Getting to G16 TCI

Pumper · 03-21-2015, 07:27 PM

I am trying to change the G16 TCI, the fan cover has 5 bolts I can get 4 off but the rear bottom one I can see but can't get to it.

Do I have to lift the engine? Any ideas?

cgtech · 03-22-2015, 01:57 AM

1/4 drive rachet then extension then universal joint or"swivel" and short 10mm socket. I have done plenty, and never lifted the engine to do it. I would put one of the easy ones back in, so the cover doesnt start moving around when the bottom bolt is loose, but not all the way out.

Pumper · 03-22-2015, 08:20 AM

Thanks cgtech for your reply.

I just tried your suggestion but still can't get to that bolt. The intake cover seems to be in the way. Tried to remove it but the front lower screw is behind the frame the engine sits on so I could not remove it.

Are the G16's different?

cgtech · 03-22-2015, 09:48 AM

You took the gas tank & air filter box out, right?

Pumper · 03-22-2015, 10:18 AM

I took the air filter box off but not the gas tank.
Maybe that is the secret, I will try that.

Pumper · 03-22-2015, 01:31 PM

The G16 has a large cover plate under the engine frame held on with 6 blind rivets. Near the bolt I could not reach I pried this plate down about an inch and stuck a piece of wood to hold it down. That gave me access to the bolt without removing the gas tank. Now all I need to do is get a new TCI.

I also have a 2007 Yamaha YDRA model and it does not have that troublesome bolt nor does it have a cover plate on the bottom of the engine frame, that would be no trouble getting to.

I would like to remove the six rivets and the plate on the bottom of the G16. It has some sort of foam or fiber material on the inside of it that collects oil and dirt, looks like a fire trap to me. I can't get the cart high enough at this time to drill out those rivets.

KingPin · 03-26-2015, 10:08 AM

I just had to replace my TCI on a g16. I had a very similar issue getting to the bottom bolt on the stupid cover. I ended up on my back with the side slightly lifted with a floor jack. I found that placing the ratchet bit on the bolt first and then attaching the socket wrench made it a lot easier. Using one of the 10mm extended sockets also made that job easy.

When buying your TCI do your best to by OEM parts. I have an aftermarket TCI i picked up online and it needed some washers as spacers to get the bolts to set properly.

I'm having some other issues after replacing my TCI and I'm not sure, at this point, if it is directly tied to the TCI or perhaps my coil pack. I'm not a mechanic so I'm doing the best I can on that one.

Also - When you go to remove the TCI -- spin the fly wheel you will see to notches together on the side. These notches will line up near perfectly with the bolts on the TCI allowing you to use a longer 10mm ratchet against them to remove them.

Hope this helps you out.

03-21-2015, 07:27 PM	#1
Pumper Not Yet Wild Join Date: Jun 2009 Location: The Villages Florida Posts: 57	Getting to G16 TCI I am trying to change the G16 TCI, the fan cover has 5 bolts I can get 4 off but the rear bottom one I can see but can't get to it. Do I have to lift the engine? Any ideas?

03-22-2015, 01:57 AM	#2
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: Getting to G16 TCI 1/4 drive rachet then extension then universal joint or"swivel" and short 10mm socket. I have done plenty, and never lifted the engine to do it. I would put one of the easy ones back in, so the cover doesnt start moving around when the bottom bolt is loose, but not all the way out.

03-22-2015, 08:20 AM	#3
Pumper Not Yet Wild Join Date: Jun 2009 Location: The Villages Florida Posts: 57	Re: Getting to G16 TCI Thanks cgtech for your reply. I just tried your suggestion but still can't get to that bolt. The intake cover seems to be in the way. Tried to remove it but the front lower screw is behind the frame the engine sits on so I could not remove it. Are the G16's different?

03-22-2015, 09:48 AM	#4
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: Getting to G16 TCI You took the gas tank & air filter box out, right?

03-22-2015, 10:18 AM	#5
Pumper Not Yet Wild Join Date: Jun 2009 Location: The Villages Florida Posts: 57	Re: Getting to G16 TCI I took the air filter box off but not the gas tank. Maybe that is the secret, I will try that.

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03-22-2015, 01:31 PM	#6
Pumper Not Yet Wild Join Date: Jun 2009 Location: The Villages Florida Posts: 57	Re: Getting to G16 TCI The G16 has a large cover plate under the engine frame held on with 6 blind rivets. Near the bolt I could not reach I pried this plate down about an inch and stuck a piece of wood to hold it down. That gave me access to the bolt without removing the gas tank. Now all I need to do is get a new TCI. I also have a 2007 Yamaha YDRA model and it does not have that troublesome bolt nor does it have a cover plate on the bottom of the engine frame, that would be no trouble getting to. I would like to remove the six rivets and the plate on the bottom of the G16. It has some sort of foam or fiber material on the inside of it that collects oil and dirt, looks like a fire trap to me. I can't get the cart high enough at this time to drill out those rivets.

03-26-2015, 10:08 AM	#7
KingPin Not Yet Wild Join Date: May 2013 Location: Southern Alberta Posts: 29	Re: Getting to G16 TCI I just had to replace my TCI on a g16. I had a very similar issue getting to the bottom bolt on the stupid cover. I ended up on my back with the side slightly lifted with a floor jack. I found that placing the ratchet bit on the bolt first and then attaching the socket wrench made it a lot easier. Using one of the 10mm extended sockets also made that job easy. When buying your TCI do your best to by OEM parts. I have an aftermarket TCI i picked up online and it needed some washers as spacers to get the bolts to set properly. I'm having some other issues after replacing my TCI and I'm not sure, at this point, if it is directly tied to the TCI or perhaps my coil pack. I'm not a mechanic so I'm doing the best I can on that one. Also - When you go to remove the TCI -- spin the fly wheel you will see to notches together on the side. These notches will line up near perfectly with the bolts on the TCI allowing you to use a longer 10mm ratchet against them to remove them. Hope this helps you out.