Very 'wet' exhaust on the G1

SteveKen

I just got into working on my '87 G1 (picked it up for a whopping $200)

The previous owner looks to have rebuilt or put a new carb on it.

I'm troubleshooting the engine and currently have the muffler and drive belt off. I'm pretty sure it's running and idles, but is spewing a lot of gas/oil out of the exhaust.

I'm pretty sure but not 100% sure it's running on it's own and not off the battery. I'm using an OEM Audi battery with like 900 CCA since I had it lying around. Hope I'm not doing any harm by using it.

Compression is 105 psi.

I plan on bbq'ing the muffler, but fear that I'll immediately clog it back up.

When I run it with the muffler, it smokes pretty good and I get a lot of fuel/oil blown by the rings of the exhaust flange where it meets the exhaust.

I followed the recommended settings in the manual about on turn past snug on the pilot screw and about 2.5 turns after the throttle stop screw touches the throttle lever.

Basically have the wet exhaust with no throttle response.

Any thoughts?

I'm totally new to the 2-stroke scene, but have heard nightmares about adjusting snowmobile carbs.

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

sho305

If its running, when you open the throttle it will rev up. It will also be pretty loud with no muffler. If its real rich, it will smoke a lot and '4 cycle' meaning it will miss a lot like chainsaws often do when not under load. They do that at idle but run smooth any time they are making the cart move.

The carbs are jetted, it should run with stock jet unless something else has been changed...has wrong carb on it, or wrong jet in it, etc. They jet like anything else, except if you jet to lean and run it hard they like to stick a piston. Make sure it does not have too much oil mixed in it or something, that could also change the mixture.

SteveKen

Thanks for the input. Maybe it's actually not really running on it's own.

I checked and do indeed have spark. If' it is merely running off the battery, any ideas what the issues could be?

I also didn't use the choke. I didn't think I needed to after seeing all the gas coming out the exhaust port.

There's also a new spark plug in there and it still looks brand new and had a light oily film on it.

Can anyone tell me the proper procedure for starting this beast?

Also after doing some research, my 105 psi compression number wasn't done at WOT. I'm thinking it will be higher if I retest the compression at WOT.

SteveKen

Update:

I decided to pull the coil and be sure that it wasn't running off the battery. There's clearly a different sound without spark and it's definitely running on it's own. I actually can get some throttle response without the muffler.

I put the muffler back on and the throttle response was gone. No power.

I also noticed Mr. Coffee under my clutch side of the motor. I'm guessing the crank seal has failed. I'll be replacing both sides I suppose.

I also re-checked the compression at WOT and it's still at 105 psi.

So here's the short list:

Three (3) new airbox clips
Pre-filter sponge element
Crank seals

Anything else I should do while I'm tearing things up a bit?

Also, I'm going to work on bypassing the governor as all the stock plastic linkages are broken or missing. If I do this, has anyone installed a tachometer? Also, what's the yellow line and red line on these motors?

sho305

You have to choke it hard and it maybe might run at higher rpm with bad seals if you can get it going. Get a new plug it may be fouled though likely its the seals unless something else is wrong inside. Likely fuel is from poor combustion.

Red line as in rpm? As much as it will spin. I ran one a little modified for years sometimes down a road for a mile with no problems....on stock 18" cart tires too. They say it can trash the generator at some point but I never had a problem with that or my G9 with no governor, but the 4 stroke can't get the rpm the G1 did that thing really screamed.

Cleaning/lubing the clutches is always a good idea if they need it. Poor shifting takes power away.

Does it have the exhaust valve on it? If so fix it open if you take the linkage off. Some carts did not have it all it really did was quiet them down at low throttle openings and may have helped plug the mufflers faster.

SteveKen

I've decided to do an engine refresh. Having the jug bored today and will order new piston kit, gaskets, seals, bearings and seals.

I'm currently working on making a flywheel puller and will then split the case.

I figure that I'll do up the motor now and worry about the looks and other mechanicals over winter.

I'll rebuild the fuel pump, oil pump, etc. as well.

DOOmsman

While its down find out what is the right carb
and jet for the engine.
You may go to all the work of rebuilding and
still have wrong parts.

kwest0425

DOOmsman and Sho305 are right. Make sure you have the right carb. I bought a 1982 G1 with a new carb on it. Turns out it was really a 1981 and the carbs are not interchangable. Got the correct carb and it made all the difference in the world.

As for the wet exhaust, I recently saw the same thing. I was converting to premixed gas/oil and was running the unmixed gas out of the fuel line and carb bowl while squirting oil directly into the carb (probably way to much oil). Saw a lot of smoke and wetness around the exhaust mount cylinder flange. Could you somehow be getting to much oil in the mix? For example, your oil injection is working and...you have oil/gas premix in the tank.

-kwest