'82 G1 not getting gas

happilymaad · 01-16-2011, 03:26 PM

Any pointers on what to look for? This will be my first teardown and rebuild. Thanks.

GMB74 · 01-16-2011, 03:39 PM

A piston that is damaged should be replaced. A scored-up cylinder means a rebore or upper-end replacement. Check your lower connecting rod bearing when you get it apart- should rotate nice and smooth. If bad, you need to replace the crank. The good news is all these parts are available from the forum sponsors and are not too expensive.
A manual, which I highly recommend getting, is available from Yamaha:

http://store.kencook.com/yml/index.c...tegory=SERVICE MANUAL

Or, can be dowloaded here:

http://www.manualuniverse.com/

Click on 'catalog' click on 'Yamaha" on the list of makes type 'G1' in the model section.
It is a scan of the 1983-89 factory manual in a zip file. Some of the images are kind of dark, but it is worth the price, which I see is now lower than when I purchased it in December. If you have an earlier G1, most of the info is still relevant, differences can be worked around by searching here on the forum.

happilymaad · 01-16-2011, 08:46 PM

Excellent. Thank you. I will get crackin on it. I'll let ya know what I find.

happilymaad · 01-18-2011, 07:38 PM

I started taking it apart this afternoon. When I was loosening the nuts on the head, one of them wasn't very tight. Can you guess which one?

This is the under side of the head.

Here are some more pics. Certainly needs to be cleaned up (and down).

Piston:

Lastly, looking down into the crankshaft:

Overall, it seems to be going pretty smooth, so far. I certainly appreciate the help.

ky_mike · 01-18-2011, 09:45 PM

Keep the pics coming! It will be very useful when I have to do mine.

GMB74 · 01-19-2011, 05:41 AM

Piston shows some scuffing. What is the cylinder like? Any scratches you can feel with your fingernail?
How much debris was in the crankcase from the bearing cage breaking up?

happilymaad · 01-19-2011, 06:13 AM

Will do, KY_Mike.

I will clean up the piston and cylinder and take more pics, probably Thursday. I do not recall seeing or feeling any scratches on cylinder wall. I haven't split the case yet, probably Thursday evening or Friday evening.

Anyone recommend a good cleaner to use?

GMB74 · 01-19-2011, 08:33 PM

Paint thinner (mineral spirits) works well and is less hazardous than some solvents. Use plenty of ventilation, be careful of heat and sparks, and wear your gloves. The nitrile ones you have work well, latex ones don't like mineral spirits much.

happilymaad · 01-22-2011, 09:02 PM

Update: Got it split. Followed the steps in a post by another member and it worked well!

Crankcase was pretty dirty and dry. I think the crankshaft is still good. The connecting rod spins freely and isn't loose or sloppy.

Crankshaft isn't rusted or rusty, just a bad picture or two.

Cleaned:

The piston and cylinder were scuffed on the lower half. Does it need to go to the machine shop for a bore / hone?

happilymaad · 01-22-2011, 09:13 PM

Piston and Cylinder:

What is the "burnt" mark on the cylinder wall? Is that common?

Picture of the crankshaft right after I got it out. Not rusted or bent like it looks like in the other pic. LOL.

I think it is coming along well. I'm working on getting the parts order together.

Looking forward to reassembling! :)

01-16-2011, 03:26 PM	#11
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25	Re: '82 G1 not getting gas Any pointers on what to look for? This will be my first teardown and rebuild. Thanks.
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25

01-16-2011, 03:39 PM	#12
GMB74 Gone Wild Join Date: Jun 2009 Location: Heluvabump,VT Posts: 623	Re: '82 G1 not getting gas A piston that is damaged should be replaced. A scored-up cylinder means a rebore or upper-end replacement. Check your lower connecting rod bearing when you get it apart- should rotate nice and smooth. If bad, you need to replace the crank. The good news is all these parts are available from the forum sponsors and are not too expensive. A manual, which I highly recommend getting, is available from Yamaha: http://store.kencook.com/yml/index.c...tegory=SERVICE MANUAL Or, can be dowloaded here: http://www.manualuniverse.com/ Click on 'catalog' click on 'Yamaha" on the list of makes type 'G1' in the model section. It is a scan of the 1983-89 factory manual in a zip file. Some of the images are kind of dark, but it is worth the price, which I see is now lower than when I purchased it in December. If you have an earlier G1, most of the info is still relevant, differences can be worked around by searching here on the forum.

01-16-2011, 08:46 PM	#13
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25	Re: '82 G1 not getting gas Excellent. Thank you. I will get crackin on it. I'll let ya know what I find.
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25

01-18-2011, 07:38 PM	#14
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25	Re: '82 G1 not getting gas I started taking it apart this afternoon. When I was loosening the nuts on the head, one of them wasn't very tight. Can you guess which one? This is the under side of the head. Here are some more pics. Certainly needs to be cleaned up (and down). Piston: Lastly, looking down into the crankshaft: Overall, it seems to be going pretty smooth, so far. I certainly appreciate the help.
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25

01-18-2011, 09:45 PM	#15
ky_mike Gone Wild Join Date: Aug 2010 Location: Kentucky Posts: 207	Re: '82 G1 not getting gas Keep the pics coming! It will be very useful when I have to do mine.

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01-19-2011, 05:41 AM	#16
GMB74 Gone Wild Join Date: Jun 2009 Location: Heluvabump,VT Posts: 623	Re: '82 G1 not getting gas Piston shows some scuffing. What is the cylinder like? Any scratches you can feel with your fingernail? How much debris was in the crankcase from the bearing cage breaking up?

01-19-2011, 06:13 AM	#17
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25	Re: '82 G1 not getting gas Will do, KY_Mike. I will clean up the piston and cylinder and take more pics, probably Thursday. I do not recall seeing or feeling any scratches on cylinder wall. I haven't split the case yet, probably Thursday evening or Friday evening. Anyone recommend a good cleaner to use?
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25

01-19-2011, 08:33 PM	#18
GMB74 Gone Wild Join Date: Jun 2009 Location: Heluvabump,VT Posts: 623	Re: '82 G1 not getting gas Paint thinner (mineral spirits) works well and is less hazardous than some solvents. Use plenty of ventilation, be careful of heat and sparks, and wear your gloves. The nitrile ones you have work well, latex ones don't like mineral spirits much.

01-22-2011, 09:02 PM	#19
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25	Re: '82 G1 not getting gas Update: Got it split. Followed the steps in a post by another member and it worked well! Crankcase was pretty dirty and dry. I think the crankshaft is still good. The connecting rod spins freely and isn't loose or sloppy. Crankshaft isn't rusted or rusty, just a bad picture or two. Cleaned: The piston and cylinder were scuffed on the lower half. Does it need to go to the machine shop for a bore / hone?
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25

01-22-2011, 09:13 PM	#20
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25	Re: '82 G1 not getting gas Piston and Cylinder: What is the "burnt" mark on the cylinder wall? Is that common? Picture of the crankshaft right after I got it out. Not rusted or bent like it looks like in the other pic. LOL. I think it is coming along well. I'm working on getting the parts order together. Looking forward to reassembling! :)
happilymaad Not Yet Wild Join Date: Jul 2008 Posts: 25