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Yamaha Manuals
Utility Vehicle
UMAX
Service manual
Yamaha UMAX Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
Identification
Utility Vehicle Serial Number
Engine Serial Number (Yum1A/Yum2A)
Traction Motor Serial Number (Yum2E)
Motor Control Unit Serial Number (Yum2E)
Safety Precautions
Safety Lockout Procedure
Discharge the Motor Control Unit Capacitor
Recommended Jack Points
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Rubber Parts
Basic Service Information
Quick Fasteners
Electrical System
Special Tools
Specifications
General Specifications
Engine Specifications (Yum1A/Yum2A)
Chassis Specifications
Drive Train Specifications (Yum1A/Yum2A)
Drive Train Specifications (Yum2E)
Electrical Specifications (Yum1A/Yum2A)
Electrical Specifications (Yum2E)
Tightening Torques
General Tightening Torque Specifications
Engine Tightening Torque (Yum1A/Yum2A)
Fuel System Tightening Torque (Yum1A/Yum2A)
Drive Train Tightening Torque (Yum1A/Yum2A)
Drive Train Tightening Torque (Yum2E)
Chassis Tightening Torque
Cable Routing
Periodic Checks and Adjustments
Periodic Maintenance
Introduction
Periodic Maintenance Charts (Yum1A/Yum2A)
Periodic Maintenance Charts (Yum2E)
Pre-Operation Checks
Checking the Engine Oil Level (Yum1A/Yum2A)
Checking the Engine Cooling Inlet Duct (Yum1A/Yum2A)
Checking the Fuel Line (Yum1A/Yum2A)
Checking the Fuel Level (Yum1A/Yum2A)
Checking the Battery (Yum1A/Yum2A)
Checking the Batteries (Yum2E)
Checking the Brake Pedal Free Play
Checking the Steering Operation
Checking the Wheels
Checking the Tires
Checking the Body and Chassis
Checking the Fasteners
Checking the Reverse Buzzer
Monthly Checks
Checking the Drive Belt (Yum1A/Yum2A)
Replacing the Drive Belt (Yum1A/Yum2A)
Checking the Shift Lever (Yum1A/Yum2A)
Checking the Battery Electrolyte (Yum2E)
Checking the Wiring Connection (Yum2E)
Checking the Accelerator Pedal and Brake Pedal Operation
6-Month Checks
Checking the Air Filter (Yum1A/Yum2A)
Checking the Engine Compression Pressure (Yum1A/Yum2A)
Checking the Spark Plug (Yum1A/Yum2A)
Checking the Wire Harness (Yum2E)
Checking the Brake Cables
Checking the Shock Absorbers
Checking the Fuel Hose (Yum1A/Yum2A)
Annual Checks
Changing the Engine Oil (Yum1A/Yum2A)
Adjusting the Throttle Cables (Yum1A/Yum2A)
Checking the Exhaust System (Yum1A/Yum2A)
Lubricating the Primary Sheave (Yum1A/Yum2A)
Lubricating the Secondary Sheave (Yum1A/Yum2A)
Checking and Adjusting the Starter Generator Belt (Yum1A/Yum2A)
Checking the Drive Belt (Yum1A/Yum2A)
Checking the Speed Limiter Operation (Yum1A/Yum2A)
Checking the Battery Terminals
Checking the Wire Harness (Yum1A/Yum2A)
Testing the Discharge Load (Yum2E)
Checking the Rear Axle Bearings
Checking the Steering Knuckles
Adjusting the Wheel Alignment
Checking the Front Wheel Bearing
Checking the Transmission Oil Level
Adjusting the Parking Brake Release Timing
4-Year Checks
Checking the Starter Generator Brushes and Commutator (Yum1A/Yum2A)
Checking the Cylinder Head Bolts (Yum1A/Yum2A)
Adjusting the Valve Clearance (Yum1A/Yum2A)
Changing the Transmission Oil
Checking the Brake Shoes
Chassis
General Chassis (1)
Installing the Seats
Removing the Seats
General Chassis (2)
General Chassis (3)
Removing the Mudguard
Installing the Mudguard
General Chassis (4)
General Chassis (5)
Removing the Hood
General Chassis (6)
Installing the Steering Wheel
General Chassis (7)
Front and Rear Wheels
