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Old 09-05-2010, 09:59 PM   #1
SwampFox
Not Yet Wild
Yamaha
 
Join Date: Sep 2010
Location: South Carolina
Posts: 50
Default G9? What are potential problems

Just picked up a JG5 gas that appears to be a 1991 G9? Does that sound right?
Cart runs OK kind of abused.
I need to reinstall the neutral start switch, adjust the gear selector, set camber/toe in.
Muffler is stock but some idiot drilled some holes in it then patched with a muffler repair kit. Also drilled a bunch of holes in the bottom of the air box.
Found when I got it home the frame had damage, or broken under the battery and next to the back up buzzer. Very amateurish repair.
Basically ragged out but the brakes are good and the engine seems strong, no smoke starts easily without choking.
No front bumper, rear bent, torn up and painted seat covers.

I plan on using this on some acreage I have, no hills but can be rough.
This is what I plan I would love all opinions.
Have the frame welded professionally, change to K&N air filter, just because I don't want to hassle and expense finding a new air box and filter. Plowman muffler.
Possibly lift the cart 4-6 inches but am unsure about the Jakes VS the less expensive lift kits. $200 difference.Not including having to buy new tires and wheels.

I've been reading through page after page on the site, lot of good info but I also need to find out what to look for as for possible problems in the clutch area or trans., suspension etc. Any other potential problem areas? I am a mechanic but not familiar with gas carts. Sorry for long post.
Thanks!

Oh where can I get a oil breather filler cap?
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Old 09-06-2010, 09:57 AM   #2
Flintrock
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Join Date: Nov 2008
Location: Central Texas
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Default Re: G9? What are potential problems

91 was the first year they made G9's so it could very well be. Look for the ID tag on the frame under the seat behind the driver. The K&N will work but you will need a larger jet, they are available from site sponsors. The g9's are tough little carts, but you are right to have the frame professionally welded. As for the lift, you said the going could get rough, and there is a reason the Jakes and others are more expensive than the cheaper imitations, they are made out of stronger materials. Pay the difference for a quality lift kit. Good luck with the cart and post up pictures of your progress!
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Old 09-06-2010, 07:42 PM   #3
Mike Mac
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Join Date: Jun 2009
Location: Phoenix
Posts: 7,799
Default Re: G9? What are potential problems

Good deal on reading the Yamaha site. Read the whole thing, you will learn much!

Do all the maintenance on the cart, it will alleviate most if not all problems with the cart, short of welding the frame and the holes in the muffler and air filter.

I fiber glassed part of the filter housing, that I had to modify on mine, so that is doable to keep the large stock filter element. Also water proof!

Before you spend money on it, you may want to measure from the center cross member to the front and rear suspension on both sides to make sure the frame isn't bent or sprung beyond its useful purpose.

I agree with Flint, about the lift. Jakes, you wont be sorry, and with tall tires, you wont believe the suspension and ride you will acquire. The cheaper lifts, tend to bend, or worse, break, leaving you stranded.

On a happy note, these Yamaha carts have a way of growing on you, and you might have allot of fun working and playing with it. Most of us here are bitten by the bug.

The oil cap can be purchased from a sight vender or local Yamaha dealer.
Good luck Mike
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Old 09-06-2010, 07:54 PM   #4
sho305
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Join Date: Jun 2009
Location: West MI
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Default Re: G9? What are potential problems

My tag is under the seat hinge, about under the shifter, inside the seat.

Watch for electrical connection issues, bad grounds, etc. The airbox you can replace maybe find on ebay or like you said just rejet it. You can hog the jet with a torch tip cleaner until you get some plug color thats what I did.

The lift, yeah if you really want a nice one get one with front shocks like the all sport or jakes they work/ride better in the rough. What ever you do get one that fits 22" ATV tires, get offset wheels, much more stable and the ATV tires much more durable and wider range of tread choices. Get some big tread they climb stuff when they don't spin if you know what I mean. The stock shocks only do so much, the larger tires do make them ride better than stock though, but then you get off road and start climbing over fallen trees and stuff, lol.

I'd clean and lube the clutches it will run best with them working properly, get a new belt with your lift unless its over 1 1/8" wide. Worn belt is gutless on a lifted cart. Check the tension cable under the starter pulley, if that is not tight it also will bog up hills. Too tight it will lose top speed. Get the new cart plug (ngk bpr2es? not the 4) and run that.
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