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Manuals
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Yamaha Manuals
Golf Cars
G22 A/E
Service manual
Yamaha G22 A/E Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Symbol Identification
Index
General Information
Safety Precautions
Prepare for Emergencies
Handle Fuel Safely
Handle Batteries Safely
Secure the Vehicle
Recommended Jack Points
Discharge the Speed Controller Capacitor
Wear Protective Clothing
General Service Information
Serial Numbers
Washing and Cleaning
Correct Tools
Tightening Torque
All Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearing and Oil Seals
Circlips
Disassembly and Assembly Suggestions
Special Tools for Tune up
Special Tools for Engine Service
Special Tools for Power Train
Special Tools for Chassis Service
Special Tools for Electrical Components
Periodic Inspection and Adjustment
Periodic Maintenance
Inspection and Adjustment Engine for G22A
Valve Clearance Adjustment
Engine Oil Level Measurement
Engine Oil Replacement
Crankcase Breather Hose Inspection
Air Filter Cleaning
Compression Pressure Measurement
Carburetor Adjustment
Accelerator Stop Switch
Inspection/Accelerator Pedal Position Adjusting Bolt Height Adjustment
Throttle Cable Adjustment
Speed Limiter Adjustment
Choke Cable Adjustment
Fuel Pump Inspection
Fuel Filter Inspection
Fuel Hose Inspection
Power Train
Transmission Oil Level Measurement
Transmission Oil Replacement
Drive Belt Inspection for G22A
Primary Sheave Lubrication for G22A
Sheave Inspection
Lubrication Secondary Sheave
Shifting Cable Adjustment
Chassis Brake Cable Inspection
Chassis Parking Brake Adjustment
Chassis Brake Shoe Lining Inspection
Brake and Accelerator Pedals
Steering Inspection
Steering State Axial Play
Steering Linkage Inspection
Tie Rod End
Wheel Alignment
Toe-In
Tire and Wheel Inspection
Front Wheel Bearing Inspection
Rear Axle Bearing Inspection
Shock Absorber Inspection
Electrical for G22A
Spark Plug Inspection
Starter Belt Inspection
Starter Belt Adjustment
Battery Inspection
Battery Charging
Electrical for G22E
48V Charger Features
48V Charger Operating Instructions
Led Readings - Normal Charge Cycle
Led Readings - Abnormal Charge Cycle
Charge Receptacle Inspection
Controller Connector Inspection
Discharge Minutes Adjusted for Temperature
Battery Discharge Chart
Battery Discharge Testing
Chassis
Front and Rear Bumper Removal
Front and Rear Bumper Installation
Bumpers
Seat Removal
Seat Installation
Seat
Front Cowling Removal
Front Storage Panel Removal
Front Cowling Installation
Front Cowling
Rear Body Removal
Rear Floor Cover Removal
Rear Body Installation
Rear Cowling for G22A
Rear Cowling for G22E
Front Wheel
Front Wheel Removal
Front Wheel Inspection
Front Wheel Installation
Rear Axle Wheel for G22A
Rear Axle Wheel for G22A Removal
Rear Axle Wheel for G22A Inspection
Rear Axle Wheel for G22A Installation
Rear Axle Wheel for G22E
Rear Axle Wheel for G22E Removal
Rear Axle Wheel for G22E Inspection
Rear Axle Wheel for G22E Installation
Brake
Brake Pedal
Brake Pedal Disassembly
Brake Pedal Inspection
Brake Pedal Assembly
Accelerator Pedal for G22A
Accelerator Pedal for G22E
Steering System
Steering System Removal
Steering System Disassembly
Steering System Inspection
Steering System Assembly
Steering System Adjust
Steering System Installation
Front Suspension
Front Suspension Removal
Front Suspension Inspection
Front Suspension Installation
Rear Arm Suspension for G22A
Rear Arm Suspension for G22E
Rear Arm Suspension Removal
Rear Arm Suspension Inspection
Rear Arm Suspension Installation
Cable Maintenance
Frame for G22A
Frame for G22E
Power Train for G22A
Primary Sheave
Primary Sheave Removal
