G1 Thread: Everything About G1's for Newbies
 

I thought I'd contribute a thread dedicated to G1 information geared toward new G1 owners. Here they can find all the great threads with pics and info about their "new to them" G1 golf carts.

Please post info only, no questions. Start a new thread for questions.

Please post links to "good" threads that contain quality info and pics.

Please do not post anything other than "good info" relating to G1's.

This thread will contain the basics about G1 carts, maintenance, common problems and solutions, lift kit and tire information, and custom modifications.

Let's keep this thread clean for the new forum members so they can read "everything" about G1's.

Thanks to everyone that wants to contribute, and good luck!

Re: G1 Thread: Everything About G1's for Newbies
 

I'll start with a basic overview of the G1 gas carts.

Yamaha G1 Golf cart
Built from 1979 to 1986
Available in both 2 stroke gas and electric models

Timeline http://www.yamahagolfcar.com/corpora...rtimeline.aspx

Serial # ID http://www.3rsalesandservice.com/3r-...amaha-year.asp

G1 GAS:
The G1 gas cart is a 215cc two stroke oil injected engine. The engine was derived from a snowmobile engine, possibly the Enticer 250 since some of the parts are interchangeable and the block castings are nearly identical. They are known for their ruggedness and durability, as some of these carts are 30 yrs or older and still going strong!

Reverse gear does not exist on these carts, rather the engine turns backwards to get reverse. You'll note on the inner fender on the passenger side there are a set of solenoids. These are the components that allow the engine to start backwards and run in reverse.

The factory oil injection system mixes the oil automatically at ratios ranging from 150:1 to 300:1, according to the service manual. Sometimes these injection systems can fail and cause engine damage, so often times people disconnect them and use premixed oil/gas. Reported premix ratios range from 40:1 to 100:1, maybe even higher, and are "at your own risk". I am not recommending this modification, simply reporting what I've found on this forum. Please do this modification at your own risk and be aware that engine damage and failure can result if the mix ratio is not correct.

Power for these carts is in the 8hp range, give or take 1 depending upon weather, fuel, and driving conditions. Getting more power is not easy on these engines because they are low compression, low rpm engines and are not really designed for max power. Switching to a "big block" is not usually a good option because you would lose your reverse and would need to swap out the rear end/transaxle to a 4 stroke model with a reverse gear.

Speed of these carts have been reported around 12-15mph with the governor intact and as high as 30mph with the governor modified. Do not modify your governor or engine damage could result.

Body parts are both plastic and fiberglass. The front fenders/clip portion is some sort of a plastic material and the rear section is a reinforced fiberglass with a steel framework that tilts up for engine access.

Year Identification is typically done by verifying the serial number on the frame. The common location is behind the rear bumper on the round main frame. The number is stamped/engraved and might not be visible if there is alot of rust and dirt. Clean the area off and lightly sand the area with a scotchbrite type pad to reveal the numbers. Do not sand off the paint or rust will start there.

Lift kits are available from a couple aftermarket mfgs and some people choose to install their own fabricated lift. 4" lift is required for 20" tires. 5-6" lift is required for 22" tires. Any more than 22" tires will require some kind of a custom lift and/or swing arm drop, which is quite a lot of work for most. Some frame trimming in the wheel wells may be needed. The frame may need modified to allow clearance for the primary clutch.

Re: G1 Thread: Everything About G1's for Newbies
 

My first recommendation is to purchase a service manual from one of our fine sponsors. The manual contains specs, procedures, drawings of pretty much everything you need to know to work on your G1. All of the info you need on the following problems can be solved with the info in the manual. Read through the entire manual and you'll learn a ton!:thumbup:

Common Problems

Since most of the G1's are high use carts and very old, your typical issues come up... tune up issues, spark plug, air filter, fuel filter, carb cleaning, clutch maintenance, belts, old gas, oil mix, dead battery, etc.

Compression needs to be in the 100psi range to run good, and a fresh rebuild should have around 120-130psi. If you happen to have a 1982 model, sorry but your engine is a lower compression unit and will be around 90-100psi. The 1982 model was Yamaha's attempt to calm down emission and noise, but they scrapped that idea when they realized how much performance was lost and for 1983 went right back to normal. Lower compression is most commonly caused by worn piston rings or oil seals.

Frame rust is always an issue, particularly in the battery tray area. Alot of people over the years cut the old tray out and don't replace it. There are a number of ways to replace the tray, but a custom fab job is likely what needs done. Some new metal angle, sheet metal, a new hold down, some cutting and welding and paint will be in the project. Some other areas are the cross tubes and swing arms because they see the most action and dirt/grime and get washed off the least. Again custom fab to repair.

Oil Injector failure is something that comes up, although I've never seen one fail, I have heard reports of that happening. If this happens it will likely cause engine damage.

