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Gas Yamaha Gas Yamaha Golf Cars; G1 through "The Drive" and U-Max Utility Vehicles



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Old 06-17-2015, 11:22 PM   #1
stalt
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Default G1 CDI bad or am I doing it wrong?

Hi there, Have an 84 G1 and it was working this spring then all of a sudden it started to miss and then finally stopped with no spark ( On the 3rd hole..with the wife)!! The starter motor is still turning and will move the cart very slowly but I decided to tow it to not wear out the starter motor. Been reading around and also have the service manual.

Took spark plug out and checked for spark. Wanted to be sure it was not bad gas or seals etc. Confirmed no spark.

Took wires off CDI and checked for resistance and continuity. The manual says there should be no continuity to ground. The Brown wire HAS continuity to ground.

So I am pretty sure the CDI is toast and I will go through the cheap CDI build, but not being a professional I thought someone might have another idea or something else to check? Or am I missing something?

Any input would be appreciated.
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Old 06-20-2015, 11:38 AM   #2
stalt
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Default Re: G1 CDI bad or am I doing it wrong?

Well no responses so I guess I will go ahead and order.

Did some more research. Found what I think are the right CDI an wiring harness. Can anyone confirm?

CDI
Link to Amazon Link to Amazon


Wiring Harness -
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Old 06-20-2015, 11:56 AM   #3
1989Marathon
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Default Re: G1 CDI bad or am I doing it wrong?

Before you buy anything, disconnect the black, and black/white wires from the switch under the gas pedal, and see if you get spark when pressing the pedal.
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Old 06-20-2015, 12:30 PM   #4
stalt
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Default Re: G1 CDI bad or am I doing it wrong?

Heading to the campground later today. I'll give that a try. I did check that switch earlier this spring when I was having Starter motor problems and it was working correctly, but I guess it could have always just failed by coincidence.
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Old 06-20-2015, 12:36 PM   #5
1989Marathon
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Default Re: G1 CDI bad or am I doing it wrong?

You know it's a dual switch right?
Black, black/white open when pedal pressed.(ignition circuit)
White, red/white close when pedal pressed.(starter circuit)
Both need to be zero ohms when closed, and OL when open.
No continuity between the 2 sets of contacts inside the switch.
Everything checked with switch disconnected.
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Old 06-20-2015, 01:33 PM   #6
stalt
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Default Re: G1 CDI bad or am I doing it wrong?

Well.....it does fire with those 2 wires disconnected! Had to choke the crap out of it to start but after a while it worked as expected. Could only turn off by turning key. So new stop switch I am guessing??!!lol!
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Old 06-20-2015, 01:51 PM   #7
stalt
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Default Re: G1 CDI bad or am I doing it wrong?

Ok I disconnected all 4 wires at the switch and got the following

black and black white reads 0 at rest and 1 when gas pedal pressed
Red and white reads 1 when at rest and 0 when gas pedal pressed.

That's what is expected correct?
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Old 06-20-2015, 02:02 PM   #8
stalt
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Default Re: G1 CDI bad or am I doing it wrong?

Stumped again.

Reconnected the accl/ stop switch and everything seems to be working....for how long I don't know. Does it point to a faulty accl/ stop switch? Might it be corroded? The rubber boot for sure is cracked and water could easily get in there.
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Old 06-20-2015, 02:29 PM   #9
cgtech
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Default Re: G1 CDI bad or am I doing it wrong?

Points to bad start/stop switch to me.
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Old 06-20-2015, 02:49 PM   #10
stalt
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Default Re: G1 CDI bad or am I doing it wrong?

Once it got going I took it for a short drive around the campground and it operated normally, however when I got back to our site I lifted the seat and the muffler was smoking right at the exhaust port. It looked like had been some moisture dripping out of that connection down onto the starter motor guard. gave it a wipe and it was oil and gas. That has me a bit more concerned. It may have been leaking during my initial test, but the muffler may not have been hot enough to cause the smoking and I didn't notice it. I took the exhaust butterfly apart last year and cleaned it all up as it was sticking. It moves freely now, but not sure why there would be this oil and gas seepage....and not sure why that would have caused the earlier no spark issue. I am running a mix of about 70-1 gas/oil.

Any thoughts?
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