06-24-2011, 07:25 PM | #1 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
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Yamaha G1 budget build 500
Me and a few friends picked up this g1 golf cart for $300 delivered.
This will be a build thread of the entire restoration including installing a engine from a polaris indi 500 Its in rough shape and the engine is not running right but we have big plans for it... First up carb cleaning... Pretty simple just pulling it apart cleaning the jets and such So the carb cleaning didn't really fix the problems we were having with the engine. So after some investigating we found that the fuel pump was getting weaker we figured this was the problem so we ordered up a fuel pump. this didn't help... So rather than wasting a nice day we decided we would start on the body work. We couldn't get the steering wheel off so we had to unbolt the steering box and fish it through the body Prep work PO used a ton of bondo Sanding... |
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06-24-2011, 07:26 PM | #2 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
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Re: Yamaha G1 budget build 500
Engine work... Found a Problem
After pulling the belt off we found that the crankshaft had about a quarter inch of play it it... not good So we pulled the engine apart to see what we needed to order. Everything was pretty much shot. bearings, piston/cylinder, seals all trashed. Time to start searching for an engine... Fiberglass work... Our roller lol Then bondo Sanding Sanding and more Sanding |
06-24-2011, 07:32 PM | #3 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
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Re: Yamaha G1 budget build 500
We purchased a 89 polaris indy 500 for the price of $150
stuffed the bltch on a trailer Engine |
06-24-2011, 07:43 PM | #4 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
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Getting it running right
Although the engine was running when we bought it we couldn't get it to stay running.
So we cleaned the carbs, replaced the plugs, and drained the old gas. But the real problem was this: The open tubes you see in the pic above are apparently supposed to be plugged so any debris settles in the bottom of the tubes rather than the bowl. as you can see they were not plugged. It runs! |
06-24-2011, 07:51 PM | #5 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
|
Heart transplant...
Alright so now came the challenge of getting the engine out of the snowmobile.
Be sure to label things clearly All cleaned out And its out! gotta make sure to label it Most of this is useless Bringing the engine to the cart. |
06-24-2011, 08:00 PM | #6 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
|
Mounting the 500 (sort of)
Got a little done, and then it started to rain.
Bought some square tubing and marked off a measurement Put in this vice and cut it. Looks something like this The engine will sit kinda like this. We then went and removed the golf cart spaghetti Pretty good amount of clearance. We will have to bend and reshape the passenger side frame so it clears the block. We also may have to cut a notch in the driver side frame as well. |
08-08-2011, 07:11 PM | #7 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
|
Re: Yamaha G1 budget build 500
Up next Engine mounts...
Had to cut a slot in one of the mounts and then cut out a round section there Yeah... removed the gas tank and did some cleaning and prepping for welding tacked into place |
08-08-2011, 07:15 PM | #8 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
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Re: Yamaha G1 budget build 500
We have been putting the front back together so we can move it around easier.
wired wheeled some things and painted it. Nose is still waiting for paint... probably military green Got the engine rails fully welded and primed |
08-08-2011, 07:20 PM | #9 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
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Re: Yamaha G1 budget build 500
Some very "precise" holes
This is what the engine will sit on The engine is sitting in place A bit tight but nothing hits when the suspension is fully compressed |
08-08-2011, 07:27 PM | #10 |
Not Yet Wild
Join Date: Jul 2010
Location: MA
Posts: 38
|
Re: Yamaha G1 budget build 500
Some paint (no not the body)
Bolted the engine in again and of course forgot to put the belt on Time to figure out a redneck throttle In order to get a full throw on the carbs we had to take the peddle off and move a few splines back We also cut off the throttle stop thing on the back To be continued... |
Tags |
big block, build, governor, snowmobile engine, swap |
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