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Yamaha G22 A/E Service Manual

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Table of Contents

6
Symbol Identification
7
Index
9
General Information
11
Safety Precautions
11
Prepare for Emergencies
11
Handle Fuel Safely
11
Handle Batteries Safely
12
Secure the Vehicle
12
Recommended Jack Points
12
Discharge the Speed Controller Capacitor
13
Wear Protective Clothing
14
General Service Information
14
Serial Numbers
15
Washing and Cleaning
15
Correct Tools
15
Tightening Torque
16
All Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearing and Oil Seals
17
Circlips
17
Disassembly and Assembly Suggestions
18
Special Tools for Tune Up
18
Special Tools for Engine Service
19
Special Tools for Power Train
20
Special Tools for Chassis Service
21
Special Tools for Electrical Components
23
Periodic Inspection and Adjustment
25
Periodic Maintenance
28
Inspection and Adjustment Engine for G22A
28
Valve Clearance Adjustment
30
Engine Oil Level Measurement
30
Engine Oil Replacement
31
Crankcase Breather Hose Inspection
32
Air Filter Cleaning
33
Compression Pressure Measurement
35
Carburetor Adjustment
36
Accelerator Stop Switch
36
Inspection/Accelerator Pedal Position Adjusting Bolt Height Adjustment
36
Throttle Cable Adjustment
38
Speed Limiter Adjustment
40
Choke Cable Adjustment
40
Fuel Pump Inspection
42
Fuel Filter Inspection
42
Fuel Hose Inspection
43
Power Train
43
Transmission Oil Level Measurement
44
Transmission Oil Replacement
45
Drive Belt Inspection for G22A
46
Primary Sheave Lubrication for G22A
46
Sheave Inspection
47
Lubrication Secondary Sheave
47
Shifting Cable Adjustment
48
Chassis Brake Cable Inspection
49
Chassis Parking Brake Adjustment
49
Chassis Brake Shoe Lining Inspection
51
Brake and Accelerator Pedals
52
Steering Inspection
52
Steering State Axial Play
53
Steering Linkage Inspection
53
Tie Rod End
54
Wheel Alignment
54
Toe-In
56
Tire and Wheel Inspection
56
Front Wheel Bearing Inspection
57
Rear Axle Bearing Inspection
57
Shock Absorber Inspection
58
Electrical for G22A
58
Spark Plug Inspection
59
Starter Belt Inspection
59
Starter Belt Adjustment
60
Battery Inspection
61
Battery Charging
62
Electrical for G22E
63
48V Charger Features
63
48V Charger Operating Instructions
63
Led Readings - Normal Charge Cycle
64
Led Readings - Abnormal Charge Cycle
68
Charge Receptacle Inspection
68
Controller Connector Inspection
71
Discharge Minutes Adjusted for Temperature
72
Battery Discharge Chart
72
Battery Discharge Testing
73
Chassis
75
Front and Rear Bumper Removal
75
Front and Rear Bumper Installation
76
Bumpers
77
Seat Removal
77
Seat Installation
78
Seat
79
Front Cowling Removal
79
Front Storage Panel Removal
80
Front Cowling Installation
81
Front Cowling
82
Rear Body Removal
82
Rear Floor Cover Removal
83
Rear Body Installation
84
Rear Cowling for G22A
85
Rear Cowling for G22E
86
Front Wheel
87
Front Wheel Removal
88
Front Wheel Inspection
89
Front Wheel Installation
90
Rear Axle Wheel for G22A
91
Rear Axle Wheel for G22A Removal
91
Rear Axle Wheel for G22A Inspection
92
Rear Axle Wheel for G22A Installation
94
Rear Axle Wheel for G22E
95
Rear Axle Wheel for G22E Removal
95
Rear Axle Wheel for G22E Inspection
96
Rear Axle Wheel for G22E Installation
98
Brake
99
Brake Pedal
100
Brake Pedal Disassembly
101
Brake Pedal Inspection
102
Brake Pedal Assembly
105
Accelerator Pedal for G22A
106
Accelerator Pedal for G22E
107
Steering System
108
Steering System Removal
110
Steering System Disassembly
111
Steering System Inspection
113
Steering System Assembly
114
Steering System Adjust
115
Steering System Installation
117
Front Suspension
118
Front Suspension Removal
119
Front Suspension Inspection
121
Front Suspension Installation
122
Rear Arm Suspension for G22A
123
Rear Arm Suspension for G22E
124
Rear Arm Suspension Removal
125
Rear Arm Suspension Inspection
125
Rear Arm Suspension Installation
126
Cable Maintenance
128
Frame for G22A
129
Frame for G22E
