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Old 01-14-2013, 10:16 PM   #1
smp258
Not Yet Wild
Yamaha
 
Join Date: Apr 2011
Location: Sedalia, MO
Posts: 9
Default '96 G16 restoration... Minor build

First post

I picked up the cart for $300 on Saturday. It runs and drives but there are some issues. The guy who had it before me was a good friend, who is not one to fix things, so he sold it to me and bought himself a new cart.

I played golf with him this summer and the cart would run great until it got warm, the engine would keep running but the primary clutch would quit grabbing the belt, and the cart would not go up an incline of 2 degrees .

This is my first cart so I don't know much about them, but I grew up working on cars, motorcycles, etc with my dad and love to tinker, so I figured for $300 I couldn't lose.

I have been reading this site and will keep reading, but any help will be much appreciated.

Here is a copy from my note book with added pictures on what i plan on doing.

Engine:
Compression test - 140 psi, good to go
New NGK plug - had a NGK bpr5es, replaced with bpr2es
Change oil - done
New air filter - ordered
Check engine mounts for cracks - engine moves a solid inch when pushed by hand, must be bad (should I just order them? Or is this normal function?)
Check that battery volts increase to 14/15 volts while running to verify its charging - will do after everything else

Primary Clutch:
Check rollers - this is the worst one, TRASH! do I need an entire clutch kit, or just rollers?

Check weights - not sure how to check
Sheaths - look good and straight

Secondary Clutch:
I'm not sure i really know what to check yet.
Check spring - pending taking it apart
Check plastic ramp sliders - should I replace?

Sheaths - look good and straight

Grease both clutches - after rebuild

Body paint (roll on method):
Before


During




After:
Will update with pics

Supplies:
Bondo for scratches in body
Plastic Jb weld for filling no step holes
Duplicolor adhesion promoter cp199
Tack cloth
Duplicolor premium sandable primer
1 quart Rust scat topcoat deep royal blue (Ben Moore) from Dugan's paint and flooring - my family owns
1 quart Acetone
1 can Deep royal blue spray paint for unroll able areas - Dugan's
4 - High density foam rollers - Dugan's
320 grit - prep
600 grit - prep
800 grit - in between every 2 top coats
1000 grit then 1500 grit then 2000 grit - after 8-10 top coats
2 coats rubbing compound
2 coats polishing compound with a new pad
2 coats wax

Roof:
Paint roof with duplicolor bumper coating black - done
Paint roof supports with Bed liner - done
Almost done


Rolling chassis:
Clean and repaint where necessary
12" Black wheels w/ low profile tires - 2/5 offset? I want them to be flush, i.e. no poke, no tuck
Fix Steering play - very minor but might as well do everything I can
Check brakes - pending
Lubricate chassis - need to research where
Change Differential oil with sae 90 gear oil .42 liters - pending

Other:
Locking dash - probably going to get a faux carbon fibre one
Has a light kit - need to cleanly rewire
Reupholster seats - not sure of direction to go yet

I know it needs cleaned badly, but it too cold outside right now. Haha
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Old 01-15-2013, 07:14 AM   #2
gray horse
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Join Date: Aug 2012
Location: Colona, Illinois
Posts: 473
Default Re: '96 G16 restoration... Minor build

Lookin good so far. Seems like you've got the right ideas. Keep the pics coming.
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Old 01-15-2013, 08:10 AM   #3
Todd Dolfi
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Location: Ohio
Posts: 1,143
Default Re: '96 G16 restoration... Minor build

Hell of a deal for $300 U can't go wrong..
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Old 01-15-2013, 08:25 AM   #4
hello
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Join Date: Sep 2010
Location: ontario
Posts: 182
Default Re: '96 G16 restoration... Minor build

Hi if you want to change out your rollers go to cart part plus cpp he has the roller repair kit just did mine last week.
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Old 01-15-2013, 11:19 AM   #5
smp258
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Yamaha
 
Join Date: Apr 2011
Location: Sedalia, MO
Posts: 9
Default Re: '96 G16 restoration... Minor build

Thanks guys. I will keep the pics coming as I work on the cart. I am a CPA and with tax season coming up, I'm going to have very limited time to work on it, so I'm trying get everything done as fast as I can.

Hello - I hadn't looked at CPP yet, but I just placed an order for a couple parts including the roller kit. I called them to verify that all I needed was the roller and the guy I talked to was very knowledgeable. The parts were also cheaper than anywhere else I looked and had free shipping. I will be ordering from them again.
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Old 01-15-2013, 11:00 PM   #6
smp258
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Yamaha
 
Join Date: Apr 2011
Location: Sedalia, MO
Posts: 9
Default Re: '96 G16 restoration... Minor build

I suck at using filler. I didn't realize how fast it cures, so I mixed up way to much at once and used most of the hardener. And I put it on way to thick, which took a lot more sanding than necessary. I guess you got to learn somehow.

I finished priming and rolled on the first coat of 8-10. Tomorrow night I lay the 2nd coat. Then Wednesday, sand and 3rd coat. Thursday, 4th coat, and on and on. You have to wait 6 hours in between coats according to what I have read.




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Old 01-20-2013, 03:53 PM   #7
smp258
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Yamaha
 
Join Date: Apr 2011
Location: Sedalia, MO
Posts: 9
Default Re: '96 G16 restoration... Minor build

Got everything running perfect, finished the paint job, and added a missile switch!

I'm done for now.... But I want to get a windshield, black seat covers, low profile tires and 12" wheels, add a couple USB ports for cell phone charging, etc...





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Old 01-21-2013, 08:15 AM   #8
gray horse
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Default Re: '96 G16 restoration... Minor build

Cart turned out great. Like the launch switch.
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Old 01-21-2013, 01:54 PM   #9
smp258
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Yamaha
 
Join Date: Apr 2011
Location: Sedalia, MO
Posts: 9
Default Re: '96 G16 restoration... Minor build

Thank you. It turned out perfect for me. I'm just glad I got it running the way it should. I'm actually thinking about selling it and using it for the seed money to buy more carts and fix them up. I really enjoyed fixing it up.
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Old 01-21-2013, 06:41 PM   #10
stuff4mason
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Join Date: Sep 2010
Location: Middle of Virginia, USA
Posts: 4,265
Default Re: '96 G16 restoration... Minor build

Quote:
Originally Posted by smp258 View Post
Thank you. It turned out perfect for me. I'm just glad I got it running the way it should. I'm actually thinking about selling it and using it for the seed money to buy more carts and fix them up. I really enjoyed fixing it up.
Oh man! You got the bug....it is very dangerous. Before you know it, you'll have 4 parts carts and be thinking about quiting your job and open a golf cart shop!!! I think just about every one of us has caught the bug!!!
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