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Old 09-13-2023, 08:02 PM   #1
Snakeoil
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Default Rob's G1 Adventure

This is my first post other than my intro post. Just picked up a G1. Based upon the numbers, it is a 1981 cart. Runs but needs a lot of choke to get to start. Once going, runs well. I just brought it home tonight so can't give any further detail.

Tomorrow the adventure begins. I got a spare engine with the cart. I think I'm going to see if I can get it to start and run better tomorrow. Might just need to tinker with the carb. I did a little research of the past couple days and see that there is a butterfly valve in the exhaust. I imagine that could make it start hard if not adjusted properly. But my gut says that if the carb cannot be sorted, it's going to need rings or crank seals.

If I get it to start better and run, then I might just attack the spare engine first and see if it cannot be rebuilt. It's missing the fan shroud and carb. But everything else is there. If nothing else, it's a good practice mule to learn more about these machines. I'm not a snowmobile guy so am not familiar with the details of the clutches. I understand how they function. My background is cars and motorcycles. And I was a gas turbine field engineer in my youth and worked with large rotating equipment as an engineer all my career. So, I don't expect any insurmountable issues. I'm also a formally trained machinist so I can make special tools and such if necessary.

I did a frame up restoration on a 1966 T120R Triumph about 10 years ago and started a restoration thread on a Triumph forum. I think I may do that here as I work thru this cart.

Stay tuned...
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Old 09-14-2023, 09:51 AM   #2
Tech_By_Trade
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Default Re: Rob's G1 Adventure

I would start with a compression test before you dig too far.
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Old 09-14-2023, 10:38 AM   #3
mikeasis
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Default Re: Rob's G1 Adventure

first compression test. 120 psi is what your looking for unless the engine is stamped J17 on the cylinder behind the clutch then its a 1982 J17 low compression engine 80-90 psi.

if your having to choke it alot to get it to run or stay running its due for crank seals. very common on these old carts
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Old 09-14-2023, 05:56 PM   #4
Snakeoil
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Default Re: Rob's G1 Adventure

Thanks for the replies/suggestions, guys. I'm not a 2-stroke guy, at least not 2-strokes with reeds.

Today was carburetor day. Pulled it off the engine and first thing I noticed how sloppy the throttle butterfly shaft was. This is what I found.

The bushing in the carb body is badly worn. The shaft has mating wear. The combination of the two spelled serious vacuum leak. So, although I know a new carb needs to go on the shopping list, I thought I'd try to fix the shaft to reduce the leakage and see if the problem was reduced.

I soldered up the wear area and dressed it down until it fit the carb. Worn bushing meant it would not be tight, but it would be better.

Also noticed that the throttle return spring had a missing loop on the carb body end. Trimmed it back and put a new loop on the end.

Put the carb back on and found that it took forever to prime the fuel pump. Ended up having to blow into the tank to fill the float bowl. Suspect that is another symptom of bad crank seals as leaky seals should reduce the pressure signal from the crankcase to the fuel pump.

Finally got it to start. Takes choke to get it to take the gas and accelerate. Once it gets going, it goes pretty well. But, if you stop and restart or slow to an idle by keeping slight pressure on the gas pedal, when the pedal is pushed to accelerate, it just bogs and goes nowhere. Will not take the gas. Choking helps and if you get it right, it will start to take the gas and then take off. Other times it will just sit there and idle with the pedal to the floor Very temperamental to say the least. And yes, I adjusted all the linkages so that they are correct. Although I'm using a later model, J24 manual that I downloaded here. Imagine this stuff is pretty much the same for mine.

I have a question for the more experienced. Are the reeds ever a problem or are they normally not an issue? I thought about going into the reeds when I had the carb off, but decided to give the entire engine/chassis area a good bath with engine cleaner and the pressure washer. It certainly needs it.
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Old 09-15-2023, 08:28 PM   #5
Leon willis
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Default Re: Rob's G1 Adventure

I will buy the worst engine off you I have a cart I donít have a motor for and oh way you need to replace that carb and I would check those reeds
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Old 09-18-2023, 07:05 AM   #6
Snakeoil
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Default Re: Rob's G1 Adventure

Sounds like a good time. Do most of the events start out with something like, "Here, hold my beer and watch this."?

This cart is destined for the gun club I belong to. We shoot out to 500 yds and walking that to paint or reset targets is just silly. Plus, I'm 71 and one of the younger guys in the club. So, the energy level is dismal. I got the idea to get a cart because a chimp can drive one, they don't go too fast so not prone to abuse when nobody is around and pretty simple to maintain.
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Old 09-18-2023, 09:59 AM   #7
Tech_By_Trade
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Default Re: Rob's G1 Adventure

It would be Ideal for a situation like that if you can get it up and running.
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Old 09-18-2023, 10:36 AM   #8
mikeasis
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Default Re: Rob's G1 Adventure

Quote:
Originally Posted by Leon willis View Post
I will buy the worst engine off you I have a cart I donít have a motor for and oh way you need to replace that carb and I would check those reeds
Id suggest joining the G1 G3 or G1 only groups on facebook. Bob Hamels rebuilds and sells G1 engines and probably has cores if thats the way you want to go
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Old 09-18-2023, 05:58 PM   #9
Snakeoil
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Default Re: Rob's G1 Adventure

Quote:
Originally Posted by mikeasis View Post
Id suggest joining the G1 G3 or G1 only groups on facebook. Bob Hamels rebuilds and sells G1 engines and probably has cores if thats the way you want to go
Thanks. I'll check that out. I'm not a big fan of FB because of how it is structured. If there is a lot of traffic, it's tough finding an older post. I guess the solution is to copy and paste any good info into a Word document on my computer.
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Old 09-18-2023, 06:21 PM   #10
mikeasis
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Default Re: Rob's G1 Adventure

Hereís a carb repair thread:

https://www.buggiesgonewild.com/showthread.php?t=50660

Another:

https://www.buggiesgonewild.com/showthread.php?t=145064

Tool thread:

https://www.buggiesgonewild.com/showthread.php?t=115742

And of course a service manual link at the bottom of my post
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