133
Power Train for G22A
133
Primary Sheave
134
Primary Sheave Removal
135
Primary Sheave Disassembly
135
Primary Sheave Inspection
136
Primary Sheave Assembly
137
Primary Sheave Installation
138
Secondary Sheave
139
Secondary Sheave Disassembly
140
Secondary Sheave Inspection
140
Secondary Sheave Assembly
142
Drive V-Belt Inspection and Replacement
143
Transmission
144
Transmission Removal
146
Transmission Differential Disassembly
147
Transmission Differential Inspection
147
Transmission Disassembly
149
Transmission Inspection
150
Transmission Assembly
152
Differential Assembly
153
Differential Installation
155
Power Train for G22E
156
Power Train for G22E Transmission Removal
156
Power Train for G22E Transmission Disassembly
159
Power Train for G22E Transmission Inspection
159
Power Train for G22E Transmission Assembly
160
Power Train for G22E Transmission Installation
161
Engine Overhaul
163
Engine Removal
163
Preparation for Removal
164
Drive Belt
164
Primary Clutch
164
Air Cleaner Case
164
Carburetor
165
Wiring and Hose
165
Starter Generator
166
Muffler
167
Engine Oil Drain
167
Air Shroud
168
Flywheel
169
Cylinder Head
169
Crankcase Cover
170
Camshaft
170
Balancer Shaft and Crankshaft
171
Piston and Connecting Rod
171
Oil Sender and Wire Guide Plate
171
Bearings
172
Cylinder Head Inspection and Repair
174
Valve
175
Valve Seat
178
Valve Spring
179
Valve Installation
180
Rocker Arm
182
Gears
182
Cylinder and Piston
183
Piston Ring and Pin
184
Piston Ring Oversize
185
Piston Pin
186
Crankshaft Runout
186
Crank Pin Outside Diameter
186
Connecting Rod Oil Clearance
188
Piston, Connecting Rod and Crankcase Cover
189
Bearings Installation
189
Piston and Connecting Rod Installation
191
Crankshaft, Balancer Shaft and Camshaft
196
Cylinder Head and Rocker Arm
198
Ignition Unit
199
Remounting Engine
203
Carburetion
206
Carburetor Section View
206
Main Metering System
207
Float System
215
Electrical
217
G22A Wiring Diagram
218
Electrical Component Locations
219
Electrical Components (Engine)
220
Ignition System
221
Ignition System Components
222
Troubleshooting
222
The Starter Does Not Turn
226
No Spark or Wear Spark
228
G22A Ignition System Troubleshooting
228
Engine Will Not Run, No Spark
230
The Battery Is Not Charged
233
Starter-Generator
239
Solenoid Relay
240
Voltage Regulator
240
Generator Voltage Inspection
242
Signal System (Oil Warning/Reverse Buzzer)
243
Signal System Components
244
The Oil Level Indicator Light Does Not Come On
247
The Reverse Buzzer Does Not Operate
250
G22E Wiring Diagram
252
Electrical Components
253
Traction Motor
254
Traction Motor Removal
255
Traction Motor Disassembly
257
Tractor Motor Inspection and Testing
260
Tractor Motor Assembly
261
Tractor Motor Installation
262
Motor Control Unit
267
Electrical Troubleshooting
267
Acceleration Becomes Rough, Uneven or Jerky
267
Visual Inspection
267
Test Throttle Position Sensor
268
Car Does Not Slow On Downhill Grade And/Or Car Will Roll Away Without Slowing
268
Speed Sensor Wire Harness Check
269
Car Has No Reverse Warning Beeper
269
Speed Sensor Test
269
Speed Sensor Magnet Check
269
Buzzer Wiring Check
270
The Car's Top Speed Is Slower
270
Ground Wire Check
270
Check Brakes and Chassis
271
Car Won't Run Either Direction, Solenoid Does Not Click
271
Reset Controller
271
Fuse Check
272
Tow Switch Test
272
Wire Check Solenoid to Tow Switch
272
Controller Ground Wire Check
272
Solenoid Ground Bypass
273
Wire Check - Solenoid to Controller
273
Solenoid Relay Bench Test
274
Car Won't Run Either Direction, Solenoid Does Click
274
Throttle Position Sensor Check
275
Main Switch Check
275
Accelerator Stop Switch Check
276
Direction Switch Check
276
Check Traction Motor
278
Z-1 Diagnostic Tester
278
Z-1 Harness Identification
280
Operation Instructions
285
Specifications
287
General Specifications
288
Engine Specifications
291
Transmission Specifications
293
Electrical Specifications
295
Power Train Specifications
296
Cable/Wire Routing for G22A

