2002 Yamaha G22, Gas - Rebuild Drive (Primary) Clutch, New Belts

[@lennonnewberry137]

This is the best video we could possibly get if you have clutch issues. It gives you step by step instruction plus all the #'s you need to order parts. Thanks so much Kevin's Golf Carts.

[@Acula33RC]

I recently received 3 golf carts from a business that said they were "blown up, no good". I never owned a cart but I know my way around a garage so I accepted them for the fee of hauling them away. All 3 look great inside and out and are different makes. They are a green Ez Go gas 1996, 2000 Yahama G20 stretched, and a Melex one cylinder 80s 90sish. None would crank or start... until I out new fuses and battery's in them. They all 3 run like Champs. I'm so glad I found your channel to help me keep these in top notch shape. Your videos are excellent and male it easy to understand all of it. Your a good teacher dude. Keep up the great content, subscribed 👍

[@BobGallagher-dk8jo]

Nice video, very informative. One suggestion - it would be nice to know the width of the new main clutch drive belt for us that want to check how much wear our existing belts may have.

[@farley1935]

Very well done. Your audio is well described on every step

[@waltoncude748]

I haven't pulled mine yet, but think you just saved me lots of work and headaches....Thanks There are lots of videos out there, few as good as yours.

[@patcorrigan3624]

Great video, explains everything in straightforward detail along with best of camera work. Thanks for yamaha clutch part numbers.

[@darrelhooper976]

This was so helpful, I have a 2005 G22 needing the exact same thing, Thank you

[@123hotdog111]

Perfect video. I have a 2004 Toro Twister side by side and looked forever to find a video like this. Glad I found this channel. Thanks Kevin, you made a complex repair super simple.

[@ernielaurent671]

I bought a 2000 g22 last week I’ve been playing with it I find its very ez to work on & well designed. I enjoyed this video thank you .i put a lighktkit mirrors & a radio. I’m 70 years old & still like to turn wrenches. Hope to see more Yamaha videos great channel.

[@phcllc24]

Brother, this video gave me the knowledge of how to do this repair. It was exactly what i am dealing with...worn out rollers.

[@lwc2009]

I followed your steps and found the exact same thing only the roller was worn clear thru to the pin!! awaiting parts now... many thanks for this excellent video...

[@Kevinsgolfcarts]

Glad it helped

[@carsandguitars7064]

@12:00 when you’re taking the clutch apart,applying a little heat to the “spider” part of the clutch makes it easier to take apart. There is lock tight compound that’s applied to those threads.

[@Kevinsgolfcarts]

Its only red loctite. No heat needed. I prefer to avoid heat with aluminum parts.

[@s.benedetto2147]

Thanks for helping me learn more about my G16.

[@DizzyBeeApiary]

Love your videos. I had been looking for a cart for my disabled mom to get around my acreage. Came across an 07 ydra g29? They suspected blown engine. I literally just watched you repair a cart with same symptoms so for $100 figured...what the hell...got it home and found it was stuck float flooding crankcase (exact repair I watched) so $100 for the cart and a tune up kit it runs like new.. huge fan (goes back to binge watching)

[@Kevinsgolfcarts]

G29 is a Yamaha Drive. Those are solid carts. I'm not a fan of their braking system but it still beats the crap EZGO puts on their electric carts. I'm glad the video has helped you.

[@chuckstephan]

Always appreciate the videos. I've become a campground mechanic on these things. Made some extra cash using your videos!!!

[@brianpooley6635]

really appreciate this instructional video as we have a guy at the club who was a mechanic and makes it sound like every repair can only be done by a mechanic and the rest of us are too stupid to do it. The only tool most of us are missing is the removal tool. Does this tool fit all makes and also are there grease fittings on a Club Car clutch. Again these videos (which we can look up anytime) are priceless. Thanks a million

[@Kevinsgolfcarts]

I hate when someone talks down to others because they know more about something. Even the most knowledgeable person had to start from nothing. Clutch pullers are specific to a clutch type or cart make. They are not a one size fits all tool. Yamaha is the only one that I've worked on that has grease zerks on the clutches.

[@2cjtrans]

Really appreciate the video, my Yamaha Pro Hauler 700 uses the same clutch and has all the same problems as the clutch you rebuilt!

[@14hubbajo]

I just replaced my clutch rollers with the help of this video. They were worn through so bad the holding pins for them were starting to get grooves worn in them!

[@ericmekanik9683]

This is the most amazing clear video I have ever seen Kevin. Its a Go Pro you said?