Primary Sheave Disassembly
Primary Sheave Inspection
Primary Sheave Assembly
Primary Sheave Installation
Secondary Sheave
Secondary Sheave Disassembly
Secondary Sheave Inspection
Secondary Sheave Assembly
Drive V-Belt Inspection and Replacement
Transmission
Transmission Removal
Transmission Differential Disassembly
Transmission Differential Inspection
Transmission Disassembly
Transmission Inspection
Transmission Assembly
Differential Assembly
Differential Installation
Power Train for G22E
Power Train for G22E Transmission Removal
Power Train for G22E Transmission Disassembly
Power Train for G22E Transmission Inspection
Power Train for G22E Transmission Assembly
Power Train for G22E Transmission Installation
Engine Overhaul
Engine Removal
Preparation for Removal
Drive Belt
Primary Clutch
Air Cleaner Case
Carburetor
Wiring and Hose
Starter Generator
Muffler
Engine Oil Drain
Air Shroud
Flywheel
Cylinder Head
Crankcase Cover
Camshaft
Balancer Shaft and Crankshaft
Piston and Connecting Rod
Oil Sender and Wire Guide Plate
Bearings
Cylinder Head Inspection and Repair
Valve
Valve Seat
Valve Spring
Valve Installation
Rocker Arm
Gears
Cylinder and Piston
Piston Ring and Pin
Piston Ring Oversize
Piston Pin
Crankshaft Runout
Crank Pin Outside Diameter
Connecting Rod Oil Clearance
Piston, Connecting Rod and Crankcase Cover
Bearings Installation
Piston and Connecting Rod Installation
Crankshaft, Balancer Shaft and Camshaft
Cylinder Head and Rocker Arm
Ignition Unit
Remounting Engine
Carburetion
Carburetor Section View
Main Metering System
Float System
Electrical
G22A Wiring Diagram
Electrical Component Locations
Electrical Components (Engine)
Ignition System
Ignition System Components
Troubleshooting
The Starter Does Not Turn
No Spark or Wear Spark
G22A Ignition System Troubleshooting
Engine will Not Run, no Spark
The Battery Is Not Charged
Starter-Generator
Solenoid Relay
Voltage Regulator
Generator Voltage Inspection
Signal System (Oil Warning/Reverse Buzzer)
Signal System Components
The Oil Level Indicator Light Does Not Come on
The Reverse Buzzer Does Not Operate
G22E Wiring Diagram
Electrical Components
Traction Motor
Traction Motor Removal
Traction Motor Disassembly
Tractor Motor Inspection and Testing
Tractor Motor Assembly
Tractor Motor Installation
Motor Control Unit
Electrical Troubleshooting
Acceleration Becomes Rough, Uneven or Jerky
Visual Inspection
Test Throttle Position Sensor
Car Does Not Slow on Downhill Grade And/Or Car will Roll Away Without Slowing
Speed Sensor Wire Harness Check
Car Has no Reverse Warning Beeper
Speed Sensor Test
Speed Sensor Magnet Check
Buzzer Wiring Check
The Car's Top Speed Is Slower
Ground Wire Check
Check Brakes and Chassis
Car Won't Run Either Direction, Solenoid Does Not Click
Reset Controller
Fuse Check
Tow Switch Test
Wire Check Solenoid to Tow Switch
Controller Ground Wire Check
Solenoid Ground Bypass
Wire Check - Solenoid to Controller
Solenoid Relay Bench Test
Car Won't Run Either Direction, Solenoid Does Click
Throttle Position Sensor Check
Main Switch Check
Accelerator Stop Switch Check
Direction Switch Check
Check Traction Motor
Z-1 Diagnostic Tester
Z-1 Harness Identification
Operation Instructions
Specifications
General Specifications
Engine Specifications
Transmission Specifications
Electrical Specifications
Power Train Specifications
Cable/Wire Routing for G22A
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Table of
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Table of Contents
Troubleshooting
Troubleshooting
222
G22A Ignition System Troubleshooting
228
Electrical Troubleshooting
267
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G22 a
G22 e
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