Restoring 1992 Yami G9 36v back to factory spec

[UncleJerm76]

I’m a Club Car DS guy - I could wire one of those “back to stock” with my eyes closed. But there seems to also be a lot more documentation available for the DS model. Anyway, a few of us local guys are all chipping in to help a new widow rebuild the family golf cart – a 1992 Yamaha G9 36v toaster cart.

As of right now, nothing under the seat is fastened down – Batteries, wires, even the solenoid is just lying there unbolted. Riding the grand kids around on the property and one day solenoid bounced around until it shorted out on something and the cart sat for a while. FF to present day...

I am very familiar with the way these “toaster” carts (aka resistor carts) work, having rewired my own DS toaster cart back in the day. Simply wiring everything up just to “work” I can do no problem - but my goal with this G9 is wiring it back to stock/factory spec and I’m having a difficult time finding diagrams that shows the location of where things were routed as they came off the assembly line.

For example, where does the solenoid mount from the factory?, where are the wires routed?, what is the proper wire color of each wire? …those are just a few of things that I’m looking for. Every wiring diagram I’ve been able to google thus far only shows me how things are hooked up electrically. Any help, links, pictures, documentation would be greatly appreciated – as long as they are as they were stock.

[LukeL]

I have an electric G2 toaster cart I could take pictures of if you need. The solenoid mounts in the back under a plastic cover. Yours might be a G2 also. Many G9’s (not all of them) were controller carts.

Mine is completely stock.


Club Car DS driver’s club #59

[UncleJerm76]

Cool thanks for the offer Luke, I would appreciate any pics you can provide, especially those of where the solenoid is mounted and how the wiring is routed from the key switch back, as well as the wire colors. Currently almost all the wires are red which cant be right?

I'm pretty sure its a G9, based on the serial number but I did notice a lot of the G2's are cross referenced with the G9 also, so I'm not aware of the differences between the two - or if those differences matter in restoring the wiring back to factory spec for a G9.

[LukeL]

Solenoid is in the black cover. If you need me to open it up let me know.


Club Car DS driver’s club #59

[LukeL]

I can get more pics after lunch[emoji106][emoji2532]


Club Car DS driver’s club #59

[UncleJerm76]

I think that will do for now, thank you sir


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[UncleJerm76]

How are the small wires from the ignition switch routed? Are they in wire loom or taped


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[LukeL]

Mine are in wire loom


Club Car DS driver’s club #59

[UncleJerm76]

Ok thanks.

In your pic I don’t see any battery hold downs, they are missing in this one and I’m having a difficult time seeing what they look like.


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[smallblock450sl]

Go to www.yamahagolfcar.com Go to "owners". Select "owners manual" from the drop link. Select 1990. Select "golf car" from the drop link. Select G2 electric from the drop link and download the owners manual. at the end it will show the battery configuration/ hold downs and a wiring diagram. Hope that helps.