Oil seals for the crankshaft are common wear points. If you have trouble starting your cart or it runs poorly, the oil seals are one of the common causes. Worn seals will cause lower compression and poor performance. Look behind the primary clutch and see if there is wetness or oil residue on the crankshaft. If so you'll likely need to to replace the seals.

Clutch issues will cause poor power and speed. The primary clutch can accumulate dirt and grease and cause the clutch to not engage properly. Taking the cover off and cleaning all the dirt and gunk out regularly will go a long way to restore performance. Don't forget to lube the shaft with a tiny amount of grease, too much will cause it to fly out into the clutch housing. The secondary clutches often wear through and/or "dish out". This causes the cart to not have a high top speed, or can cause it to have no low end power.

Drive belts will often wear out/down and cause poor shift out and poor power/speed. Replace belts regularly and measure them to make sure they are in spec.

Fuel pumps often fail in these carts. You can rebuild/clean yours so read up on that. New ones can be found for around $40-50. Or you can rig up a fuel pump from a tractor. If you don't have fuel at the carb, look to the pump or fuel filter.

Old gas is really a basic that people often forget. The gas in the tank from a cart that has been sitting is likely not any good. And likewise the gas in your gas can from last fall may not be that good either. If you can't get your cart running, buy some fresh gas and try a new plug. Don't forget to fill the oil reservoir!

More to come.....

Re: G1 Thread: Everything About G1's for Newbies
 

:thumbup:


So here is a quick walk though putting crank seal in the clutch side of a G1.



Step 1. remove the gas tank

http://www.buggiesgonewild.com/attac...1-sam_0203.jpg
Attachment 42603




Step 2. remove the outer clutch cover via the Phillips head screw
http://www.buggiesgonewild.com/attac...1-sam_0204.jpg
Attachment 42604


Step 3. Remove the long bolt holding the outer clutch plate one (7/8" head)Remove the outer clutch plate


Step 4. Remove the drive belt and starter belt.
http://www.buggiesgonewild.com/attac...1-sam_0205.jpg
Attachment 42605





Step 5. Using a clutch puller (can be bought or you can make your own. I bought mine) remove the inner clutch plate/shaft
http://www.buggiesgonewild.com/attac...1-sam_0206.jpg
Attachment 42606




Step 6. Remove the oil pump gear housing and pull BOTH the inner and outer housing off of the engine case
http://www.buggiesgonewild.com/attac...1-sam_0207.jpg
Attachment 42607

Step 7. run a screw into the seal and using a claw hammer pry the old seal out.

Step 8. put the new seal in (put some oil on the part of the seal where it slides on the crank shaft to keep it from catching and tearing).

Step 9. Reinstall everything the way it came off.

Hope this helps



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~



http://www.buggiesgonewild.com/gas-y...-fan-side.html





,

Re: G1 Thread: Everything About G1's for Newbies
 

I would have to say that the electrical is by far the #1 issue with these carts. The sticky up top ( so your yami won't start) is very helpful, take your time and go through it twice or more. Don't think that it couldn't be that, double check it and you'll find the problem.

Re: G1 Thread: Everything About G1's for Newbies
 

Here's the link

http://www.buggiesgonewild.com/gas-y...turn-over.html

Re: G1 Thread: Everything About G1's for Newbies
 

Fuel Pump

Here is the link to the fuel pump thread. If you have checked the fuel line at the carb and you aren't getting fuel, it could be your fuel pump or fuel filter. Change or remove the filter first. If that's not it, check this link....

http://www.buggiesgonewild.com/gas-y...fuel-pump.html

Re: G1 Thread: Everything About G1's for Newbies
 

First of all, great idea on this thread Slo! :thumbup: I'm a newbie myself (bought my G1 last fall) I've found lots of great info on this site. One tidbit I came across (Sorry, no link as I don't remember where :lhmo: ) Has to do with what I'm guessing would be a common upgrade, adding lights.

The frame on the G1 is NOT grounded. If you wish to add lights or other electrical accessories you will have to run a ground lead as well as a positive lead back to the battery. Many of the new light assemblies for tailights, marker lights, etc for auto/trailer applications don't even have a ground wire. They rely on a screw into metal to ground. You can still use these, just mount with a machine screw and attach a ground lead to the back side with a nut and washer. I'll try and get some pics of my tailight install up this weekend.

Re: G1 Thread: Everything About G1's for Newbies
 

Solenoids:

These parts are mounted on the passenger side inner fenderwell and are responsible for directing power to the starter/gen. One solenoid is used for forward operation. The other is used for reverse. If you are having trouble with one direction but not the other, look to these solenoid or the related wiring. If you do not have a service manual, this would be one area that you should consider getting one to help you. The wiring diagrams will help you figure out where things go and what does what.

