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Old 06-24-2011, 07:25 PM   #1
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Default 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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Old 06-24-2011, 07:26 PM   #2
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Default 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



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Old 06-24-2011, 07:32 PM   #3
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Default 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

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Old 06-24-2011, 07:43 PM   #4
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Default 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!

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Old 06-24-2011, 07:51 PM   #5
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Default 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.

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Old 06-24-2011, 08:00 PM   #6
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Default 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.
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Old 08-08-2011, 07:11 PM   #7
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Default 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
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Old 08-08-2011, 07:15 PM   #8
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Default 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

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Old 08-08-2011, 07:20 PM   #9
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Default 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

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Old 08-08-2011, 07:27 PM   #10
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Default 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...
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