Yamaha G22 Lift Kit Installation

Tools & Equipment:

• Wheel Chocks
• Floor Jack
• Jack Stands
• Small Pry Tool
• Socket Set Wrench Set
• Needle Nose Pliers
• Mini Impact Driver with approved attachments and sockets.
• Parts Cleaning Solution
• Grease Gun – With Wheel Bearing Grease
• Torque Wrench
• Shop Rags

Personal Safety Equipment

• Work Gloves,
• Exam Gloves (Allergy Free),
• Safety Glasses

Parts: (Not provided in the kit)

• Cotter pins – If not re-using the original pins Bolts and Nuts – Inspect all parts and determine if you will clean and re-use or replace them.

Procedures:

Front

1. Make the cart as safe as possible for lifting with a floor jack. Chock the rear wheels and apply the parking brake. Remove the key from the ignition. Note: Unless otherwise specified, assume that all bolts, nuts, spacers, washers, clips, pins and/or other fasteners will be cleaned, inspected, lubricated and re-used. Some, but not all, of these items have replacements that come with the kit.
2. Loosen the lug nuts for the front wheels.
3. Lift the front end of the cart high enough to accommodate the lift kit and larger tires. Lower the cart onto the jack stands and roll the floor jack out of the way.
4. Remove the front wheels. (Note: New lug nuts come with the new wheels/tires.)
5. Starting on one side of the cart, remove the dust cover, cotter pin and nut securing the wheel hub assembly.
6. Carefully pull the wheel hub assembly off the old spindle. Set it aside for now.
7. Remove the cotter pins and bolts from the steering arm at the spindle. Push the steering arm away from the spindle. Note: Yamaha refers to these as “Flange Bolts”.
8. Remove the cotter pin and bolt attaching the spindle to the yoke. Note: Yamaha also refers to this as a “Flange Bolt”.
9. Carefully pull the spindle off the cart. (Remember, the cart is on jack stands.) Note: There’s a spindle bushing (thrust washer) at the top and bottom of the spindle. These will be reused. Yamaha refers to these as “Thrust Covers”.
10. The new spindles will have a part number stamped into them. The letter “D” or “P” will follow the part number. D = Drivers Side, P = Passenger Side.
11. Install the spindle bushings (thrust washers) on the new spindle. Note: Use a little wheel bearing grease to lubricate the top and bottom of the bushings.
12. Carefully slide the spindle into the yoke.
13. Install the spindle bolt. Torque the bolt to manufacturer’s specifications. Install the cotter pin.
14. Using the grease fitting, lubricate the bearings of the wheel hub assembly with wheel bearing grease.
15. Install the steering arm bolts. Torque the bolts to manufacturer’s specifications. Install the cotter pins.
16. Apply a small amount of grease to the spindle.
17. Press the wheel hub assembly onto the spindle and attach the nut. Tighten the nut and spin the wheel hub assembly at the same time. Once the nut is tight, ensure the wheel hub assembly still spins easily. Back off the nut ¼ turn.
18. Install the cotter pin.
19. Install the dust cover.
20. Repeat the steps for the other side.
21. Install the new Wheels/Tires using the new lug nuts. 22. Using the floor jack, raise the front of the cart.
22. Remove the jack stands.
23. Lower the cart.
24. Torque the lug nuts to manufacturer’s specifications.
25. Drive the cart forward approximately 25 feet.
26. Check the Toe-In.
27. Proper Toe-In is approximately 1/8”. Note: Check the owner’s manual for manufacturer’s specifications. For a tutorial on checking and adjusting Toe-In, see our “How To Video”.

Rear

1. Make the cart as safe as possible for lifting with a floor jack. Chock the front wheels. Remove the key from the ignition.
2. Remove the rear body section. Note: Removing the body isn’t absolutely necessary, but it makes the job a lot easier.
3. Loosen the lug nuts for the rear wheels.
4. Remove the sway bar from the Drivers Side
5. Lift the rear end of the cart high enough to accommodate the lift kit and larger tires. Place the jack stands on the outermost frame sections. Lower the cart onto the jack stands.
6. Reposition the floor jack (if needed) to support the innermost frame sections. Raise the floor jack up, just enough to support the center section but not lifting it.
7. Remove the rear wheels. (Note: New lug nuts come with the new wheels/tires.)
8. Be prepared for the innermost section to move at the completion of the next step.
9. Carefully remove the top bolts for the rear shocks. Note: Now is when you’ll be glad you supported the innermost frame section with the floor jack. The center section is now being fully supported by the floor jack.
10. Slowly, lower the floor jack and watch the fuel lines, vacuum lines, choke cable, electrical wiring and anything else that may be affected during this process. If needed, replace items being adversely affected. Lower the center section only enough to complete the next step.
11. Attach the “Goal Post/Shock Riser” to the frame section where the shocks used to be, using the hardware provided in the kit.
12. Install the shocks to the “Goal Post/Shock Riser”, using the original hardware.
13. Ensure the shocks are not binding. If they are, remove the bolt from the lower section of the shock and “oversize” the mounting holes.
14. Install the new sway bar bracket using the hardware provided in the kit. Note: The mounting holes may have to be enlarged to accommodate the new bracket.
15. Attach the sway bar to the new bracket using the original hardware.
16. Install the new Wheels/Tires using the new lug nuts.
17. Using the floor jack, raise the rear of the cart.
18. Remove the jack stands.
19. Lower the cart.
20. Torque the lug nuts to manufacturer’s specifications.
21. Attach the “Warning Label” to an area visible to operators
22. Recheck all bolts and fasteners for tightness, use torque values recommended by the manufacturer.
23. While driving, notice if the shocks are binding. If they are, “oversize” the lower shock mounting holes a little more.