[@johndavis6569]

Great video. Gives a easy to understand way to rebuild the primary clutch for my golf cart without having to dick around trying to figure things out on my own and wind up having to take it to my mechanic. Thanks.

[@thegourmetgalley260]

Thank you Kevin. I believe that’s the same problem on my g16 1996!

[@avantgardedntl]

Kevin huge thank you. I also became a campground mechanic thanks to you. Im watching and enjoying on all of your videos and on all brands and electric even though I own 2 yamaha gas powered golf carts. I see you using Red Hawk parts a lot I found a site of a guy who specializes on yamaha carts may be you know them “plowmans golf carts” they have some goodies. Just wanted to share with you. Thank you.

[@jaimec7971]

Thank you … this video is super helpful! I have this same cart G22 and will be doing this maintenance soon. Thx!

[@robertjeffery6100]

Great video Do you have a video same cart but my parking brake doesn’t like to release

[@Superspreader11]

I believe there is threadlocker on these clutches from the factory, I usually use heat to break the threadlocker loose and add it on reassembly

[@garysundelius8323]

great vedeo. do you have any thing on the 1985 G1- AM5 s/n J31-111769

[@marksutton4171]

The exact problem I have with my g16 brilliantly explained. Thank you

[@Kevinsgolfcarts]

Glad it helped

[@jamesnorris605]

Thanks for the info, was wondering about using grease on rollers . Thanks again.

[@Kevinsgolfcarts]

Glad to help

[@joemiceli9681]

Great Job Kevin on the video , your definitely a mechanic and know what your doing. Thanks it answered a lot of questions

[@Kevinsgolfcarts]

Glad to helped!

[@dcrickerson7611]

Great video! Thanks for bringing us along.

[@ericshepherd9407]

Thanks Kevin very informative. Great video!

[@silver-hy6mi]

Great video Kevin, with a good explanation of all parts and how the clutch actually works!

[@buzzer51]

Great video Kevin and excellent explanation on how a clutch works and repair.

[@alliejnelson6880]

Do you have any videos on Gas 2003 yamaha G16 that won't drive forward or reverse

[@Kevinsgolfcarts]

It sounds like you have a carb issue and the engine is just cranking and not starting. You would have to remove and clean the carb to ensure there is no debris in it. Also check for fuel flow from the pump while cranking the engine. Remove the spark plug and make sure its getting good spark.

[@garysundelius8323]

how much play can there be in the roller pin holes ?

[@Shamar-eo2bu]

Hey Kevin do you know the part number for the starter generator adjustment bolt's part number?? Or anyone else may know.

[@frankconan3153]

Best one. I have now subscribed

[@nolanmccluskey4429]

Great video, helped me out a lot, thank you!

[@markotusun5376]

Great video Kevin, i just swapped my rollers, easy when you know what to do...:) I have another issue if you can advise what to do. I have Yamaha U Max Medium Duty 1 and engine is same as G22. Suddenly lost power, drives slow and smokes through the valve cover hose. I checked compression and gauge showed 120. Is that enough or needs to be more. Please if you have advice what to check , or rebuild is needed. Thanks

[@modobadibadi1162]

Good content bro, keep it coming

[@ericshepherd9407]

Great Job! Great info!

[@Kevinsgolfcarts]

Thanks for watching!

[@charlesgreen4247]

Very Interesting Kevin! Good Job!

[@timpope1221]

Hey Kevin great video...Question will that clutch fit onto a Robins engine crank, I have a small engine repair shop and work mostly on lawn mower's but I occasionally get a golf cart in the shop so I refer to your videos for help the cart is a early 90's Ezgo 38 with a Robins engine the cart had sit for many years so after going through the carburetor and getting it running the primary clutch would not engage so I contacted a local golf cart repair shop and they advised that those type of clutches could not be rebuilt so I pulled it off and removed the spring plate I blew out all the dust and added graphite to the weights and got the clutch to slide in and out I reinstalled in and it works but to loses speed on hills which I believe is partly due to a engine with a lot of hours and a old belt but I also think the clutch is not performing as it should, so after pricing the clutch which was close to $400.00 and the clutch in your video was much cheaper I thought about using that one but I don't know what the crank size is for the one in your video if you could provide the crank size and if that clutch will work it would be greatly appreciated. Thanks !

