may as well mark the timinf plate and pull it off right behind it is the crank seal you will have the hard part done inspect it and probably be worth replacing

CP241

Well, we have 5 great pyrenees (moat of which came from up near your neck of the woods). They're working dogs so the only time they get hooked to a leash they know it's either bath time, or vet time lol. Neither of which is a pretty outcome (our male is 140+ lbs and doesn't have a clue how to walk on tile floors. Think giant white furry Scooby doo... Luckily he is SUPER furry so he slides nicely lol because you aren't gonna pick him up!)

As long as there's threaded holes to grab, the harmonic puller would be the first tool I'd reach for. And a strap wrench (or a chain wrench with an old belt) can also work well to hold the pulley while breaking the bolt loose if you don't have an impact. But I'm with the unicorn, if it's never been off and there's that much gunk back there it's probably worth pulling it to replace the crank seal. You clean up all the nasty stuff that's accumulated it you may create a leak that 2as sealed by 35 years of dirt, dust, and mud!