G1 Top end worn out and rebuild

[jetboatjosh]

Compression was 60psi so i took the piston and cylinder off. There was definitely some blowby, and a lot of carbon build up in the exhaust. The cylinder has some small gouging from what looks like the end of one of the rings.

[griffo002]

Hi...I not long ago rebuilt my top end...My cylinder was worn 40 thou.I had the cylinder bored out and a new oversize piston and ring put in...I can't remember the oversize...It was the first one in a list of 4 oversizes you can get for the G1.
It was $100au for the rebore plus $88 for the piston rings bearing gaskets, so not all that expensive.
Now its a completely different cart...More power than I'll ever need..Pulls a trailer with ease.

[jetboatjosh]

Update: I ordered a .25 over piston and ring set. when it arrived the rings were standard bore and the gaskets are missing. I emailed the company and they said they did not have the rings that i needed or the gasket kit so they returned my money. On top of that i can't find a machine shop that will bore the cylinder. The auto machine shop says they have no way of holding the cylinder and the motorcycle shop said they will not work on a golf cart. The golf cart shop says they send everything back east. So i honed the cylinder and installed the standard size new rings on the old piston. Waiting on A gasket kit and will check compression after that. Wish me luck.

[Field6565]

Let us know how it works out. Should work. I'm not sure why people are boring theses cylinders when you can buy a complete top end kit for these around $225. ( DIY golf carts )That includes a NEW cylinder, piston, rings, wrist pin/clips and all the gaskets needed for the job. No searching for a shop to bore an old cylinder.

[griffo002]

Here is a new top end on Ebay...$405....DIY the go at $225 thats for sure...They never had it stock when I enquired.

https://www.ebay.com.au/itm/Yamaha-G...yeH:rk:22:pf:0

The Aussie seller here wanted over $600 just for the cylinder...They rip you off down here the so and so's.

[mikeasis]

Originally Posted by Field6565

Let us know how it works out. Should work. I'm not sure why people are boring theses cylinders when you can buy a complete top end kit for these around $225. ( DIY golf carts )That includes a NEW cylinder, piston, rings, wrist pin/clips and all the gaskets needed for the job. No searching for a shop to bore an old cylinder.

not everybody has or wants to drop $225+. You can get a piston kit for around $60 with gaskets and about that to bore it or less. I find it odd no one wants to bore it for you but then machine shops seem to be a dying art.

[OgreTX]

I went the same route when I bought one that wouldn't run. (thread here: http://www.buggiesgonewild.com/gas-y...1-experts.html)

If you're thinking of the $225+ route, don't! Plowman's has a $249 G1 top end kit that's a much better option. here: G1 Top End Kit

BTW, I would be wary of the "Nivel" brand on Ebay. It's been discussed here frequently, and I am pretty sure Plowman's is the way to go if you are going to spend over $200.

Ogre

[mikeasis]

Originally Posted by OgreTX

I went the same route when I bought one that wouldn't run. (thread here: http://www.buggiesgonewild.com/gas-y...1-experts.html)

If you're thinking of the $225+ route, don't! Plowman's has a $249 G1 top end kit that's a much better option. here: G1 Top End Kit

BTW, I would be wary of the "Nivel" brand on Ebay. It's been discussed here frequently, and I am pretty sure Plowman's is the way to go if you are going to spend over $200.

Ogre

you know ive wondering about Nivel brand as of late. If im not mistaken they are the ones producing the top end kit for the Harley carts as well. Id love to go OE but they are getting harder to come by. Do you know of aftermarket brands to look for? Just not much out there that I can tell.

The plowmans route would be what I would do if looking for a complete top end.