G16 Body Removal

[Mike D]

I'm getting close to painting my G16. Got the paint and the other materials, and am going to start the small amount of bodywork that needs tto be done this week. My questions are, does anyone have the steps for body removal? I imagine that the service manual has it laid out, but of course I don't have a manual yet. The front section of the body doesn't seem too hard. The rear section appears more involved. How is the F/R handle removed so paint can be sprayed there? I'm also having some problems finding all of the fasteners that hold the body on. Does the plastic tray or well on the back of the cart need to be removed to expose more fasteners? What about the plastic fender covers that state "No Step" on them? Can I take those off, or do they need to be there to cover some kind of holes? Unfortunately, I looked the body over very quickly, so I haven't had much time to research these things without consulting everyone on the forum. If there is a difference, the cart is a 1999. Thanks for any help provided.

[technoid]

Originally Posted by Mike D

I'm getting close to painting my G16. Got the paint and the other materials, and am going to start the small amount of bodywork that needs tto be done this week. My questions are, does anyone have the steps for body removal? I imagine that the service manual has it laid out, but of course I don't have a manual yet. The front section of the body doesn't seem too hard. The rear section appears more involved. How is the F/R handle removed so paint can be sprayed there? I'm also having some problems finding all of the fasteners that hold the body on. Does the plastic tray or well on the back of the cart need to be removed to expose more fasteners? What about the plastic fender covers that state "No Step" on them? Can I take those off, or do they need to be there to cover some kind of holes? Unfortunately, I looked the body over very quickly, so I haven't had much time to research these things without consulting everyone on the forum. If there is a difference, the cart is a 1999. Thanks for any help provided.

Its quite easy. Now I am doing this from memory so I might miss a bolt or screw. I just did my G16 last week. First remove the seat. It just lifts out. Remove the screws that go across the top just under where the seat was and just above the shift. The gear shift handle comes off by pushing the clip off like a bobby pin. Take a close look where the handle meets the body. You might have to push in a little on the body to see it. Just pull the clip and remove the handle. The choke cable comes off by removing the knob first and knurl nut. There is a small set screw under the rubber in the knob that hides it. remove the knob then Loosen the knurl nut and pull the cable inside the engine compartment. Then you have the floor push-in buttons that hold the mat down. Just remove the ones close to the shift side. In back you need to remove the body buttons on golf bag center plastic guard. Take out 2 screws on the bag platform. remove both. That will expose the transmission compartment. You have to remove the 4 bolts that hold the golf bag and seat back rest assembly. Lift that out. There are 2 screws to remove on the lower mid body sides. I think I got it all so you should be able to lift the rear body off. Now if your doing the front remove all the screws and cut washers that hold the front hood trim in place. Remove the trim. Remove the Yamaha emblem and the 2 scews under it. Note how the angle bracket sits for re-assembly. The hood should lift off. Everything should come off easy. If not look again for any screws I might have missed. And yes the "No Step" rubbers can come off. If you plan to reuse the buttons, use a punch from the inside to tap the pins out. I found that they are a bit stubborn to remove and re-install.

[Mike D]

Thanks for the help...that will definitely get me moving in the right direction. I'm going to do as much of the body preparation for the paint with the cart assembled, then take it off for any small items and spraying. I think I'll start tomorrow night after the kids go to bed. I appreciate your input

[technoid]

Originally Posted by Mike D

Thanks for the help...that will definitely get me moving in the right direction. I'm going to do as much of the body preparation for the paint with the cart assembled, then take it off for any small items and spraying. I think I'll start tomorrow night after the kids go to bed. I appreciate your input

Np, enjoy the job!

[Mike Mac]

Mike, think about filling the holes where the "No Step" pads are, and not putting them back on. Makes for a newer, cleaner look!

[Mike D]

I would rather not put them back on, but I don't know what is under them. If it's just small holes for mounting those pads, what did you fill them in with? I previousy read on the forum about not using too much body filler. I've got quite a background in fiberglass work (my father repaired boats for 40 years with his own business) so I could do it that way. What suggestions can you give me? Again, thank you for the tips

[Mike Mac]

Go to auto paint supply. It is a 2 part filler (mix like epoxy) that they repair plastic bumpers with. The stuff that I used, goes in a special calking gun, and mixes as you pump it out. Also, if your lifting the car, it might be a good idea to fill the choke knob hole, because you may have to redrill the hole in a slightly different place for the choke cable to reach. Sorry can't remember the name of the filler, but paint supply should know what I'm talking about!

[Mike D]

Thanks, I know exactly the material that you're talking about. I've done a little auto body work while I was in college. There's a place that I used to deal with... I'll call them tomorrow.

[Mike D]

Well, I'm underway with the bodywork finally. My twin boys both have ear infections, so that has slowed my progress the last few days. Anyhow, I filled the holes for the no step pads with JB Weld. It actually worked very well. The glazing putty is setting up right now. Everything is just about ready to pull bot body sections off. Looks like tomorrow is spray day. Gonna get up[ early, and try to get it done in one day, at least to clear coat. I'm using lacquer, so it will dry quickly. Also I'm introducing my wife into the world of bodywork and painting. I'll keep everyone posted...

[Mike Mac]

Good luck tomorrow, never thought of JB weld!
What color did you pick?
MIke
PS. hope the marriage survives!!