Yamaha Golf Cart Repair Manual J17 G1

28.12.2019

Yamaha Golf Cart Repair Manual J17 G1 3,9/5 5494 reviews

Yamaha Golf Cart Engines
Yamaha Golf Cart Troubleshooting
Yamaha Golf Cart Repair Manual

I thought I'd contribute a thread dedicated to G1 information geared toward new G1 owners. Here they can find all the great threads with pics and info about their 'new to them' G1 golf carts. Please post info only, no questions. Start a new thread for questions. Please post links to 'good' threads that contain quality info and pics.

Please do not post anything other than 'good info' relating to G1's. This thread will contain the basics about G1 carts, maintenance, common problems and solutions, lift kit and tire information, and custom modifications. Let's keep this thread clean for the new forum members so they can read 'everything' about G1's. Thanks to everyone that wants to contribute, and good luck! I'll start with a basic overview of the G1 gas carts. Yamaha G1 Golf cart Built from 1979 to 1986 Available in both 2 stroke gas and electric models Timeline Serial # ID G1 GAS: The G1 gas cart is a 215cc two stroke oil injected engine.

The engine was derived from a snowmobile engine, possibly the Enticer 250 since some of the parts are interchangeable and the block castings are nearly identical. They are known for their ruggedness and durability, as some of these carts are 30 yrs or older and still going strong! Reverse gear does not exist on these carts, rather the engine turns backwards to get reverse. You'll note on the inner fender on the passenger side there are a set of solenoids. These are the components that allow the engine to start backwards and run in reverse.

The factory oil injection system mixes the oil automatically at ratios ranging from 150:1 to 300:1, according to the service manual. Sometimes these injection systems can fail and cause engine damage, so often times people disconnect them and use premixed oil/gas. Reported premix ratios range from 40:1 to 100:1, maybe even higher, and are 'at your own risk'. I am not recommending this modification, simply reporting what I've found on this forum. Please do this modification at your own risk and be aware that engine damage and failure can result if the mix ratio is not correct.

Power for these carts is in the 8hp range, give or take 1 depending upon weather, fuel, and driving conditions. Getting more power is not easy on these engines because they are low compression, low rpm engines and are not really designed for max power. Switching to a 'big block' is not usually a good option because you would lose your reverse and would need to swap out the rear end/transaxle to a 4 stroke model with a reverse gear.

Speed of these carts have been reported around 12-15mph with the governor intact and as high as 30mph with the governor modified. Do not modify your governor or engine damage could result.

Body parts are both plastic and fiberglass. The front fenders/clip portion is some sort of a plastic material and the rear section is a reinforced fiberglass with a steel framework that tilts up for engine access.

Year Identification is typically done by verifying the serial number on the frame. The common location is behind the rear bumper on the round main frame. The number is stamped/engraved and might not be visible if there is alot of rust and dirt. Clean the area off and lightly sand the area with a scotchbrite type pad to reveal the numbers.

Do not sand off the paint or rust will start there. Lift kits are available from a couple aftermarket mfgs and some people choose to install their own fabricated lift. 4' lift is required for 20' tires. 5-6' lift is required for 22' tires.

Any more than 22' tires will require some kind of a custom lift and/or swing arm drop, which is quite a lot of work for most. Some frame trimming in the wheel wells may be needed. The frame may need modified to allow clearance for the primary clutch. My first recommendation is to purchase a service manual from one of our fine sponsors. The manual contains specs, procedures, drawings of pretty much everything you need to know to work on your G1. All of the info you need on the following problems can be solved with the info in the manual.

Read through the entire manual and you'll learn a ton! Common Problems Since most of the G1's are high use carts and very old, your typical issues come up. Tune up issues, spark plug, air filter, fuel filter, carb cleaning, clutch maintenance, belts, old gas, oil mix, dead battery, etc. Compression needs to be in the 100psi range to run good, and a fresh rebuild should have around 120-130psi. If you happen to have a 1982 model, sorry but your engine is a lower compression unit and will be around 90-100psi. The 1982 model was Yamaha's attempt to calm down emission and noise, but they scrapped that idea when they realized how much performance was lost and for 1983 went right back to normal.

Lower compression is most commonly caused by worn piston rings or oil seals. Frame rust is always an issue, particularly in the battery tray area.

Alot of people over the years cut the old tray out and don't replace it. There are a number of ways to replace the tray, but a custom fab job is likely what needs done. Some new metal angle, sheet metal, a new hold down, some cutting and welding and paint will be in the project. Some other areas are the cross tubes and swing arms because they see the most action and dirt/grime and get washed off the least.

