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03-18-2021, 11:48 AM | #1 |
Getting Wild
Join Date: Nov 2020
Location: Edgewater. FL
Posts: 113
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G2 Input Shaft Replacement
I started troubleshooting the noise from my drive train and noticed a wobble to the secondary clutch. Chatting with users here I was informed a wobble is NOT GOOD.
The secondary clutch's internal diameter is worn so big it flops on the input shaft. The brass bushing, is nonexistant and the aluminum is even worn away. I measured over 0.03 erosion of the area of the input shaft where this sheeve slides, thereby causing the damage to the clutch. I ordered, from Don Plowman's, a clutch, updated helix, input shaft, bearings, seals and gasket. The new parts should arrive today. I disassembled the cart and cleaned up the area and transmission, years and years of crud, and I found a broken transmission mount so I need to fabricate a couple parts and borrow the neighbors welder to repair. I will post pictures as it goes back together. |
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03-18-2021, 12:07 PM | #2 |
Getting Wild
Join Date: Nov 2020
Location: Edgewater. FL
Posts: 113
|
Re: G2 Input Shaft Replacement
Here is a photo of the secondary Clutch ID
https://www.buggiesgonewild.com/pict...ictureid=30017 Here are two of the input shaft https://www.buggiesgonewild.com/pict...ictureid=30015 https://www.buggiesgonewild.com/pict...ictureid=30050 Here is one of the broken transmission mount on cross bar. https://www.buggiesgonewild.com/pict...ictureid=30055 Here is a photo of the existing engine area setup.... Plowman's parts will change the look inside here!!!! https://www.buggiesgonewild.com/pict...ictureid=30012 Thanks for looking! I hope others can learn something by my posts. |
03-20-2021, 12:45 AM | #3 |
Over This Interview Is...
Join Date: Jun 2012
Location: AZ
Posts: 17,449
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Re: G2 Input Shaft Replacement
It's really odd how it already has the "snap ring fix" on it, but the housing & bearing is so bad. They just "let it ride" like that?
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03-21-2021, 02:18 PM | #4 | |
Getting Wild
Join Date: Nov 2020
Location: Edgewater. FL
Posts: 113
|
Re: G2 Input Shaft Replacement
Quote:
I never saw the cart run before purchase but I was surprised to find a lot of issues that I have! Got it at a good price and now I'm spending to make it a trustworthy cart. Fortunately I am able to turn the wrenches, weld and even machine if necessary and with the assistance of this group, I am learning how to repair and maintain this cart. Thank you and all here that read these posts and give advise and comments!!!! I for one appreciate it. |
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03-23-2021, 12:55 AM | #5 |
Getting Wild
Join Date: Nov 2020
Location: Edgewater. FL
Posts: 113
|
Re: G2 Input Shaft Replacement
Transmission is apart and cleaned up. Need to swap helical gear and governor from old input shaft onto the new input shaft then close up the case.
If I can't remove it with a gear puller, I will take it to a local shop and have them do it. |
03-24-2021, 02:19 AM | #6 |
Getting Wild
Join Date: Nov 2020
Location: Edgewater. FL
Posts: 113
|
Re: G2 Input Shaft Replacement
I got the gear off the old shaft and installed it and the governor on the new one. Placed in case, new gasket and snugged up bolts.
Question... do I need gasket sealer, oil or use a dry gasket? |
03-24-2021, 03:45 AM | #7 |
Over This Interview Is...
Join Date: Jun 2012
Location: AZ
Posts: 17,449
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Re: G2 Input Shaft Replacement
You now need a new gasket, the difference of "skip the gasket & just use silicone" could ruin your transaxle. I'm sorry I cant give the part number for you, the "good ole" oem yamaha parts diagrams website only goes back 10 years now, that sucks.
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03-24-2021, 07:08 AM | #8 |
Searching for The Way
Join Date: Oct 2009
Location: Medina, Ohio (NEOHIO)
Posts: 11,421
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Re: G2 Input Shaft Replacement
So is the issue of using gasket maker a clearance thing? Is a gasket that much thicker?
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03-24-2021, 09:05 AM | #9 | |
Getting Wild
Join Date: Nov 2020
Location: Edgewater. FL
Posts: 113
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Re: G2 Input Shaft Replacement
Quote:
The case is only put together, 'snug', so I can test endplay of shaft. I did not torque the bolts as of yet. I am about to and I want to know if the gasket needs sealer or oil/grease to help it seal. My question is, do i use a sealer on the gasket or do i install it dry? Last edited by Jammy; 03-24-2021 at 09:40 AM.. Reason: Corrected gasket part number |
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03-24-2021, 03:23 PM | #10 |
Over This Interview Is...
Join Date: Jun 2012
Location: AZ
Posts: 17,449
|
Re: G2 Input Shaft Replacement
It was originally done with no sealer.
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