Yamaha G16E Weak Brakes

Lee Hall · 11-09-2018, 01:43 PM

This is really more of a solution that I wish to share than a question. However, I would welcome any further insights.

After floundering for almost a week, I finally discovered the solution to dangerously weak braking (despite new shoes) on a 1998 Yamaha G16E. Adjusting the cable length to set the pedal free play (25-30mm) did not increase braking power at all.

I had done everything correctly according to the Yamaha service manual - including turning the self-adjuster screw (or nut) in completely (but not tight). A visual inspection of the self adjusting mechanism looked normal but it was clear that it wasn't working (even with fresh lubrication) - not advancing the star nut on the return pedal stroke when there was excess cable length.

THE SOLUTION: I set the self-adjuster screw out (by manually advancing the star nut with a screwdriver) three full turns. I readjusted the cable length and VOILA! Braking power to spare.

It's possible that the worn drum diameter is the reason why the self-adjuster screw needed to be turned out. The drum looked fine, but I did not confirm that it was within the specified maximum of 161mm.

BTW, this solution would likely apply to 1998 and newer EZ-GO and Club Car brakes - anything with the Bendix-style self adjusters.

I hope that's helpful.

LukeL · 11-09-2018, 01:53 PM

I’ve had to do that myself before too. The automatic adjusters sometimes just don’t go enough. Good tip. Thanks.

Club Car DS driver’s club #59

11-09-2018, 01:43 PM	#1
Lee Hall Not Yet Wild Join Date: Nov 2018 Posts: 1	Yamaha G16E Weak Brakes This is really more of a solution that I wish to share than a question. However, I would welcome any further insights. After floundering for almost a week, I finally discovered the solution to dangerously weak braking (despite new shoes) on a 1998 Yamaha G16E. Adjusting the cable length to set the pedal free play (25-30mm) did not increase braking power at all. I had done everything correctly according to the Yamaha service manual - including turning the self-adjuster screw (or nut) in completely (but not tight). A visual inspection of the self adjusting mechanism looked normal but it was clear that it wasn't working (even with fresh lubrication) - not advancing the star nut on the return pedal stroke when there was excess cable length. THE SOLUTION: I set the self-adjuster screw out (by manually advancing the star nut with a screwdriver) three full turns. I readjusted the cable length and VOILA! Braking power to spare. It's possible that the worn drum diameter is the reason why the self-adjuster screw needed to be turned out. The drum looked fine, but I did not confirm that it was within the specified maximum of 161mm. BTW, this solution would likely apply to 1998 and newer EZ-GO and Club Car brakes - anything with the Bendix-style self adjusters. I hope that's helpful. Last edited by Lee Hall; 11-09-2018 at 01:46 PM.. Reason: Afterthought - with more info
Lee Hall Not Yet Wild Join Date: Nov 2018 Posts: 1

11-09-2018, 01:53 PM	#2
LukeL Gone Wild Join Date: Jun 2017 Location: Savannah, GA Posts: 6,539	Re: Yamaha G16E Weak Brakes I’ve had to do that myself before too. The automatic adjusters sometimes just don’t go enough. Good tip. Thanks. Club Car DS driver’s club #59

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