Some related links:

http://www.buggiesgonewild.com/gas-y...id-please.html

http://www.buggiesgonewild.com/gas-y...-diagrams.html

Alot of the problems I've read about have been attributed to loose connections, corrosion on terminals and connections, and frayed or chaffed wires. Make sure you get a really good flashlight and trace the wires you think are suspect and inspect them from one end to the other. Most times you'll find the issue.

Re: G1 Thread: Everything About G1's for Newbies
 

I'm going to stick this thread by Monday, so if you look for it, it will be in the top section. That way it doesn't get lost. Lots of great info. Thanks.

Re: G1 Thread: Everything About G1's for Newbies
 

How to make your G1 idle





~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~



Newbie Restoring a G1 - Great info



http://www.buggiesgonewild.com/gas-y...tml#post437477





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Re: G1 Thread: Everything About G1's for Newbies
 

Moosin- The G1's are grounded to the frame and to the battery. Here is a color wiring diagram I made up based on the one out of my manual and it plainly states "grounded to chassis"

http://i460.photobucket.com/albums/q...0G1/Wiring.jpg

This is the scan of the manual

http://i460.photobucket.com/albums/q...ps814bfa2e.jpg

Re: G1 Thread: Everything About G1's for Newbies
 

I swear some posts disappeared from this thread...

To contribute some info/ideas - pics:

- RV battery box/fuse block
- rear platform w/ hitch
- brake light switch
- Fuel gauge sending unit

I can email a PDF drawing if someone is interested in platform. I wanted something a little different for the rear seat platform.

Sending unit is Sunpro universal from Summit Racing (about $15). Brake switch is from Orielly's (for a '69 Charger - like $8). I fashioned a bracket that mounts to main bolt. Hope these are helpful!

Re: G1 Thread: Everything About G1's for Newbies
 

I cleaned it up on request.

Re: G1 Thread: Everything About G1's for Newbies
 

I noticed that, and thank you for helping this one out and making it a sticky! This really needed done for the G1 crowd. More build info coming....

Thanks all for contributing!:thumbup:

Re: G1 Thread: Everything About G1's for Newbies
 

Serial Numbers...

We seem to all have trouble with cart years/serial number. Thanks to KY_Mike who's chassis thread lead me to the numbers on the crank case. My G1 is a 1983.

Frame numbers on mine are long gone, but this should be an easy to fine SN for folks trying to determine year. You can see the numbers on the photo.

Re: G1 Thread: Everything About G1's for Newbies
 

G1 with the frame cut, --- i don't like doing it this way, but it works,

or heat it and dent the frame



http://i985.photobucket.com/albums/a...100_4419-1.jpg






Heat and dent

http://i985.photobucket.com/albums/a...2ae3095176.jpg



http://i985.photobucket.com/albums/a...d9d6d4b9d7.jpg

Re: G1 Thread: Everything About G1's for Newbies
 

Mildly useful information - steering wheel from Yamaha Rhino fits G1. This was confirmed by others, and is shown here mounted. I scored this super-clean one off Ebay for $25!:thumbup:

Re: G1 Thread: Everything About G1's for Newbies
 

That's a good tip with the Rhino steering wheel! Thanks:thumbup:

Re: G1 Thread: Everything About G1's for Newbies
 

Another tip - this one is a supplier.

I found trim fasteners @ Lowes for 52-cents each ($1.04 for a 2-pack) that fit in the holes, but that is expensive. I found same ones online at clipsandfasteners.com. Purchased 45 fasteners for $17.

They are perfect for holes for flooring and trim piece(s) on top of front body panel. Search for PAS1603 (item number is picture caption).

Re: G1 Thread: Everything About G1's for Newbies
 

:thumbup:

Re: G1 Thread: Everything About G1's for Newbies
 

Here's some links to seal replacement....:thumbup:

http://www.buggiesgonewild.com/gas-y...ent-files.html

Re: G1 Thread: Everything About G1's for Newbies
 

Here you go. Just google "yamaha G1 clutch tool" and you'll find it all over the place. Check with our sponsors page first!

Re: G1 solenoid repair rather than replacement
 

http://www.buggiesgonewild.com/gas-y...newbies-4.html




When your new parts arrive, it will be more obvious what i am talking about.

Re: G1 Thread: Everything About G1's for Newbies
 

somehow this got added to the stickies without the rest of the story that goes with it. these are the terminals that must be unsoldered if you were going to remove the caps for repair. if you do not unsolder them the solenoid coil will be destroyed

Two little things.
If the cap on your little oil tank cracks or fails somehow. A gas cap for a B&G lawnmower fits perfectly and costs far less than one that has Yamaha on it.

