G9 rebuild specs and info

[BLES]

Anyone have the info from a service manual on a G9 (JG5-216414)? I got a G9 that looks ok but needs to be re-assemled. I got new rings, gaskets, etc. but need timing info, torque patterns, etc. I saw rod and head bolt torque values on here somewhere during my searching but need the other info to get it back to running. Thanks.

BLES

[Flintrock]

There's some info in the Yamaha gas header (sticky) section.

http://www.buggiesgonewild.com/gas-y...-g9-specs.html

Investing in a shop manual is money very well spent, walks you through everything you will need.

[BLES]

Thanks Flintrock. I'd read that and some other stuff when I was looking for the info a while back. That doesn't include the info I need, though.
BLES

[ace_ripper]

I found these a while back. It's not a complete list of all specs or sequences, but it should help.

Specs for G1 Gas Engine:
Std. Bore 68.00mm
Piston Clearance 0.03 ~ 0.035 mm
Ring End Gap 0.2 ~ 0.4 mm
Flywheel Nut 52.6 ft. lbs.
Clutch Bolt 43 ft. lbs.
Crankcase Bolts 4.7 ft. lbs.
Head Bolts (Initial) 14.5 ft. lbs. (Final) 18 ft. lbs.

Specs for G2,G8 & G9 Gas Engine:
Std. Bore 73.00mm
Piston Clearance 0.03 ~ 0.05 mm
Ring End Gap 0.2 ~ 0.4 mm
Intake Valve (Cold): 0.1mm
ExhaustValve(Cold): 0.1mm
Connecting Rod Cap 29 ft. lbs.
Flywheel Nut 54 ft. lbs.
Clutch Bolt 54 ft. lbs.
Crankcase Bolts 17 ft. lbs.
Head Bolts 20 ft. lbs.
Oil Drain Plug 22 ft. lbs.

Specs for G14 thru G21 Gas Engine:
Std. Bore 78.00mm
Piston Clearance .03~.05mm
Ring End Gap 0.2 ~ 0.4 mm
Intake Valve (Cold): 0.1mm
ExhaustValve(Cold): 0.1mm
Connecting Rod Cap 14 ft-lbs
Flywheel Nut 54 ft-lbs
Clutch Bolt 75 ft-lbs
Crankcase(8mm) 19 ft-lbs(10mm) 27 ft-lbs
Cylinder Head 36 ft-lbs
Oil Drain Plug 22 ft-lbs

Specs for G22 Gas Engine:
Std. Bore85.00mm
Piston Clearance
Ring End Gap
Intake Valve (Cold): 0.1mm
ExhaustValve(Cold): 0.1mm
Connecting Rod Cap
Flywheel Nut
Clutch Bolt
Crankcase Bolts
Head Bolts
Oil Drain Plug

[BLES]

Still looking for some info on timing. Has no one on here rebuilt a G9 engine? I think I know how it goes but it's not something I want to "assume" on. Too much work to guess! There are marks on the counterbalance gear but not sure what they line up with on the crank. Also, there are marks on the crank/camdrive gear but no marks on the cam gear except for a hole drilled on the inner part of the gear. Anyone?? Thanks in advance.

BLES

[chompy]

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[chompy]

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[BLES]

Thanks Chompy! Exactly what I needed as the marks are gone from the crank gear.
BLES

[MagicMel]

Choppy is this the same for a g14? I have tore down and am replacing rod bearings on mine. The crankshaft dot and front gear dot are lined up but the front gear dot is on opposite side. The rear smaller gear dot is lined up directly towards center of crankshaft closet to it. I have not changed any of this when tearing down this is first time engine ever been opened. Going to attempt to add pictures. Thanks for any input.

[peter196358]

Originally Posted by BLES

Still looking for some info on timing. Has no one on here rebuilt a G9 engine? I think I know how it goes but it's not something I want to "assume" on. Too much work to guess! There are marks on the counterbalance gear but not sure what they line up with on the crank. Also, there are marks on the crank/camdrive gear but no marks on the cam gear except for a hole drilled on the inner part of the gear. Anyone?? Thanks in advance.

BLES

the hole line s up with the punch mark .