Again custom fab to repair. Oil Injector failure is something that comes up, although I've never seen one fail, I have heard reports of that happening. If this happens it will likely cause engine damage.

Oil seals for the crankshaft are common wear points. If you have trouble starting your cart or it runs poorly, the oil seals are one of the common causes. Worn seals will cause lower compression and poor performance. Look behind the primary clutch and see if there is wetness or oil residue on the crankshaft.

If so you'll likely need to to replace the seals. Clutch issues will cause poor power and speed. The primary clutch can accumulate dirt and grease and cause the clutch to not engage properly.

Taking the cover off and cleaning all the dirt and gunk out regularly will go a long way to restore performance. Don't forget to lube the shaft with a tiny amount of grease, too much will cause it to fly out into the clutch housing.

The secondary clutches often wear through and/or 'dish out'. This causes the cart to not have a high top speed, or can cause it to have no low end power. Drive belts will often wear out/down and cause poor shift out and poor power/speed. Replace belts regularly and measure them to make sure they are in spec. Fuel pumps often fail in these carts.

You can rebuild/clean yours so read up on that. New ones can be found for around $40-50. Or you can rig up a fuel pump from a tractor. If you don't have fuel at the carb, look to the pump or fuel filter. Old gas is really a basic that people often forget.

The gas in the tank from a cart that has been sitting is likely not any good. And likewise the gas in your gas can from last fall may not be that good either. If you can't get your cart running, buy some fresh gas and try a new plug. Don't forget to fill the oil reservoir! More to come.

So here is a quick walk though putting crank seal in the clutch side of a G1. Remove the gas tank Step 2. Remove the outer clutch cover via the Phillips head screw Step 3. Remove the long bolt holding the outer clutch plate one (7/8' head)Remove the outer clutch plate Step 4. Remove the drive belt and starter belt. Using a clutch puller (can be bought or you can make your own.

I bought mine) remove the inner clutch plate/shaft Step 6. Remove the oil pump gear housing and pull BOTH the inner and outer housing off of the engine case Step 7. Run a screw into the seal and using a claw hammer pry the old seal out.

Put the new seal in (put some oil on the part of the seal where it slides on the crank shaft to keep it from catching and tearing). Reinstall everything the way it came off. Hope this helps. First of all, great idea on this thread Slo! I'm a newbie myself (bought my G1 last fall) I've found lots of great info on this site. One tidbit I came across (Sorry, no link as I don't remember where ) Has to do with what I'm guessing would be a common upgrade, adding lights.

The frame on the G1 is NOT grounded. If you wish to add lights or other electrical accessories you will have to run a ground lead as well as a positive lead back to the battery. Many of the new light assemblies for tailights, marker lights, etc for auto/trailer applications don't even have a ground wire. They rely on a screw into metal to ground. You can still use these, just mount with a machine screw and attach a ground lead to the back side with a nut and washer. I'll try and get some pics of my tailight install up this weekend. Solenoids: These parts are mounted on the passenger side inner fenderwell and are responsible for directing power to the starter/gen.

Yamaha Golf Cart Engines

One solenoid is used for forward operation. The other is used for reverse. If you are having trouble with one direction but not the other, look to these solenoid or the related wiring. If you do not have a service manual, this would be one area that you should consider getting one to help you.

The wiring diagrams will help you figure out where things go and what does what. Some related links: Alot of the problems I've read about have been attributed to loose connections, corrosion on terminals and connections, and frayed or chaffed wires. Make sure you get a really good flashlight and trace the wires you think are suspect and inspect them from one end to the other. Most times you'll find the issue.

Yamaha Golf Cart Year & Model Guide for Golf Cart Accessories Performance Plus Carts carries a wide selection of Yamaha Golf Carts, Golf Cart Parts and Accessories. To help you find the right parts and accessories for your Yamaha Golf Cart, we've put together a basic year and model guide. Yamaha Serial Numbers will indicate the year of production. View the serial guide below or contact us for questions. Yamaha G1 Golf Cart began production in 1979. The serial number is located near the drivers side rear tire underneath the golf cart.

G1 - GAS G1 - ELECTRIC J10-000101 = 1979 J14-000101 = 1980 J10-007705 = 1980 J14-100101 = 1981 J10-030101 = 1981 J22-000101 = 1982 J17-000101 = 1982 J26-000101 = 1983 J24-000101 = 1983 J36-000101 = 1984 J31-000101 = 1984 J36-010101 = 1985 J31-100101 = 1985 J36-011212 = 1986 J31-140101 = 1986 000-000000 = 0000 J31-159082 = 1989 000-000000 = 0000 - The Yamaha G2 began production in 1985 and the serial number can be located in one of two places. Either under the seat towards the front of the golf cart, or under the front bumper on the frame of the golf cart.