Table of Contents

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Table of Contents

6
Symbol Identification
7
Index
9
General Information
11
Safety Precautions
11
Prepare for Emergencies
11
Handle Fuel Safely
11
Handle Batteries Safely
12
Secure the Vehicle
12
Recommended Jack Points
12
Discharge the Speed Controller Capacitor
13
Wear Protective Clothing
14
General Service Information
14
Serial Numbers
15
Washing and Cleaning
15
Correct Tools
15
Tightening Torque
16
All Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearing and Oil Seals
17
Circlips
17
Disassembly and Assembly Suggestions
18
Special Tools for Tune Up
18
Special Tools for Engine Service
19
Special Tools for Power Train
20
Special Tools for Chassis Service
21
Special Tools for Electrical Components
23
Periodic Inspection and Adjustment
25
Periodic Maintenance
28
Inspection and Adjustment Engine for G22A
28
Valve Clearance Adjustment
30
Engine Oil Level Measurement
30
Engine Oil Replacement
31
Crankcase Breather Hose Inspection
32
Air Filter Cleaning
33
Compression Pressure Measurement
35
Carburetor Adjustment
36
Accelerator Stop Switch
36
Inspection/Accelerator Pedal Position Adjusting Bolt Height Adjustment
36
Throttle Cable Adjustment
38
Speed Limiter Adjustment
40
Choke Cable Adjustment
40
Fuel Pump Inspection
42
Fuel Filter Inspection
42
Fuel Hose Inspection
43
Power Train
43
Transmission Oil Level Measurement
44
Transmission Oil Replacement
45
Drive Belt Inspection for G22A
46
Primary Sheave Lubrication for G22A
46
Sheave Inspection
47
Lubrication Secondary Sheave
47
Shifting Cable Adjustment
48
Chassis Brake Cable Inspection
49
Chassis Parking Brake Adjustment
49
Chassis Brake Shoe Lining Inspection
51
Brake and Accelerator Pedals
52
Steering Inspection
52
Steering State Axial Play
53
Steering Linkage Inspection
53
Tie Rod End
54
Wheel Alignment
54
Toe-In
56
Tire and Wheel Inspection
56
Front Wheel Bearing Inspection
57
Rear Axle Bearing Inspection
57
Shock Absorber Inspection
58
Electrical for G22A
58
Spark Plug Inspection
59
Starter Belt Inspection
59
Starter Belt Adjustment
60
Battery Inspection
61
Battery Charging
62
Electrical for G22E
63
48V Charger Features
63
48V Charger Operating Instructions
63
Led Readings - Normal Charge Cycle
64
Led Readings - Abnormal Charge Cycle
68
Charge Receptacle Inspection
68
Controller Connector Inspection
71
Discharge Minutes Adjusted for Temperature
72
Battery Discharge Chart
72
Battery Discharge Testing
73
Chassis
75
Front and Rear Bumper Removal
75
Front and Rear Bumper Installation
76
Bumpers
77
Seat Removal
77
Seat Installation
78
Seat
79
Front Cowling Removal
79
Front Storage Panel Removal
80
Front Cowling Installation
81
Front Cowling
82
Rear Body Removal
82
Rear Floor Cover Removal
83
Rear Body Installation
84
Rear Cowling for G22A
85
Rear Cowling for G22E
86
Front Wheel
87
Front Wheel Removal
88
Front Wheel Inspection
89
Front Wheel Installation
90
Rear Axle Wheel for G22A
91
Rear Axle Wheel for G22A Removal
91
Rear Axle Wheel for G22A Inspection
92
Rear Axle Wheel for G22A Installation
94
Rear Axle Wheel for G22E
95
Rear Axle Wheel for G22E Removal
95
Rear Axle Wheel for G22E Inspection
96
Rear Axle Wheel for G22E Installation
98
Brake
99
Brake Pedal
100
Brake Pedal Disassembly
101
Brake Pedal Inspection
102
Brake Pedal Assembly
105
Accelerator Pedal for G22A
106
Accelerator Pedal for G22E
107
Steering System
108
Steering System Removal
110
Steering System Disassembly
111
Steering System Inspection
113
Steering System Assembly
114
Steering System Adjust
115
Steering System Installation
117
Front Suspension
118
Front Suspension Removal
119
Front Suspension Inspection
121
Front Suspension Installation
122
Rear Arm Suspension for G22A
123
Rear Arm Suspension for G22E
124
Rear Arm Suspension Removal
125
Rear Arm Suspension Inspection
125
Rear Arm Suspension Installation
126
Cable Maintenance
128
Frame for G22A
129
Frame for G22E
133
Power Train for G22A
133
Primary Sheave
134
Primary Sheave Removal
135
