Yamaha Build

[Rye]

Hello hello my friends, first time poster here, wanted to share my project Yamaha golfcart build..... still a work in progress, but still a pretty rad setup.

Got the cart from a coworker who had abandoned the project for a steal.

Was told it is a 95 G16 (though after getting it, more likely a mix of a few different models.

Had a 78 Skidoo everest 440e engine that runs (ran) as well as a Jake's front and rear suspension lift and disk brakes kit.

The day she came home!











This will be a picture heave thread, if there is anything anyone wants a better picture of let me know.

Enjoy the build!

-Rye

[Rye]

First order of business, replace the starter because pull starting is a PITA.

Couldnt find the exact one, so got this one via FLEA-bay. Made it work with some modification to the bracket and some grinding on the starter nose.







Starts with ease now.... 🍻

[Rye]

After some messing about... decided to tear it down and fix the bits that were hacked.... down the rabbit hole!







More dirty than anything else.... also the motor was mounted terribly... and the brake master was not installed effectively so yank.

[Rye]

Removed the swingarm and mocked the motor up where it was level and had room to move....



Cut all the old BS off the swingarm and cleaned it up...



Cut and welded the swingarm at 10 degrees to keep the axle at the proper angle and started the motor mounting brackets..

[Rye]

Really hated where the rear wheel fell with the lift kit, so decided to strech the swingarm.... first ordered new links to replace the bent original ones with long and stronger... only real issue was the bushings being for 1/2" so turned some bushing inserts to use stock bolts on axle and frame connection points.






Rear wheel sits much nicer now....

[Rye]

Got a stock pipe for this motor on ebay as well for 50$, gonna slice it up and get it routed where I want...





Also relocated the rear shocks (these are off a motorcycle) to fit the longer wheelbase...





Further bracing for the engine mount:

[Rye]

Had a local metal shop plasma cnc some parts I designed out of .25" A36 steel, this will act as motor slide for belt tensioning as well as support gussets for the swingarm:



Mocked up: (also slid the motor further forward)

[Rye]

Full swingarm assembly out for weldup.







Got tired of looking at the rusty exhaust so I blasted it.

[Rye]

Decided to run a rear only handbrake, and remove the locking footbrake mechanism.... had to make some weird brackets but works good.



Basically uses a short brake cable from the handbrake to pull on this level I made with bearing pivot to push the rear brakes.... could have made it fancier... but never seen and it works.

Ill have to take some pictures of how it engages... sorry

Also added a pulley setup to move the pull start: (and cut a big vent for the engine fan

[Rye]

Next the rear bumper setup... wanted to add a hitch, move the bumper back as well as add a rear sway bar (which ironically also came from a sled)











Also re-enforced the front end where the frame bends and where the fron suspension attaches with .25" plate