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Golf Cart C D I & Rings. Final Update.

yamaha g1

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#1 MH81 ONLINE  

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Posted October 05, 2012 - 10:13 PM

I started a thread about a derelict 1980 Yamaha Golf Cart I picked up and it's Carb Problems. It also had a case of the "Rewires". The PPO had done a real hack job adding lights, Brake lights & a turnsignal setup. I think some of the bare wires finally found a way to be more than a nuisance and caused damage to the CDI. At first, I thought I had done the damage testing the wiring out, but the more I played with the wiring and saw what had been done, the less I believe I was the culprit.

(Hey, It's my story, let me believe what i want...)

Here is a picture of an original CDI.
6 wire.JPG
It has 6 wires. Stator, Gnd, Spark trigger, Kill, and forward & reverse triggers.
They are on ebay for $302.61 right now. If I had to pay that, this unit was scrap metal.

I found another forum, similar to ours in helpful nature, but their particular addiction is old golf carts. In it, there was a thread about a guy who figured out how to use a 5 wire minibike CDI to do the same thing.

Here is a picture with pinout of the 5 wire unit.
5 wire labled.JPG

There are all manner of harness to fit that plug that you can buy online, most around $20. They are not weather proof tho.
The pins in this CDI are the little spade connectors, used in some electronics. Guess how many I had? (5)

The forward & reverse triggers in the 6 wire unit are coupled with internal diodes. Move the diodes to the harness and the CDI doesn't care. It doesn't know if it's coming or going, so to speak.
Diodes.JPG

I installed the CDI, verified my wires twice & turned the key. Even with the bad slop in the carb, it took right off. Spark in forward and reverse. :dancingbanana:

I sealed up the connector with silicone and tied the wires where they wont get into trouble. Another little job done.

The diodes I had from something or other, crimp connectors were just sitting there, only thing I had to buy was a CDI.

Total cost of the 5 wire CDI from an ebay seller? $5.48 including shipping.

Kicked the tar out of $300.
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#2 Kyocum OFFLINE  

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Posted October 05, 2012 - 10:52 PM

Nice job Allen. A little research sure goes a long way and keeps the wallet a little chubby.
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#3 Texas Deere and Horse OFFLINE  

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Posted October 05, 2012 - 11:00 PM

Way to go Alan, Glad you got it fixed.
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#4 jms180 OFFLINE  

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Posted October 06, 2012 - 06:51 AM

I think you are a very resorceful man. I love it when a plan comes together.

Edited by jms180, October 06, 2012 - 07:03 AM.

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#5 Alc ONLINE  

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Posted October 06, 2012 - 07:52 AM

That's great to be able to rework something as complex and a CDI to use in another application :thumbs: Could you explain what "forward and reverse triggers" are ? Al
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#6 MH81 ONLINE  

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Posted October 06, 2012 - 09:38 AM

This 2 cycle engine is designed to run both forward and backwards. Assuming 17 degrees BTDC when running forwards, the same pickup would be 17 After TDC when in reverse. To deal with this, they put in a second pickup, the f/r switch disconnecting the one not used.
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#7 HDWildBill OFFLINE  

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Posted October 06, 2012 - 10:45 AM

Alan that is great! When we were talking I had a bit of a problem wrapping my head on how this forward and reverse thing worked but looking at the pic's and your explanation I now see how the mod works. Nice job.
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#8 Guest_rat88_*

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Posted October 06, 2012 - 11:00 AM

Good find!
I have an '84 ezgo 3 wheeled cart. It was a basket case when I got it , but the price was right. I went through it and bought (almost) everything that could go bad while they still made parts for it. It got kinda pricey at times but it should last another 40 years.
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#9 wvbuzzmaster OFFLINE  

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Posted October 06, 2012 - 11:04 AM

Great work Alan, so what is the next step in the project?
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#10 bh115577 OFFLINE  

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Posted October 11, 2012 - 12:34 PM

Very creative repair and gotta love a $5 fix.
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#11 MH81 OFFLINE  

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Posted October 12, 2012 - 06:48 PM

OK, I managed to take a few vids before the muffler plugged up and made it nearly impossible to get started again. Too much back pressure is not something these engines like.
I'm going to try the "Muffler BBQ" method to get the nasty stuff out, but I may have to cut it open to fix... Dunno.
Anyways, here's the unit running (finally)


and I hit a button on the bump that turned the camera off, so here's part 2

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#12 olcowhand ONLINE  

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Posted October 12, 2012 - 06:56 PM

She runs nice....smokey, but nice! :D
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#13 HDWildBill OFFLINE  

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Posted October 13, 2012 - 10:49 AM

Thanks for sharing the vid's Alan. Like you said you have gotten past the first big goal and that was to get it running. Now you can address the other things it may need.
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#14 MH81 OFFLINE  

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Posted October 24, 2012 - 10:16 PM

OK, Finally have a minute to do an update.

It's been a hard starter (much better with spark) and I decided to tear into it a little. Caseguy was up for a little while. He gave me a hand and kept me on the straight & narrow.

I had it running and then I decided to do a compression test. When I say almost no compression, i mean almost none.


These are the rings.
PICT0016 (Custom).JPG
Nearly as whooped as the throttle shaft was. Testament to the tenacity of this little engine... dunno HOW it ever ran.
They have not expanded since removal and the gaps you see are what we saw when we looked in the exhaust port. Most of the missing pieces were found, but some went out the exhaust I'm sure.

PICT0017 (Custom).JPG PICT0018 (Custom).JPG
PICT0019 (Custom).JPG PICT0020 (Custom).JPG

The taper is a mystery to me, but I suppose anything is possible. IDK how many million miles are on these rings, but the cylinder is just within specs for std rings still. Got lucky there.

Waiting on a callback from the local guy, but I've found them online for around $20 + shipping.

Will update again when I get them and get a chance to install.
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#15 mjodrey ONLINE  

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Posted October 25, 2012 - 05:44 AM

Way to go ,Alan. :thumbs: Those Yamaha gulf carts are nice rigs.I have an E-Z-GO,and a Harley Davidson.The Harley smokes real bad,but keeps the skeeters away. :D





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