[@Kevinsgolfcarts]

I highly doubt this clutch will fit a Robins engine. All of these clutches have tapers as do the cranks of their respected engines. The degree of taper and crank length varies between manufacturer to prevent cross compatibility. You have to ask yourself, is it worth the risk of damage by installing the correct part? How much is it going to cost to do it right the second time? I only suggest replacing it with an exact type clutch. These clutches work with the power of centrifugal force. As long as the weights are freely moving and not binding, the internal spring is not broken and the clutch faces are evenly wore without deep grooves, it should mostly be fine. Drive belts are consumable items and need to be replaced regularly. Check the compression on the engine and make sure its at or above 120psi per cylinder. You can do a wet and dry compression test to see if its extreme engine wear causing the loss of power. Also check the operation of both clutches together. If the driven clutch is not opening all the way, which is common when they are wore out, the ratio will not change correctly and you will have loss of power.

[@timpope1221]

@@Kevinsgolfcarts Thanks !

[@jerrymulholland5752]

great video, thanks, BUT, I changed rollers due to flat spot and clutched stuck in high. first test drive , all was fine until i went to top speed, same thing happened, weight swung passed 1 of the rollers. Any ide what I should be looking for?

[@Kevinsgolfcarts]

There are other components that are wore out. It would be best to replace the entire clutch at this point. Keep the new rollers as they will work in the replacement clutch (if you replace it with the exact same type).

[@frederickgerber5491]

Is there a severe duty drive belt for the Yamaha G22?

[@williamschuster4756]

Nice video. I like to change the bushings in the sliding sheave while I'm there. Do you like those red hawk belts? I've had a few fray on me after minimal driving.

[@Kevinsgolfcarts]

I have not had any issues with RHOX belts. I'm a RHOX dealer so I use them 99% of the time.

[@patrickmbasd8724]

Kevin, Love your stuff. Thanks

[@Kevinsgolfcarts]

Glad you like them!

[@rafaelgonzalez577]

Thank you excelente video

[@5Burma]

Well explained, thank you.

[@lwc2009]

another question if I may; is there a gasket between the air box and the carb? I know there is one on each side of the separator block but there was not a gasket between the air box and carb when I took iti apart..?? cant find any reference to it in the maual... many thanks...

[@Kevinsgolfcarts]

Yes, there is a gasket between the airbox and carb, carb and spacer, spacer and head.

[@lwc2009]

@@Kevinsgolfcarts thank you... you're a very patient man to answer so many questions and I ma grateful for the assistance... my domain is mainly street motorcycles but these carts are new to me.. thank you again sir...

[@Kevinsgolfcarts]

Its no trouble. I'm not always able to answer every comment but I do try to read them all. These are very simple machines, at least the old ones are. The new ones are fuel injected and I have a bit more to learn about those systems. Thanks for watching!!

[@doylefranklin8167]

Awesome video. Thank you

[@eldonpeachey3504]

Thanks helped me out !!

[@gregdavis8152]

I have a G1 Yamaha. Can they be rebuilt?

[@davidhopper3305]

What is the rattle noise at 25:29? Mine makes that noise alot...almost like a rattle or clanking noise on acceleration

[@Kevinsgolfcarts]

It could be the internals of the primary clutch wearing out.

[@danielrabines9201]

Or secondary clutch rattle

[@dennisfrancisco1018]

How to order i need spair part for my Yamaha g22 clutch roller drive belt ang special tool puller

[@sbirdranch]

What is so special about those rollers that they are sold for near $50 US for 3 of them? They look like a simple bushing to me. Any insights? ~P

[@Kevinsgolfcarts]

They are hardened steel rollers.

[@deniseruggles6751]

What is the special tool you used to take off the back part of clutch assemble? What is it called and what thread size? Do you know where to buy one? Thank you.

[@Kevinsgolfcarts]

I'm not sure exactly what you are referring to.

[@frankjohnson7640]

Great video. Doing a G16 clutch today. Was going to install new clutch. I may rebuild now. The shaft that the clutch mounts on has play. It can pull out about 1/16 -⅛ of an inch. Is that norma? The clutch actually slid on the shaft (between sheaves about ⅛”. But after running for a while, it tightened up. Any suggestions?

[@Kevinsgolfcarts]

The internal bushings may be shot. At this point, I would just replace the clutch. It should have nearly no play.

[@frankjohnson7640]

Kevin's Golf Carts thanks. I will. I did remove cover per your video. Rollers appeared to be round. Is it worth keeping? Rebuilding? It’s a Yamaha clutch. I appreciate you taking time to answer these questions and making videos

[@Kevinsgolfcarts]

If there is any slop on the shaft that the clutch slides on, then its junk and needs to be replaced. Changing the rollers will not fix that issue.

[@frankjohnson7640]

Kevin's Golf Carts replaced clutch. Now belt won’t go into high gear ((belt is 1” from top f pulleys) at top speed. Any ideas?

[@richardkessler105]

Is there a reason you don't change the pins with the clutch in place?