Yamaha Golf Cart Troubleshooting

G2 - GAS G2 - ELECTRIC J38-000101 = 1985 J41-000101 = 1985 J38-007101 = 1986 J41-016101 = 1986 J38-020101 = 1987 J41-030101 = 1987 J38-071101 = 1988 J41-053101 = 1988 JA2-000001 = 1988 JE2-000001 = 1988 J55-000101 = 1989 J56-000101 = 1989 J55-100120 = 1990 J56-100101 = 1990 J55-200101 = 1991 J56-200101 = 1991 - The serial number on a Yamaha G3 Golf Cart is located near the passenger side rear tire underneath the golf cart. G3 - GAS G3 - ELECTRIC J42-000101 = 1986 J46-000101 = 1987 - The Yamaha G5 Golf Cart was introduced in 1990. The serial number can be located underneath the front bumper area on the frame. G5 - GAS G5 - ELECTRIC J50-000101 = 1990 J51-000101 = 1990 J50-100101 = 1991 J51-100101 = 1991 J50-200103 = 1992 J51-200101 = 1992 J50-300101 = 1993 J50-400101 = 1994 J50-500101 = 1995 - The Yamaha G8 Golf Cart serial number is located under the passenger side seat towards the front of the golf cart. G8 - GAS G8 - ELECTRIC JF2-000007 = 1990 JF3-000005 = 1990 JF2-100101 = 1991 JF3-100101 = 1991 JF2-200101 = 1992 JF3-200101 = 1992 JF2-300101 = 1993 JF3-300101 = 1993 JF2-400101 = 1994 JF3-400101 = 1994 JF3-401801 = 1994 JF3-402000 = 1995 - The Yamaha G9 serial number location is underneath the seat towards the front of the golf cart. G9 - GAS G9 - ELECTRIC JG5-000101 = 1991 JG6-000001 = 1991 JG5-100101 = 1992 JG6-100101 = 1992 JG5-200103 = 1993 JH7-000125 = 1992 JG5-300101 = 1994 JH7-100101 = 1993 JG5-400101 = 1995 JH7-200149 = 1994 JH7-201801 = 1994 JH7-300101 = 1995 - The Yamaha G11 Serial Number location is underneath the seat towards the rear of the golf cart. G11 - GAS JJ3-000101 = 1993 JJ3-100101 = 1994 JJ3-200101 = 1996 JR3-000101 = 1997 JR3-100101 = 1998 JR3-200101 = 1999 JR3-300101 = 2000 - The Yamaha G14 & G16 serial numbers are located underneath the drivers side seat towards the front of the golf cart.

Some models may have the serial number located inside the drivers side glove compartment as well. G14 - GAS G14 - ELECTRIC JN3-100101 = 1995 JN4-100101 = 1995 JN3-200101 = 1996 JN4-200101 = 1996 G16 - GAS G16 - ELECTRIC JN6-000101 = 1996 JN8-000101 = 1996 JN6-100101 = 1997 JN8-100101 = 1997 JN6-200101 = 1998 JN8-200101 = 1998 JN6-300101 = 1999 JN8-300101 = 1999 JN6-400101 = 2000 JN8-400101 = 2000 - The Yamaha G19 serial number is located inside the drivers side glove compartment or under the rear bumper attached to the frame. G20 - GAS G19 - ELECTRIC JR8-000101 = 2000 JR1-000101 = 1996 JR8-100101 = 2001 JR1-100101 = 1997 JR8-200101 = 2002 JR1-200101 = 1998 G21 - GAS JR1-300101 = 1999 JR6-000101 = 2001 JR1-400101 = 2000 JR6-100101 = 2002 JR1- 500101 = 2001 JR6-200101 = 2003 JRI-600101 = 2002 JR6-300101 = 2004 - The Yamaha G22 or better known as the G-MAX began production in 2003 and the serial number is located inside the drivers side glove compartment. G22 - GAS (G-MAX) G22 - ELECTRIC (G-MAX) JU0-000101 = 2003 JU2-000101 = 2003 JU0-100101 = 2004 JU2-100101 = 2004 JU0-200101 = 2005 JU2-200101 = 2005 JU0-209201 = 2005 JU2-205701 = 2005 JU0-300101 = 2006 JU2-300101 = 2006 JU0-310101 = 2006 JU2-306201 = 2006 JU0-400101 = 2007 JU2-400101 = 2007 - The Yamaha Drive is the newest addition the the Yamaha Golf Car line and began production in 2007.