Yamaha G1 Homemade or Improvised tools

[twobore]

I just finished a complete rebuild of my G1 Golf Cart engine, both top and bottom. I was able to improvise or make most of the special tools except the Clutch (primary sheave) puller which I bought from Amazon for $22 (also available on eBay). Here are pictures of the various tools I used or made:

Pic #1. Puller available on free loan from O'Reilly Auto Parts Stores.
Pic #2. Using O'Reilly puller to remove magneto.
Pic #3. None of the O'Reiily tools had bolts long enough to adapt directly as the case separator tool so I borrowed their steering wheel puller and added perforated plumber tape to bridge to some shorter bolts I already had. Worked like a champ.
Pic #4. My homemade clutch (primary sheave) holder. Simply a strap wrench I made from an old serpentine belt (an old timing belt would also work well). I clamp it to the hardwood handle with some scrap plates I had but you could make your own or use C clamps or even vise grips to secure the belt to the handle. I made the straps long enough so it can also hold the magneto or secondary sheave or adapt to other future projects. In the foreground I show the commercially made clutch remover tool. This would also be simple to fabric with a length of rod and a bolt but the fine thread is not available in a 14mm bolt (at least not around my area).

[Field6565]

Nice job! Sometimes you have to be creative to get the job done. You should start up a build thread.

[Spicyunicorn]

argeed the 14mm-1.0 pitch bolt witch is the thread for clutch puller is impossible to find

[TheNewGuy]

If I'm not mistaken, you can use a spark plug as the thread is 14mm. You'll have to modify it of course.

[Spicyunicorn]

Originally Posted by TheNewGuy

If I'm not mistaken, you can use a spark plug as the thread is 14mm. You'll have to modify it of course.

yes, a spark plug is 14mm thread but its a 1.5 pitch the clutch is 1.0

[slonomo]

Nice job! G1's are super easy to work on, I really enjoyed rebuilding mine. I did like you and made some tools. Still have them in the tool box, and I labeled them "Special G1 Tools" lol. IMO Yamaha carts are the best engineered carts out there, but they do require an arsenal of tools. Once you have them, you're good to go!

[twobore]

I recently posted pictures of some homemade/improvised tools I used to rebuild my Yamaha G-1 engine. I inadvertently neglected to include the crank installer I made, so here it is. Total cost $.95.

I bought a foot of 1 1/4" ABS plastic pipe, cut a 6 1/2" length, and used the original long clutch (sheave) bolt to draw the crank through the bearing. The pipe bears perfectly on the inner race of the bearing . There is about 1 1/2" of thread on that long bolt and I tried to keep at least 3/4" min in the crank, drawing up a little at a time and adding spacers as required (washers, various length sockets etc). The pipe wrench keeps the crank from rotating and the rubber bands keep the rod centered. I can't imagine a commercial unit working any better.

BTW, I cut a shorter piece of pipe and used the same method to draw the case halves together.

[cgtech]

Nice!

[smallblock450sl]

I love it! BGW members are so smart

[twobore]

DIY PRIMARY SHEAVE HOLDER and MAGNETO HOLDER FOR G1 ENGINE

Here's a couple more home made tools to add to the one's I've already posted:

1. The sheave holder (top) is made from an old fan belt, a scrap of 1 X 2 hardwood, some 1” screws, and 10” - 12” 3/8” threaded rod. A small piece of the fan belt is contact cemented to the curved wood piece that engages the sheave.

2. At bottom of picture #4, is shown a holder for the magneto to keep it from rotating when removing the large mag crankshaft nut. It bolts up to the face of the mag utilizing two of the three threaded holes provided for pulling the mag. I made it from a scrap of 1 1/4 wide X 3/16” thick metal about 10” long using a hand drill and a grinder. To use it requires removing the plastic fan from the mag (6 small bolts). Sorry I don’t have a picture of it in use.

Both of these tools work as well as their commercial equivalents.