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Old 05-23-2011, 07:31 PM   #1
Not Yet Wild
 
Join Date: May 2011
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Default Poorly running Yamaha

Greetings. New to the forum, new to golf carts. If the introductions were meant for the Intro forum, then I appologize. Live here in Viriginia, and I myself don't have a cart, but my neighbor just picked one up, and I'd like to help him get it running right. The neighbors are an older couple with mobility issues, so I'd like to see the cart fixed up right. I've been working on cars for 8 years now, so engines don't frighten me, but carbs do! Slightly.

Anyhow, he's got a 93 cart, looks like a G2 or G9, based on some info I've seen on the forum, and the cart runs, but poorly. He took me up and back the street, and the cart barely made it back up the road (smallest grade ever). I believe it's running rich, black smoke comes out the exhaust when running it in neutral, and seems to run very poorly. Cart has a new starter on it, and a new carb.

My neighbor had a local small engine guy out to check it out today, and the mechanic told my neighbor rough news, said the rings were toast, would probably need a new block. Said it was filling the air cleaner up with oil. And showed that if the hose from valve cover to air cleaner is removed it runs better.

I really haven't tinkered with it much, but told him I'd bring my compression gauge home from work tomorrow and we'd hopefully disprove the shot rings theory. Typically on cars I see around 150 psi off my gauge, expect similiar for this Yamaha? And I was taught that if rings are bad, a teaspoon of oil down the spark plug hole would boost the compression reading, and mainly confirm bad rings.

Anyhow, thoughts on things to check? I'm completely new to carts, but have taken appart a riding mower engine twice with good results, and have had plenty of car engines into pieces. Looking forward to the new challenge, thanks for any tips and help too.
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Old 05-24-2011, 08:21 AM   #2
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Default Re: Poorly running Yamaha

If you overfill the oil they will puke it into the airbox and generally trash the filter. I would drain the oil they take 1 qt, dump a qt in and the level if not lifted should be full or near. Never put more than that much oil in. Lifted it will read around half full and you should notch the stick there. What happens often with a lot of miles, is the oil ring goes bad but the compression rings still work so it runs. Comp should be around 180 for a fresh engine 150 should still run, the G2 is a little higher than G9. G9 is 91 and up iirc, it has black steering column and black rockers while they are white on a G2. Not much other difference except for the compression change. If the oil ring is bad it will smoke blue oil smoke all the time and burn oil, and carbon the plug. You will need a new airfilter unless you can clean it somehow gas didn't seem to work for me. The airbox needs to be sealed well or they will not run right, get new straps or bungee it tight, try to get the rubber elbow in there installed right. A new plug should have it going and it will smoke if the oil ring is actually bad, mostly blue smoke and all the time. Use the plug for the newer G14 its an ngk 2es not the 4(?) a G2/9 calls for. They are more resistant to fouling and my yami dealer told me to use it. If the oil ring is bad, then its rebuild time. You can slap rings in it and it will run ok, or full rebuild, or pull the motor the dealer here and sure others have swap engines you can drop in or have that one done.

Welcome to BGW of course, lots of helpful people here. Also keep an eye on wiring connection issues, well known problem but mostly free to fix. The carts are not frame grounded so the grounds (wire connections) can go bad and cause issues.

Black smoke could be from rich condition if the airfilter is plugged with oil, hard to say. I would do above and run it some to clear the cylinder and muffler and see what you get. If it keeps on smoking after a while it needs a rebuild otherwise it should clear up and run ok. The bad oil ring ones I have seen make blue smoke all the time once in a while some white smoke, plug will look ugly black. They stop smoking when the oil level gets low, that is why you ALWAYS check oil level if you buy a cart.
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Old 05-25-2011, 06:13 AM   #3
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Default Re: Poorly running Yamaha

I called a friend in town who worked at a golf cart shop for 5 years. He also pointed out the importance of the air box being sealed properly. I never would've thought of that myself.

I was going to check out the cart yesterday, but forgot my 8 month old son had swim class...and the pure joy of dunking a helpless baby in a pool was too much for me to pass up. I'll see if I can check the compression and airbox this evening. Thanks for your thoughts, I'll let you know what I find.
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Old 05-25-2011, 10:58 AM   #4
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Default Re: Poorly running Yamaha

Some Asian stuff is very particular about that, yamaha is one of them. You can rejet the carb instead.

