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  #1  
Old 01-03-2016, 05:58 PM
rmack898's Avatar
rmack898 rmack898 is offline
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Default Yanmar Ha

I have been fairly busy for the past 10 months working on this project. It was supposed to be a real quick, low budget project but it spiraled out of control after the first day or two and is still not complete after all this time although it is almost done (I think). Its going to take a while to catch you up to where I am today but I'll endeavor to persevere.

It all started when I decided to clean out the overgrown area behind my shop, it was a dumping ground for all things that found their way home with me.

I came across an '90s vintage Yamaha G16 golf cart with no motor. I was going to list it on CL and see if I could get a few bucks for it. On the way to the computer in my office I saw the brand new 3 cylinder Yanmar diesel engine that I got in trade for the labor on a job I did last year, that had been sitting under the bench collecting dust. Then I remembered that I had a brand new set of wheels and tired off an ATV sitting in the shed. I figured I would put it all together real quick and cheap since my toy budget was all gone. Well I was wrong because I have spent more than a few hundred $$ to this point and I'm still not done. I have to get it done now as I just got my next major project as a Christmas gift from one of my neighbors (I'll get to that in a separate thread).

So here is what I started with:
A Yamaha G16 cart with no motor
A brand new Yanmar 3 cylinder 23HP diesel engine
A brand new set of wheels and tires of a Suzuki 700 King Quad
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  #2  
Old 01-03-2016, 06:15 PM
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rmack898 rmack898 is offline
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If you haven't figured it out yet, I'm calling this thing the Yanmarha.

I thought the first thing to do was to make the cart a roller with the new rolling stock. The ATV wheels have a different bolt pattern and offset than the stock golf cat wheels so I needed some way to make it work. For the back wheels I opted to make a spool type adapter with the 3" offset.

I had some round stock that was almost 6" so I sliced off 4 pieces 3/4" thick for flanges and used 2" sch80 pipe for the spool. I drilled the old bolt pattern on one side and the new bolt pattern on the other and welded them up. This is the point where I had to spend some money and buy some wheel studs to go in the outside flanges. I was still in the mindset that I could do this build inexpensively, but I was unaware of how wrong I was at the time.
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  #3  
Old 01-03-2016, 06:27 PM
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rmack898 rmack898 is offline
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With the spools for the real wheels welded up, I pressed in the new wheel studs and mounted the rear wheels. That's when I realized that I had some major clearance issues with the real wheels and I need to modify something to make it work.

I figured that I needed to make the cart a roller on all 4 wheels before I went too much further so I started to figure out what to do with the front wheels because a spool type adapter was not going to work up front.
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  #4  
Old 01-03-2016, 06:48 PM
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LKeithR LKeithR is offline
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Quote:
Originally Posted by rmack898 View Post
...It was supposed to be a real quick, low budget project but it spiraled out of control..
Funny how projects like that can get away on you, isn't it?

You didn't mention which model motor you have but here's a link to a site that has a whole bunch of Yanmar engine manuals--hope yours is in there...

Yanmar Manuals

Oh, and by the way, I think you've earned a big YOU SUCK!!! A running 3 cyl. diesel engine is a nice score...
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  #5  
Old 01-03-2016, 07:08 PM
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rmack898 rmack898 is offline
That HURT!
 
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Quote:
Originally Posted by LKeithR View Post
Funny how projects like that can get away on you, isn't it?

You didn't mention which model motor you have but here's a link to a site that has a whole bunch of Yanmar engine manuals--hope yours is in there...

Yanmar Manuals

Oh, and by the way, I think you've earned a big YOU SUCK!!! A running 3 cyl. diesel engine is a nice score...
Thanks Keith but they only had the specifications for my motor on that site, no manual.
There's no suckage here, I did a job for a guy and I ate the labor in trade for this motor. While the motor is worth more than the labor on that job, that job kicked my ass.

On to the front wheels. The stock front hub on the Yamaha was made from some cheap cast or drop forged mystery metal that did not seem up to the task of supporting bigger wheels. Since I needed an additional 3" of offset, I opted to make new hubs out of steel. I took measurements from the stock hubs and turned the shoulders in the new hubs so that I could use the original Yamaha wheel bearings. Once the new hub was done, I made new flanges with the new bolt pattern for the ATV wheels and welded them up. I installed the stock bearings in had new hubs.
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  #6  
Old 01-03-2016, 08:25 PM
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rmack898 rmack898 is offline
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OK, now that I have all the wheels mounted it's officially a roller

Now that I have it rolling a whole bunch of clearance issues surfaced.
At this point I have about a month of work into this thing. Now I have to come up with some solutions to deal with the clearance for the ATV wheels.
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  #7  
Old 01-03-2016, 11:24 PM
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milomilo milomilo is offline
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Looking like fun project. Not trying to be picky, but aren't your tire treads backwards?
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  #8  
Old 01-03-2016, 11:29 PM
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Quote:
Originally Posted by milomilo View Post
Looking like fun project. Not trying to be picky, but aren't your tire treads backwards?
Look again
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  #9  
Old 01-03-2016, 11:33 PM
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Opps I looked again
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  #10  
Old 01-04-2016, 10:38 AM
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That will not matter as thte next step will be a set of 33 inch mudders , a locker diff and a Garrett turbo to get the wheel hp up for mud racing
it is amazing how quick a simple fun project becomes a serious resource consumer.
Except those tires it looks good.
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