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Unread 01-22-2019, 09:45 AM   #1
Not Yet Wild
 
Join Date: Oct 2018
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Default G2 - Piston Rings

Good morning all, looks like I will need to replace the rings on my G2.
Blue smoke, low compression but still runs.
Oil test in the piston when measuring compression has confirmed ring failure.

Looking at the service manuals on the web, I cannot find one with clear pictures that would help me in the process.

Looking for your help in confirming that I will have to remove the crankshaft to access the rings or can they be access by removing the valve body/cover?

Also, does anyone have a video of G2 ring replacements?

Thanks for your help
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Unread 01-22-2019, 10:24 AM   #2
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Default Re: G2 - Piston Rings

You won't have to remove the crankshaft, but I would recommend it to inspect it for wear. You will need to remove the head, engine side cover (clutch side) to get to the bolts holding the rod cap on.

Pull the head first and inspect the cylinder closely. If you can get away with deglazing the cylinder with a hone and using OEM rings, you might be all right. IF there's any scoring in the cylinder walls at all, don't bother boring it out, it won't last. Call plowman.

My G9 was smoking like a train, I called Don and talked to him and he explained all the reasons why nobody can bore this cylinder correctly. Quite a technical explanation, i was impressed with his knowledge. But since I had perfect compression, just smoke, I figured since I already had a new set of rings, gaskets, etc it was worth a shot. Worst case, I would still end up swapping with a plowman motor. I tore it down and confirmed my suspicions that the oil rings were toast. I got new rings, quick (and i mean QUICK) ran a hone through it just to clean up the glaze, and checked the cylinder for wear using a ring and feeler gauges. Cylinder was still true and not bell shaped, so put in new rings, bearings, etc. and it runs great, no problems. But I didn't have any scoring or anything in the cylinder walls whatsoever, I just cleaned off a bit of glaze. Took me about 2 hours to pull the motor, replace/hone everything, and put it back together. That was a while ago, no issues since.

IF the cylinder has to be bored, call Don. Or you'll be doing the same job again in about a year.

yamaha g2-g9 service manual
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Unread 01-22-2019, 11:18 AM   #3
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Default Re: G2 - Piston Rings

Quote:
Originally Posted by CP241 View Post
You won't have to remove the crankshaft, but I would recommend it to inspect it for wear. You will need to remove the head, engine side cover (clutch side) to get to the bolts holding the rod cap on.

Pull the head first and inspect the cylinder closely. If you can get away with deglazing the cylinder with a hone and using OEM rings, you might be all right. IF there's any scoring in the cylinder walls at all, don't bother boring it out, it won't last. Call plowman.

My G9 was smoking like a train, I called Don and talked to him and he explained all the reasons why nobody can bore this cylinder correctly. Quite a technical explanation, i was impressed with his knowledge. But since I had perfect compression, just smoke, I figured since I already had a new set of rings, gaskets, etc it was worth a shot. Worst case, I would still end up swapping with a plowman motor. I tore it down and confirmed my suspicions that the oil rings were toast. I got new rings, quick (and i mean QUICK) ran a hone through it just to clean up the glaze, and checked the cylinder for wear using a ring and feeler gauges. Cylinder was still true and not bell shaped, so put in new rings, bearings, etc. and it runs great, no problems. But I didn't have any scoring or anything in the cylinder walls whatsoever, I just cleaned off a bit of glaze. Took me about 2 hours to pull the motor, replace/hone everything, and put it back together. That was a while ago, no issues since.

IF the cylinder has to be bored, call Don. Or you'll be doing the same job again in about a year.

yamaha g2-g9 service manual

My yard cart has the Plowmans Hot setup. I have an extra engine, and sent that head to Don for custom work. I was going to rebuild that engine to put in the cart with all of Don's upgrades. I had the same conversation with Don that you had, and now, as weather permits, I'm breaking in my new Plowmans Powerplant. It's got some zip...
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Unread 01-22-2019, 01:12 PM   #4
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Default Re: G2 - Piston Rings

I bet it does! It was a while back when I spoke with him, so I don't remember the specifics but I do remember the big thing was when boring it, the grit used makes all the difference in the world. Most people use a 300 grit that eats the chrome off the rings, which is why they only last a year before they need rebuilt again. But using a 600 grit like Yamaha did from the factory, amongst other things he detailed, is what made that engine last 30 years to begin with. I know very little about machine work or boring a cylinder, so a lot of it was over my head to be honest. But it all made complete sense. If I didn't already have a new piston, rings, etc. in the box on the seat when I talked to him I would have just pulled it and shipped it off to him. But since I already had everything, decided to go ahead and do it. Worst case scenario, in a couple years i'm back where I started again. But the cylinder was in great shape and was clean as a whistle inside, no signs of sludge or even staining on anything... which really amazed me considering the condition the cart was in when I bought it.

Tough call between a plowman rebuild and the 23hp vegas cart upgrade. It was about $100 difference at the time, and that 23hp sounds like a lot of fun lol
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Unread 01-22-2019, 01:28 PM   #5
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Default Re: G2 - Piston Rings

He sent me a picture of the bore. It looked like a mirror.
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Unread 01-23-2019, 02:04 PM   #6
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Default Re: G2 - Piston Rings

Thanks for the information.
I was trying to avoid having to remove the engine from the cart but looks like I won't have a choice.

Would you know of any service like plowmans in Canada? As buying a rebuilt engine from the states would probably cost more than a new cart with all the duties and taxes.
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Unread 01-23-2019, 02:12 PM   #7
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Default Re: G2 - Piston Rings

Plowmans is in Flint, MI. Don Plowman is the wizard behind the curtain, there is no other substitute for the original.

And yes, you'll have to pull the engine. it's pretty easy though, I took the motor with starter/generator attached out all as one assembly. Just disconnect a few wires, exhaust, and carb. REmove the 4 motor mount bolts and it all just pulls right out. I didn't even have to remove the seat. Like I said, I spent 2 hours from when I started pulling it out, to back in and burning gas. IT's not hard to remove, takes maybe 10 minutes.
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Unread 01-23-2019, 05:48 PM   #8
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Default Re: G2 - Piston Rings

Ok, thanks
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