If you need a new sealed choke cable but don't want to pay for the OEM. You can get one at Tractor Supply Company for 12 bucks in the Tractor parts. It is generic, but robust. It is sealed in a plastic black tube, so it will not rust like the ones wrapped in spiral wire. It is not quite long enough to reach your dash, so route it out between the two front seats. It works great and is inexpensive.

http://tapatalk.imageshack.com/v2/15...53a0bdd2ea.jpg

Re: G1 Thread: Everything About G1's for Newbies
 

I found out that g2 light kits actually fits g1s good they aren't perfect but look sharp and come with a complete wire harness and switch and very easy to install
can usually find on-line for 80-100 for front and rear

Re: G1 Thread: Everything About G1's for Newbies
 

Thanks Very good info

Re: G1 Thread: Everything About G1's for Newbies
 

Glad this thread gets a lot of views....hope it helps out! :thumbup:

Re: G1 Thread: Everything About G1's for Newbies
 

So does anyone on here know where i can buy a Jet Sensor for an 83 G1

Re: G1 Thread: Everything About G1's for Newbies
 

Try starting your own thread, someone will see it an chime in. This thread is for G1 helpful info, trying to keep it clean. :thumbup:

Re: G1 Thread: Everything About G1's for Newbies
 

G1 negative fuse blowing why

Re: G1 Thread: Everything About G1's for Newbies
 

A total newbie myself n am goin bald trying to figure out why my '89 G1 got no spark!!! Upon purchase r/r batt & starter/generator....that got the bad boy started but sputtered n didn't move much...r/r the cdi & coil/plug...still nada, but did read abt the muffler being clogged so am tryin that today...just wanted to say great thread tho...ok took off muffler and still no friggin spark. Think my cdi is screwed tho bc I am reading millions on the orange. That or my magneto...any takers here????

Re: G1 Thread: Everything About G1's for Newbies
 

Thanks for the thread. I just purchased a 1982 G1. The serial number post helped me to date it. Unfortunately another post informed me that it was the low compression year. (Of course)

Re: G1 Thread: Everything About G1's for Newbies
 

Thanks for starting this, I just bought an '83 G1. Looking forward to doing to upgrades and making it look sharp.

Re: G1 Thread: Everything About G1's for Newbies
 

Fresh gas without ethanol really is a must.

This is a great thread on the never say die G1. Beyond normal maintenance I have only had to replace the crank seals in the 22 years of ownership. I use it service my three acre yard. I added a steel box and a custom roll cage and recently repainted the maize and blue paint scheme. Over the last 7 years the cart developed the need to choke the carb every time I started it whether cold or hot. I am a bit slow on recognizing and taking action to prevent leaving stale fuel in the 6.5 gallon tank. I stabilize my fuel but since 2000 all local gas is 10% ethanol. My tank was getting low so I connected my electric fuel pump and drained out the last gallon and poured in 2.5 gallons of fresh Recreational stabilized 91 octane Rec fuel is 100% gasoline. No ethanol.

It immediately started to get better. That is, simply depress the gas pedal and it starts right up like it should. Lesson learned. The gallon of stale fuel with go into my lease car.::lol:

This winter I will drain the fuel for winter storage.

I found the Rec fuel by searching the Puregas website. The nearest station is 30 minute drive. Non ethanol Rec fuel costs $.70 a gallon more.

Bill

Re: G1 Thread: Everything About G1's for Newbies
 

Any one have any info on a G1 enclosure? I have the original top and some of the encloses are not wide enough Looking for something that will keep me dry and keep the wind out on chilly nights while I drive . Thank you

Re: G1 Thread: Everything About G1's for Newbies
 

Anyone know the thread specifications for the primary fixed sheave on a 1980 G1. When I pulled mine off with a brand new puller I had a problem when I went to back the puller out of the sheave. This was all done by hand, no power tools involved until I had to take it out of the sheave. I want to see if the sheave was damaged or if it was just the puller. Looking into the threads on the sheave it, they look to be OK. See picture of puller.

Re: G1 Thread: Everything About G1's for Newbies
 

Anyone have a good wire diagram for the 1980 G1? Can’t find one that uses the older style solenoids

Re: G1 Thread: Everything About G1's for Newbies
 

Newbie also have a G1 was running fine then no cranking at all. If she sits a while can turn key to reverse, get the tone, but when hit the pedal tone goes off, there is a click from the solenoids but no crank and no more tone. If I leave it a couple days and try again, I get the reverse tone, but same results if I hit the pedal no crank and no more reverse tone. Tonight turned to reverse, get tone, hit pedal and still click from solenoid, tone goes off but no crank, checked solenoids when I hit pedal and have the key for either forward or reverse and hit the pedal I'm getting contact thru both solenoids, but shouldn't only one solenoid show voltage for forward and other for reverse? When key is off no voltage on closed side. So question is would this be a switch problem somehow causing both forward and reverse solenoid to kick in or is it CDI, or is it the starter/gen? Appreciate any help.