Yamaha G2 G9 How to Replace Rings?

[brettnico]

I have a Yamaha J38 engine from an old Taylor Dunn industrial cart (I think it’s the same used in the G2 and G9 carts). It blows smoke like crazy, so I figured I’d see if i could replace the rings. I got the engine out an part of the top end off (I can definitely see that the piston is not snug in the cylinder)... but I can’t figure out how to get to the piston out to replace the rings?

I’m pretty sure i need to go in through the crankcase, but don’t know how to get the rest of the clutch off? - I got the main part of the clutch off, but i’m sure I need to get the other half off (where the starter pulley goes on) before I can open the crankcase. after that, hopefully I can get the camshaft and unbolt and release the piston.

Need some help! - Am I at least going in the right direction (I’ve looked all over the threads as well as youtube and can’t find anything).

Would love some help. Thanks! Paul

[cgtech]

You need a specific puller bolt to remove the clutch. Available from erlandson. The same tool is used for all stock clutches from g2-g22.

[raydhd]

There is no way that will come off with the stock puller.I hope for your sake a clever yamaha man figures this one out.Somehow you got the clutch off and left the S/G pulley on.I did not this could happen.

[rfincher86]

I need to replace rings in mine as well. Sucks to know that the jug doesnt come off the crankcase..

Sent from my VS980 4G using Tapatalk

[smallblock450sl]

Most Yamaha dealers will use there puller to take it off for you, expecially if you buy the OEM parts needed from them. At least I do. As for the cylinder being part of the block, you just don't know until you disassemble/hone and check clearances. Yamaha's do have a tendancey to wear/colapse the oil rings, causing to burn oil/smoke, but many time a good hone and new ringsvalve job take care of it for many more years.

[cgtech]

Originally Posted by raydhd

There is no way that will come off with the stock puller.I hope for your sake a clever yamaha man figures this one out.Somehow you got the clutch off and left the S/G pulley on.I did not this could happen.

It absolutely will come off with a stock puller bolt. He only removed the sliding sheave, spider & weights. Once the clutch retention bolt is removed, those items slip right off (on a G2-9 style clutch). The threaded portion the puller engages is still there inside the shaft the sliding sheave rides on.

[raydhd]

I stand corrected. My bad! I did not think there was enough of the clutch left to use puller.

[slonomo]

My advice to anyone tearing into an engine....get the factory service manual. Lots of good specs, procedures, and diagrams. Will save you time and money in the long run.

[G1-G9]

Someone on here has it and can e-mail it to you but i dont remember who sent it to me. Sorry.

[whiteriver23]

Try this link:


http://yamahagolfcar.com/partsandservice/default.aspx

I had a G9 on my computer somewhere but I'm not finding it now!

JP