8mo, likely still remembers how to swim lol. They still give you a nice treat every few hours, you can't keep up they always win.
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Old 05-25-2011, 06:27 PM   #5
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Default Re: Poorly running Yamaha

Well I checked the compression this evening, and I don't believe that's an issue. The gauge quickly bumped up over 150, to around 160psi. Then I went after the air box which had only one clamp holding it on. The three others were missing with one plastic tab broken off the lower box. My local buddy suggested just driving a screw in where the tab was and secure it to that. The seal between the two parts of the air box was in shambles, and the little rubber elbow inside was folded over. There was also a pool of oil on the bottom of the air filter side of the box, and the prefilter had oil on it, as well as a good bit on the air filter.

The dipstick showed a pinch over the Max mark, so I suggested he drain a little oil, and get a new airbox seal, filter, and clean out the box. He was going to look into that little rubber elbow as well, and grab a few more rubber clamps to make sure everything is secure.

Will probably be into next week before we get into that, but a big thanks for your help so far.

Since I tinkered with the carb, and so did the small engine guru (who did so with the air cleaner off) (course I would've thought nothing of that myself until I heard of its importance), what is the proper way to adjust it? Best I could tell there were only two adjustments, the throttle plate stop screw, and one diagnal screw down into the carb which I'm guessing adjusts the mixture. The vertical screw in the carb seems that it is meant to be snug. Any further tips are welcome, and I'll let you know how we progress.
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Old 05-25-2011, 07:04 PM   #6
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Default Re: Poorly running Yamaha

They will run with the hose off the carb, my best guess is because a bare carb does not flow well a velocity stack is much better....not that it runs right that way. The elbow does not seem to affect it as much as the cover seal. You might bend it and clamp it down, come back the next day and it might stay straight.

The best way to set the carb is st idle mix (on side) at 1.5 turn out. Then set the idle speed low as it will idle and not be running on the starter. Fine tune the mixture leaner, then turn it out .25 turn. Reset idle speed if needed. That is a hair rich and it will start faster that way and not pop when you slow down. None of that has anything to do with how it runs at 25% and more throttle.
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Old 05-25-2011, 09:03 PM   #7
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Default Re: Poorly running Yamaha

Hay Rat, I bet ur out buyin a cart after you get your neighbors nunnin!!

Its a disease!!
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Old 06-02-2011, 07:41 PM   #8
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Default Re: Poorly running Yamaha

I fear I had the disease before he bought his cart! I was almost diving headfirst into building a cart from the ground up about 2 years ago, then our first born came. Now we're expecting another. I suppose I'll have to wait until my son can turn a wrench before I can coax mom into letting me burn through the coffers.

But alas, the update. I came home from work today and my pal is driving his cart full speed up quite a hill. He pulls along side my car grinning like a Cheshire cat, and says "That did it! It's fixed." I clean up and run over to check it out, and he's got the airbox sealed up tight. Nice screw holding in the one rubber clamp where the hook had broken off the lower box. Anyhow, he says he changed the oil and got the level proper, and also cleaned out the airbox and sealed it up tight, and sure enough the cart runs great. I hopped on, and he zipped around full throttle and the cart runs wide open where ever he steers, barely slowing for hills.

I helped him replace the throttle cable which the guy who sold him the cart sent as a freebee. Not too much wrong with the last one, but it was a fairly simple swap, but anyrate, big thanks to sho305 for his suggestions. Cart runs wonderfully.
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Old 06-02-2011, 09:19 PM   #9
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Default Re: Poorly running Yamaha

Cool deal! Yeah the little ones sure do trash your project time, unless you somehow happen to have a woman who loves to mind little crumb grabbers 24/7.
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Old 06-03-2011, 06:18 AM   #10
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Default Re: Poorly running Yamaha

Just had the same problem here on a 92' G9

Found problem to be the ground wire that is pigtailed into the starter generator wire was not getting ground. Took connection loose and ran a jumper wire from that wire directly to the neg post on battery and runs fine. Just be sure you check the carb spacer for cracks,air box is sealed also. Hope this helps? Keep us posted on what you find.
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