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Unread 01-05-2011, 03:53 PM   #1
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Join Date: Jan 2011
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Default 1991 Gas G2... Grinding when put in reverse

I have been working to resurrect a 1991 Yamaha G2 for a summer camp that I work for. I have restored tractors before, but this is my first venture into golf carts. It was parked probably 6 to 8 for reasons unknown and not touched until now. After cleaning the carb, new fuel, new spark plug, and rebuilding the primary drive pulley, it runs srong and drives forward great ...

HOWEVER, it will not shift into reverse. From a stop, shifting it into reverse, the annoying beeper goes off, I press the gas, the engine starts, the drive belt spins, the drive pulley spins off of the transmission, but it goes nowhere. While stepping on the gas, there is a slight grinding sound occurring around the transmission. With the cart in reverse and pushing it by hand, the drive belt moves, so my assumption is that the dog in the transmission is engaging and I don't have broken teeth or a completely trashed transmission. I have not checked the F-R cable to see if when I by hand put it in reverse it will engage and it is just a loose cable, that's my next step.

But if it is not a loose cable, where do I go from there? Tear the transmission out and replace the shifting fork because it is probably worn down? Replace the dog? Thanks for any help you can give.
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Unread 01-05-2011, 06:11 PM   #2
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Default Re: 1991 Gas G2... Grinding when put in reverse

Most likley one or both f/r shift cables are not working (they work togeather to shift, so if one is bad, it can't fully actuate the shifter lever). I would tilt the seat and watch the actuation at the forward shifter cam and at the lever on the diff. You can adjust them, you can try to lube them, but changing both at the same time is the best policy...you won't want to do that job 2 times. Good luck
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Unread 01-06-2011, 07:59 AM   #3
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Default Re: 1991 Gas G2... Grinding when put in reverse

I checked the cables and watched the movement of the lever coming off the differential that the cables attach to. Both cables appear to be good, as the lever moved both directions without fuss. Is it possible that the shifting fork is not moving enough to shift it into reverse? Will adjusting the shift cable on the f-r lever under the seat up into the other hole troubleshoot whether it's moving enough?

My next move is to remove the muffler so I can get down there and by hand switch from forward to reverse. Hopefully that will help!?
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Unread 01-11-2011, 08:01 AM   #4
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Default Re: 1991 Gas G2... Grinding when put in reverse

Update: did a serial number search on this cart and discovered that the golf cart is not a 1991 like I supposed; it's a 1987. Learn something new every day.

Speaking of learning new things, in taking off the muffler to access the shift lever off of the transaxle/transmission, discovered why our cart is so loud. The seam weld between the manifold and the muffler is broken clean off. I'm going to try and get a guy I know who is good at welding to patch that up and avoid buying a new nearly $200 muffler for a 23 year old golf cart that is being used for a summer camp and likely to receive more abuse, I mean, well and hard use.

Now, to update you on the actual topic of this thread. I discovered that where the cable attached to the shifting lever on the transaxle/transmission, the lever top was slightly bent and the little cylindrical piece that held the cable was not sitting square in the fork. This obviously was disallowing the transmission from fully shifting into reverse. Bending the shifting lever back into shape, making sure the little cylindrical piece that held the cable was seated properly in the shift lever now that it is in its proper shape, and hitting the whole kitten-caboodle with some wd-40 and pb blaster fixed the problem. Thanks for your help and wish of good luck, smallblock450sl. I'm just glad it is solved and didn't evolve into a bigger fix or problem!
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reverse problem, transaxle, yamaha g2, yamaha gas carts
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