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Old 09-13-2014, 10:28 AM   #1
1970buick
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Default G1 running issues ( I have searched)

So, the cart wasn't running at all, just turning over when I got it. I changed the plug, fuel filter, gas lines, and both crank seals. Now it fires up and runs but it is rather sporadic in rpm. I also put on a new clean primary clutch and the belts seem good. I have the exhaust off right now. So when it runs it sounds like it is revving pretty high but the speed of the rear tire is very slow when on jacks. It will not move more than 5 feet when on the ground. Same in reverse and forward. I checked compression and the cheap gage I have said 75. I put a table spoon of oil in the spark plug hole and then checked again and it was 130lbs. Does this mean a top end rebuild is needed? When the oil burns out I checked the compression again and it was down to 80lbs. Also, if it does need a top end rebuild is there a link for a step by step like the crank seal ones (which were awesome!) This is a J10 engine by the way.
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Old 09-13-2014, 11:23 AM   #2
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Default Re: G1 running issues ( I have searched)

The top end rebuild is even easier than the crank seals in my opinion. The hardest part is taking off all the stuff: carb, carb boot, plastic shroud, exhaust pipe. Once you do that you take the 4 head bolts off and remove the jug. The piston has a circlip that you need to remove for the wrist pin, slide that out, piston comes off. You'll have to take the jug to a machine shop to have it measured. If it needs an overbore, you'll have to order a piston and rings and cylinder and head gasket. Once you have the piston, take it and the jug to the machine shop and they will overbore to match the piston. Use lots of 2 cycle oil when you reassemble. Premix gas to 85:1, then after 100 hrs switch to 100:1.

Note: anytime you are doing engine work, I advise purchasing a genuine Yamaha service manual. You can get one from one of the sponsors.

Skill Level 6 out of 10 - if you did the seals, this will be easy.
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Old 09-15-2014, 06:51 AM   #3
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Default Re: G1 running issues ( I have searched)

I ordered a service manual this weekend. Just looking over everything quickly, I did not see the need for any additional special tools for the top end rebuild (I already have clutch pull on 3 hole remover) I ordered all the parts needed for the top end and an extra set of gaskets in case they rip or anything. Is it worth it to use 2 head gaskets as other members have done? Does this raise compression?

On another note, I am going to disassemble the driven clutch and clean it up and put in a performance spring.

I also want to adjust the governor while I am at it but I believe a previous owner has disabled it. Can someone post a pic of theirs so I know what I am looking for? I see a cable going to the throttle linkage and there is a bracket hanging on the cable that looks as if it may have been attached to the rear frame. Sorry, I am just a visual learner and it is hard for me to determine with no pictures.
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Old 09-15-2014, 07:10 AM   #4
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Default Re: G1 running issues ( I have searched)

One other quick question... I took the cotter pin out of the castle nut on the very outside of the driven clutch and soaked it with PB Blaster over the last couple days. Is there a trick to getting the castle nut off? It seems as if my clutch moves even with the rear wheels chocked and the brake on.
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Old 09-15-2014, 03:12 PM   #5
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Default Re: G1 running issues ( I have searched)

Using 2 head gaskets will lower compression, not sure why you'd want to do that. Just use one.

The stock throttle setups on the G1's were a nightmare because it was an extensive network of linkages that go from the exhaust butterfly valve to the carb to the governor lever on the rear end. Very complex. Just eliminate it and have the throttle cable go directly to the carb. You'll get more speed that way and better throttle response. You might have to get creative how you mount the cable to a bracket.

If your input shaft rotates on the rear end housing but does not spin the tires....that's no good. It's likely that you have a broken input shaft or gear inside the rear end.
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Old 09-15-2014, 04:51 PM   #6
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Default Re: G1 running issues ( I have searched)

Quote:
Originally Posted by slonomo View Post

If your input shaft rotates on the rear end housing but does not spin the tires....that's no good. It's likely that you have a broken input shaft or gear inside the rear end.
Well $h!t, looks like that is going to be the end of this project. I should have checked that before I ordered all the engine rebuild parts. It does move but I have to turn it about a half turn before the wheel moves.
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Old 09-15-2014, 05:26 PM   #7
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Default Re: G1 running issues ( I have searched)

So ok, maybe I'm misunderstanding you.

When you turn the input shaft on the transaxle, does either wheel spin?

If yes, then you should be ok.

If no, then there is a disconnect between the input shaft and the axles. Damage has occurred.
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Old 09-15-2014, 05:38 PM   #8
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Default Re: G1 running issues ( I have searched)

Quote:
Originally Posted by slonomo View Post
So ok, maybe I'm misunderstanding you.

When you turn the input shaft on the transaxle, does either wheel spin?

If yes, then you should be ok.

If no, then there is a disconnect between the input shaft and the axles. Damage has occurred.
OK, hopefully crisis averted. Maybe I wasn't turning it hard enough or the wheel was slipping on the grass. I got it off BUT now I need to go get new bolts because my puller doesn't have 6mm bolts and the center bolt that you turn is too long and is hitting the frame.
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Old 09-20-2014, 01:48 PM   #9
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Default Re: G1 running issues ( I have searched)

Today I put on a new jug and piston. Took about 2 hours. Man, fired it up and it ran awesome. I did some break in with the new rings and then took it for a spin. Top speed I got was 15mph. Looking to go faster. Any ideas? It has great torque off the bat and cruised nicely.
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Old 09-20-2014, 03:41 PM   #10
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Default Re: G1 running issues ( I have searched)

Went back and looked around some more and got some fresh gas. I noticed the linkage to the exhaust butterfly was off and fixed that. Took it for another spin and gained 3 mph and a lot of low end torque. Topped out at 18 this time and can easily spin out on grass. Rethinking the performance clutch spring I have coming. Not sure that it needs it in the low end. (we don't have any hills around here...all sea level)
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