Help - G9 low rpm sputtering issue

Crazy Legs · 08-22-2016, 02:15 PM

Hi guys,
I'm in need of some help, I've got a "Stock" 92 Yamaha G9 and has run flawlessly up until a couple of weeks ago.

But now only runs great at WOT (wide open throttle) anything less than that it kinda sputters, surges, even a few small coughs or backfires.

This past weekend I put a new battery in it, checked the air box seals, removed carb and found a few small particals in the bowl, put carb cleaner through it and poked the small drill bits that are in a torch tip cleaner, took the fuel pump apart and it was clean as well and new spark plug as well. Long story short it still does it.
A buddy said to actually remove the jets and clean it again? he also mention the rev limiter box but i found out that G9's don't have this feature?

Anyway it seems to be an ignition thing or gas related for sure, it just baffles me how smooth it is at wide open with no issue but anything less than that isn't good.

sho305 · 08-22-2016, 07:41 PM

The ignitor advances at 2500, sometimes when they fail you get full advance under 2500. When that happens it runs fine at 2500 and above but not good under that. I'd also try a new plug the ngk bprs2 they use in newer yamiha G16 iirc. As always check all wiring especially the plug on the igntor and so on.

Crazy Legs · 08-23-2016, 09:40 AM

hmmm ok, where is the ignitor on this thing? is it the TCI box? and where do you suggest I get one? Thanks!

Dave in VA · 08-23-2016, 09:50 AM

Did you remove the jets and the idle screw when you cleaned the carb?

Crazy Legs · 08-23-2016, 09:55 AM

Dave no I didn't, I just sprayed it and poked the tiny bits inside, that's my game plan tonight is actually remove the jets etc.

Dave in VA · 08-23-2016, 09:57 AM

Good plan

Float and needle valve, too...

sho305 · 08-23-2016, 06:45 PM

Its mounted to the side of the fuel tank, its the last thing you want to have to buy they are not cheap. Make sure it is nothing else before you do, and best to swap with another cart to make sure before you buy one. Last I knew they were 125 or so. Ignitors can be worse when hot, or hot weather. It would be rpm related and nothing else would change it such as partial choke. Do check the fuel system and all that first.

Crazy Legs · 08-23-2016, 09:47 PM

Ok cool, I've got the carb torn apart and jets out etc and I didn't see anything wrong other than this empty threaded hole?
I'm assuming something goes in here but what?? I'm assuming this has been my issue the hole time?

Dave in VA · 08-24-2016, 06:18 AM

The pilot jet is missing...

Mike Mac · 08-24-2016, 06:42 AM

Idle jet.

08-22-2016, 02:15 PM	#1
Crazy Legs Not Yet Wild Join Date: Aug 2016 Location: Oskaloosa, Iowa Posts: 7	Help - G9 low rpm sputtering issue Hi guys, I'm in need of some help, I've got a "Stock" 92 Yamaha G9 and has run flawlessly up until a couple of weeks ago. But now only runs great at WOT (wide open throttle) anything less than that it kinda sputters, surges, even a few small coughs or backfires. This past weekend I put a new battery in it, checked the air box seals, removed carb and found a few small particals in the bowl, put carb cleaner through it and poked the small drill bits that are in a torch tip cleaner, took the fuel pump apart and it was clean as well and new spark plug as well. Long story short it still does it. A buddy said to actually remove the jets and clean it again? he also mention the rev limiter box but i found out that G9's don't have this feature? Anyway it seems to be an ignition thing or gas related for sure, it just baffles me how smooth it is at wide open with no issue but anything less than that isn't good.

08-22-2016, 07:41 PM	#2
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,445	Re: Help - G9 low rpm sputtering issue The ignitor advances at 2500, sometimes when they fail you get full advance under 2500. When that happens it runs fine at 2500 and above but not good under that. I'd also try a new plug the ngk bprs2 they use in newer yamiha G16 iirc. As always check all wiring especially the plug on the igntor and so on.

08-23-2016, 09:40 AM	#3
Crazy Legs Not Yet Wild Join Date: Aug 2016 Location: Oskaloosa, Iowa Posts: 7	Re: Help - G9 low rpm sputtering issue hmmm ok, where is the ignitor on this thing? is it the TCI box? and where do you suggest I get one? Thanks!

08-23-2016, 09:50 AM	#4
Dave in VA maintaining a low profile Join Date: Oct 2009 Location: SW Virginia USA Posts: 6,316	Re: Help - G9 low rpm sputtering issue Did you remove the jets and the idle screw when you cleaned the carb?

08-23-2016, 09:55 AM	#5
Crazy Legs Not Yet Wild Join Date: Aug 2016 Location: Oskaloosa, Iowa Posts: 7	Re: Help - G9 low rpm sputtering issue Dave no I didn't, I just sprayed it and poked the tiny bits inside, that's my game plan tonight is actually remove the jets etc.

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08-23-2016, 09:57 AM	#6
Dave in VA maintaining a low profile Join Date: Oct 2009 Location: SW Virginia USA Posts: 6,316	Re: Help - G9 low rpm sputtering issue Good plan Float and needle valve, too...

08-23-2016, 06:45 PM	#7
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,445	Re: Help - G9 low rpm sputtering issue Its mounted to the side of the fuel tank, its the last thing you want to have to buy they are not cheap. Make sure it is nothing else before you do, and best to swap with another cart to make sure before you buy one. Last I knew they were 125 or so. Ignitors can be worse when hot, or hot weather. It would be rpm related and nothing else would change it such as partial choke. Do check the fuel system and all that first.

08-23-2016, 09:47 PM	#8
Crazy Legs Not Yet Wild Join Date: Aug 2016 Location: Oskaloosa, Iowa Posts: 7	Re: Help - G9 low rpm sputtering issue Ok cool, I've got the carb torn apart and jets out etc and I didn't see anything wrong other than this empty threaded hole? I'm assuming something goes in here but what?? I'm assuming this has been my issue the hole time?

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