[@Kevinsgolfcarts]

As far as I'm aware, its not possible. You have to disassemble the retainer on the top of the clutch in order to remove the pins and rollers. Its much faster and easier for me to remove the clutch and do the work on the bench.

[@jacklabloom635]

I have a general question. Can gas powered golf carts ( 1998-2010 models ) loaded with four adults ( 2 on a rear jump seat and two up front ) climb a steep driveway? I need a golf cart for transporting four adults on a 250 yard round trip, but a 140 feet of that trip in one direction involves a 46 degree ( actually went back out today and measured as best I could ) inclined concrete driveway that has one large curve about halfway up right before the incline drops to 25 degrees for another 110 feet. Other than the steep driveway, the rest of the trip is on a flat well-compacted gravel road. I went out and stepped this off. I decided I better try to find out the answer to this question before spending $3000 for a used golf cart. Will that steep climb put additional wear and tear on any particular parts, like brakes, belt and clutch, etc.? Belts are not that expensive, but I have seen replacement clutches are pretty pricey. I assume the differential gears are strong enough to handle the climb. The cart would be used for an average of four round trips each week, approximately, ten months out of the year. I'm considering buying either a used Yamaha or a used Club Cart, 2000-2010 year models. Thank you for your repair videos. You do a great service for those of us who plan to do our own maintenance, as well as for the owners of the carts you repair.

[@rogershepard6083]

You appear to be very knowledgeable about clutches and Im have a clutch issue. I need to increase engine speed before the clutch engages. Would slightly lighter weights do that for me? Ive had the 420cc engine swap and my motor idles and it wants to creep away. Im wanting it to remain still till rpm"s are increased... Again, Lighter weights will achieve what Im needing, Right? Thanks for the video and I subscribed. Going to look for that red grease.. I like it...

[@Bo12346hhgfgdg]

where do i get that tool to remove the clutch (the large looking bolt)? thanks for the video btw.

[@Kevinsgolfcarts]

You will need a clutch puller to match the cart you are pulling the clutch from.

[@GLDWING893]

Why would a clutch like that rattle like a clattering sound when running

[@davidhopper3305]

Having same issue...have a rattle or clanking noise when accelerating...

[@DaleB809]

Always look forward to your videos Thank you

[@PatriotDad]

Great video Kevin! I am looking for some G1 clutch overhaul parts but didn't see any on your site. Do you know where I could source some? Thank you!

[@Kevinsgolfcarts]

You are probably going to have to replace the entire clutch. The older carts are getting hard to get parts for.

[@PatriotDad]

Kevin's Golf Carts Thank you for the reply! I actually lucked out. I remove the clutch and found it was full of dirt and petrified grease. I cleaned it and lubed it and it works like a champ.

[@kennethbell7318]

Awesome! Thank You Kevin

[@johnadargo3716]

How often and how much grease do you put into the grease zert?

[@Kevinsgolfcarts]

Yearly, one or 2 pumps.

[@johnhicks2593]

A GREAT video!

[@davidl7672]

Kevin, im looking at getting a 2000 yahama golf cart, im not certain of the exact model. the owner says it runs, but smokes a little. How difficult or expensive would it be to do an engine overhaul on one of these?

[@davidl7672]

actually its a 2000 G16AU - G16A (Ultima)

[@Kevinsgolfcarts]

You would be looking at a partial rebuild. Most engine places will do full rebuilds (the ones that only work on golf cart engines). Look up BG-Parts and tell him I sent you. He does amazing work.

[@rtc-1840]

I am looking to buy a 2022 Yamaha Quiet Drive2, the seller says the cart goes 32-33mph because of dealer upgraded clutches and belts. Yamaha dealer told me what gives you more speed is gears and controller, not belts….does a clutch and belt upgrade give you that much speed?

[@Kevinsgolfcarts]

The dealer is correct. Clutches and belts will not give you more speed. They have torque kits that increase the pressure the clutches need to engage/disengage. This will cause you to have less top up speed but massive torque. Gas carts to gain speed when you change the gear ratio in the transaxle and/or adding larger tires and wheels. Electric carts gain speed by replacing the stock controller, motor and battery pack. With the gain in speed, you loose torque. You may be able to do 20-30mph on flat ground but you will barely be able to climb hills.

[@rtc-1840]

@@Kevinsgolfcarts Is it OK for the engine to be running at 30mph speed’s? Because I don’t know exactly what the modifications were I’m worried the engine will blow should I worry?