Primary Sheave Disassembly
135
Primary Sheave Inspection
136
Primary Sheave Assembly
137
Primary Sheave Installation
138
Secondary Sheave
139
Secondary Sheave Disassembly
140
Secondary Sheave Inspection
140
Secondary Sheave Assembly
142
Drive V-Belt Inspection and Replacement
143
Transmission
144
Transmission Removal
146
Transmission Differential Disassembly
147
Transmission Differential Inspection
147
Transmission Disassembly
149
Transmission Inspection
150
Transmission Assembly
152
Differential Assembly
153
Differential Installation
155
Power Train for G22E
156
Power Train for G22E Transmission Removal
156
Power Train for G22E Transmission Disassembly
159
Power Train for G22E Transmission Inspection
159
Power Train for G22E Transmission Assembly
160
Power Train for G22E Transmission Installation
161
Engine Overhaul
163
Engine Removal
163
Preparation for Removal
164
Drive Belt
164
Primary Clutch
164
Air Cleaner Case
164
Carburetor
165
Wiring and Hose
165
Starter Generator
166
Muffler
167
Engine Oil Drain
167
Air Shroud
168
Flywheel
169
Cylinder Head
169
Crankcase Cover
170
Camshaft
170
Balancer Shaft and Crankshaft
171
Piston and Connecting Rod
171
Oil Sender and Wire Guide Plate
171
Bearings
172
Cylinder Head Inspection and Repair
174
Valve
175
Valve Seat
178
Valve Spring
179
Valve Installation
180
Rocker Arm
182
Gears
182
Cylinder and Piston
183
Piston Ring and Pin
184
Piston Ring Oversize
185
Piston Pin
186
Crankshaft Runout
186
Crank Pin Outside Diameter
186
Connecting Rod Oil Clearance
188
Piston, Connecting Rod and Crankcase Cover
189
Bearings Installation
189
Piston and Connecting Rod Installation
191
Crankshaft, Balancer Shaft and Camshaft
196
Cylinder Head and Rocker Arm
198
Ignition Unit
199
Remounting Engine
203
Carburetion
206
Carburetor Section View
206
Main Metering System
207
Float System
215
Electrical
217
G22A Wiring Diagram
218
Electrical Component Locations
219
Electrical Components (Engine)
220
Ignition System
221
Ignition System Components
222
Troubleshooting
222
The Starter Does Not Turn
226
No Spark or Wear Spark
228
G22A Ignition System Troubleshooting
228
Engine Will Not Run, No Spark
230
The Battery Is Not Charged
233
Starter-Generator
239
Solenoid Relay
240
Voltage Regulator
240
Generator Voltage Inspection
242
Signal System (Oil Warning/Reverse Buzzer)
243
Signal System Components
244
The Oil Level Indicator Light Does Not Come On
247
The Reverse Buzzer Does Not Operate
250
G22E Wiring Diagram
252
Electrical Components
253
Traction Motor
254
Traction Motor Removal
255
Traction Motor Disassembly
257
Tractor Motor Inspection and Testing
260
Tractor Motor Assembly
261
Tractor Motor Installation
262
Motor Control Unit
267
Electrical Troubleshooting
267
Acceleration Becomes Rough, Uneven or Jerky
267
Visual Inspection
267
Test Throttle Position Sensor
268
Car Does Not Slow On Downhill Grade And/Or Car Will Roll Away Without Slowing
268
Speed Sensor Wire Harness Check
269
Car Has No Reverse Warning Beeper
269
Speed Sensor Test
269
Speed Sensor Magnet Check
269
Buzzer Wiring Check
270
The Car's Top Speed Is Slower
270
Ground Wire Check
270
Check Brakes and Chassis
271
Car Won't Run Either Direction, Solenoid Does Not Click
271
Reset Controller
271
Fuse Check
272
Tow Switch Test
272
Wire Check Solenoid to Tow Switch
272
Controller Ground Wire Check
272
Solenoid Ground Bypass
273
Wire Check - Solenoid to Controller
273
Solenoid Relay Bench Test
274
Car Won't Run Either Direction, Solenoid Does Click
274
Throttle Position Sensor Check
275
Main Switch Check
275
Accelerator Stop Switch Check
276
Direction Switch Check
276
Check Traction Motor
278
Z-1 Diagnostic Tester
278
Z-1 Harness Identification
280
Operation Instructions
285
Specifications
287
General Specifications
288
Engine Specifications
291
Transmission Specifications
293
Electrical Specifications
295
Power Train Specifications
296
Cable/Wire Routing for G22A

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This manual is also suitable for:

G22 a G22 e