After seeing numerous posts about Yamaha's not starting, I figured that I would document an easy repair to a VERY common problem. The Yamaha stop switches are known to fail often, and this simple fix can potentially save you $50-$80.
If you are having intermittent starting problems when you step on the gas pedal this is most likely your problem. Meaning, you have to push the gas pedal a few times in order to get a proper contact. The stop switch pictured should be the same of both gas and electric, and ranging from G11 to G29 (Drive) models.
** It is advised to have the key turned off and the cart in neutral during this repair **
Remove plastic floor mat rivets with a flat headed screw driver, and pull back the mat to expose the floor plate.
Once floor plate is removed, you will see the stop switch located at the pedals. Switch is secured by two Phillips screws. Unplug the switch, and remove screws. (You will also need to open up the wiring harness retaining clip.
With backing plate facing upwards, carefully remove the four small Phillips screws. Keeping in mind that there is a spring with ball bearing behind the backing plate.
Once apart, clean the rocker plate with electrical contact cleaner. Paying particular attention to the contact area on the underside.
Now grab the other half of the switch and turn it upside down in the palm of your hand carefully, as not to drop the ball bearing or spring and lose them.
Once removed, take the spring and slightly stretch it. This will put more force on the rocker switch, and assure a better contact. You don't need to stretch it much.....probably 2-3mm. Note in the pictures above that the spring is barely seen under the ball bearing. Once stretched slightly, the spring should sit a higher in its mounting hole.
Re-assemble the switch and test prior to re-installing.
Plug the switch in and with the cart in NEAUTRAL, hold the plunger in and turn on the key. When plunger is released, your cart should turn over. Check this operation a few times prior to installation.
Be sure to turn ignition key to the off position again prior to installation. When re-installing the switch, it is helpful to push the gas pedal down to align the bolts.
You just saved yourself $50-$80 ........ Now go buy yourself a cold beer, and some other custom accessories
