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Old 05-03-2013, 09:51 PM   #1
johnray13
Not Yet Wild
Yamaha
 
Join Date: May 2013
Location: Chantilly, Va
Posts: 27
Default G9A overhaul project

Newbie here and a short background on this project:
Last year I bought some property in the mountains. My family goes out there quit a bit, including my mom and dad who are getting up there in the years. Mom has a bum knee and has a hard time getting around. My parents love the place and spend as much time as they can there with my boys and all the rest of the family and grand kids, as both my brothers are close by. I think it's great and wanted to encourage my folks to come out and stay active and have fun with all the little ones running around. I suggested to my dad the he should get a golf cart for mom to help her get around.

So today my dad picked up a G9A gasser for mom. Truth is, we will all use this thing and it'll be perfect for camp, getting to the river, hauling the cooler around...etc. My 7 year old was having the time of his life driving it around the back yard tonight. He wants to be Nana's chauffeur.

He brought it by tonight for me to take a look at.

The 1995 car looks okay and runs decent with some intermittent smoke. But it is leaking oil. After a once over on the motor, I think the seller band-aided it together for the sale. The oil, air filter and spark plug are all new. There is also a lot of RTV sealant on several gaskets and hoses.
After a 5 minute once over, I think maybe the oil could be coming from the breather but there was a puddle on the driveway after sitting for only 30 minutes. I really won't know more until I get a little deeper.

So tomorrow I will start getting into this. I tend to have moderate to severe OCD with motors and if the past is any indication, I will end up doing a rebuild. This would be the fifth motor since March...my wife just closes her eyes, shake her head and walks away...

I'd like to do a pic by pic from start to finish. If anyone has a copy of the shop manual for the G9A, It'll help out for sure.

Here is where I am starting from, with the close ups of the breather and oil puddled on the motor just under the muffler.

John
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Old 05-03-2013, 10:20 PM   #2
jackel440
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Yamaha
 
Join Date: Aug 2009
Location: Galveston,IN
Posts: 386
Default Re: G9A overhaul project

Welcome to the board
Nice looking cart you got there.
I can't help you on the engine as when I got my G9 the wrist pin was almost seized and wouldn't run.So I swapped in a clone engine into it.I love how tough these yamahas are.good luck with yours
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Old 05-04-2013, 09:49 PM   #3
Honorstick
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Join Date: Apr 2012
Location: Northern Michigan
Posts: 841
Default Re: G9A overhaul project

johnray

PM me an email address and I can help you out with a copy of the owner's manual and service manual that I have for the G9. I love mine and it seems to have plenty of power for the traveling through the woods that I do, hauling another rider, myself and a deer or two.

Bill
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Old 05-04-2013, 10:19 PM   #4
slonomo
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Join Date: Oct 2009
Location: Medina, Ohio (NEOHIO)
Posts: 11,421
Default Re: G9A overhaul project

Oil leaking that bad is never a good sign, you know that though, right? So you won't know what's wrong until you get it apart. You might want to think about that clone install though, I've read up on in and it's not all that hard. You might just spend the same amount of money in a full rebuild on the stock engine. I know I did on my G1. That's a good cart to build, no matter what you do to it! Good luck and post lots of pics!
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Old 05-04-2013, 10:22 PM   #5
Tonka329
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Location: Limestone, Illinois
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Default Re: G9A overhaul project

Good pick up!
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Old 05-05-2013, 01:03 AM   #6
johnray13
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Yamaha
 
Join Date: May 2013
Location: Chantilly, Va
Posts: 27
Default Re: G9A overhaul project

Bill- PM in route as soon as I earn that privilege.

I didn't get to the oil leak today-got hung up on the primary sheave. I noticed that it had a hole in in so I pulled it to have a look. One of the weight link assemblies had cracked and came apart. I looked up the part number...and found it online for $50! Wow.

I had some aluminum plate in the shop so I decided to just make one.
I ripped the plate on my table saw, traced the shape and cut in on my Port-a-band with an improvised table. I finished off the shape with a belt sander and drilled the holes.

The only thing left to do was reassemble it and press the pins in with my shop press. I am happy with how it turned out. I'll get the sheave reinstalled in the morning.
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Old 05-05-2013, 01:08 AM   #7
johnray13
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Default Re: G9A overhaul project

A few more
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Old 05-05-2013, 01:11 AM   #8
johnray13
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Default Re: G9A overhaul project

The finished part..
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Old 05-05-2013, 01:29 AM   #9
Honorstick
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Default Re: G9A overhaul project

Nice work!!!
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Old 05-05-2013, 06:25 AM   #10
johnray13
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Default Re: G9A overhaul project

Bill, PM en route.
Thanks- John
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