[@Kevinsgolfcarts]

Most small gas engines have a maximum of 3400-3600 RPMs. If the gearing and tires ratios aren't way out of wack, it should stay under these max RPMs. Just like your car, it has a transmission in between the engine and tires. The engine doesn't know how fast the cart is moving along the ground. If you are worried about it, just walk away from this deal. It already sounds like its been oversold and hyped up.

[@jws3925]

Hey Kevin; A while back I made a comment on one of your videos regarding the quality and reliability of different brands of carts. I have had good luck with Yamaha gas carts and mentioned something about it was my choice for gas. You came back and said that sadly Yamaha has made some changes to their carts which you felt was a step in the wrong direction and likely "cheapened" their carts. Could you be more specific? I am in the market for a new gas cart and was automatically thinking Yamaha but if there is another brand I should consider in your opinion, I'd like to know what it is and why. Thanks for all your videos!

[@Kevinsgolfcarts]

I'd go with Club Car. Yamaha has cheapened their carts to a disappointing level.

[@jws3925]

@@Kevinsgolfcarts Even with the Kohler motor? I've had some bad experiences with Kohler motors on mowing machines. If they still had the Kawasaki motor I'd likely be looking more at Club Car because my present 1994 with the Fe290 has been absolutely dependable. So, have you worked on the Kohler motors in the Club Car yet? If so, you think they will hold up like the Kawasaki's? Any specific areas that you feel Yamaha has cheapened their carts? Thank you for taking the time to respond. It is much appreciated. So far, I have done all more own work on my cart, many times thanks to you!

[@joncutt872]

I have a g2 thats a bit jumpy when you give it just a little gas. I think it's in the linkage on the axle. Any thoughts?

[@Kevinsgolfcarts]

It could be the drive belt. When they get wore out, they don't "grab" correctly and slip. It could be the clutches are wore out. Saying its "jumpy" its a bit vague. Does the engine run smooth or rough? Service the engine by changing the oil, spark plug and filters. Clean the carb if its been a while. Make sure the brakes are adjusted so they are not dragging.

[@magicfalcon1]

Hi I smell gas when going downhill without throttle any idea why

[@Kevinsgolfcarts]

Your throttle cables may be out of adjustment. If the butterfly valve (the part tha moves inside the carb when you press on the gas pedal) is staying open when the accelerator pedal is fully released, then you will need to adjust them so it completely closes. If this is open when the pedal is released, it allows the engine to pull in unburned fuel and pump it out the exhaust. This can cause backfiring as well.

[@magicfalcon1]

@Kevinsgolfcarts thanks for the reply I shall check that tomorrow

[@Kulpythekulpster]

ok I'm an idiot. I broke the tensioner bolt. I tried to find the bolt online. you happen to know the bolt size and thread or a part number?

[@Kulpythekulpster]

m6x1 or m5x0.8 ?

[@jessegrimm9274]

Thanks for the great info!

[@kevinsherrill711]

excellent video!!!!

[@Kevinsgolfcarts]

Thank you!

[@jacklabloom635]

Another great video.

[@EluderRacing]

another great video!!! I have a off topic question for you I have a 36volt ezgo cart with a lift and oversized tires and like most now it has a lot less power and struggles to go up hills and pull my trailer. my question is I always see a lot of people installing high torque motors and speed controls cables etc... but I never hear anyone ever mention changing the gear ration in the rear end or installing rear ends out of other types of carts. do you know if anyone sells gear sets for carts? or is there a rear end swap that can been done?

[@Kevinsgolfcarts]

Depending on the generation of your cart, high speed and high torque gear sets are available for most carts. There is a fine line between speed and torque. To gain one, you lose some of the other. If you have modified the drivetrain and pulling a trailer, I would suggest a high torque motor/controller and 48 volt battery upgrade. Most high torque motors and controllers run on 48 volts only. Swapping out gearsets is an option as well but electric carts do better with motor/controller upgrades. Keep in mind, regardless of the battery pack voltage, higher energy consumption will result in less drive time.

[@seadog1955]

My g16still pops fire out the carb

[@lanceulbrich6249]

They red tlloctite them from the factory hit it with just a bit of heat it will just come right off

[@danielrabines9201]

Now do it on it Yamaha g29/drive please 🥺

[@Kevinsgolfcarts]

G29 clutches are not rebuildable.

[@lwc2009]

this wil be my guide to fixing my &%$#@*& up clutch... many thanks... love your vids!!!

[@Kevinsgolfcarts]

Great to hear!

[@DaleB809]

Where r ya

[@ramboollie8115]

Put some heat to it

[@Contractorrepair]

she's locked up. rollers , etc..

[@garysundelius8323]

how much play can there be in the casting roller pin holes ?