Remove the Wheels
Checking the Wheels
Checking the Wheel Hubs
Front and Rear Brakes
Checking the Brakes
Installing the Brakes
Pedal Assembly
Assembling the Accelerator Pedal
Installing the Pedal Assembly
Adjusting the Throttle Position Sensor (Yum2E)
Steering System
Removing the Tie-Rod
Checking the Steering Joint
Checking the Tie-Rod Ends
Installing the Steering System
Lubricating the Steering Shaft
Front Suspension Components
Checking the Front Lower Arms
Checking the Front Shock Absorber Assemblies
Checking the Steering Knuckles
Installing the Front Lower Arms and Front Shock Absorber Assemblies
Rear Suspension Components
Checking the Rear Shock Absorber Assemblies
Checking the Rear Suspension Arm
Checking the Connecting Rod and Stabilizer
Installing the Connecting Rod
Engine (Yum1A/Yum2A)
Engine Inspection
Measuring the Compression Pressure
Engine Removal (1)
Engine Removal (2)
Installing the Engine
Cylinder Head and Rocker Arms
Removing the Cylinder Head
Checking the Cylinder Head
Checking the Rocker Arms and Rocker Arm Shafts
Checking the Push Rods
Installing the Cylinder Head
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Installing the Valves
Starter Generator
Checking the Starter Generator
Assembling the Starter Generator
Flywheel
Removing the Flywheel
Installing the Flywheel
Camshaft
Removing the Crankcase Cover
Checking the Camshaft
Checking the Decompression System
Checking the Valve Lifters
Installing the Camshaft
Installing the Crankcase Cover
Crankshaft and Piston
Removing the Connecting Rod and Piston
Checking the Cylinder and Piston
Checking the Piston Rings
Checking the Piston Pin
Checking the Crankshaft and Connecting Rod
Checking the Balancer
Installing the Connecting Rod and Piston
Fuel System (Yum1A/Yum2A)
Fuel Tank
Checking the Fuel Pump Body
Installing the Fuel Pump
Installing the Fuel Tank
Removing the Fuel Pump
Removing the Fuel Tank
Checking the Fuel Pressure
Air Filter Case
Throttle Body
Removing the Throttle Body
Checking the Fuel Injector
Checking the Throttle Body
Checking the Intake Manifold
Checking the Intake Manifold Joint
Installing the Throttle Body
Drive Train
Primary and Secondary Sheave (Yum1A/Yum2A)
Removing the Primary Sheave
Removing the Secondary Sheave
Checking the Primary Sheave
Checking the Secondary Sheave
Disassembling the Secondary Sheave
Assembling the Primary Sheave
Assembling the Secondary Sheave
Transmission (Yum1A/Yum2A)
Disassembling the Transmission
Checking the Transmission
Assembling the Transmission
Installing the Shift Cables
Transmission (Yum2E)
Checking the Transmission
Traction Motor (Yum2E)
Assembling the Traction Motor
Electrical System
Ignition System (Yum1A/Yum2A)
Circuit Diagram
Troubleshooting
Electric Starting System (Yum1A/Yum2A)
Circuit Diagram
Troubleshooting
Charging System (Yum1A/Yum2A)
Circuit Diagram
Troubleshooting
Charging System (Yum2E)
Circuit Diagram
Troubleshooting
Lighting System (Yum1A/Yum2A)
Circuit Diagram
Troubleshooting
Lighting System (Yum2E)
Circuit Diagram
Troubleshooting
Signaling System (Yum1A/Yum2A)
Circuit Diagram
Troubleshooting
Signaling System (Yum2E)
Circuit Diagram
Troubleshooting
Fuel Injection System (Yum1A/Yum2A)
Circuit Diagram
Reading Error Codes - Fuel Injection System
Fuel Pump System (Yum1A/Yum2A)
Circuit Diagram
Troubleshooting
Drive System (Yum2E)
Circuit Diagram
Troubleshooting
Electrical Components (Yum1A/Yum2A)
Checking the Switches
Adjusting the Headlight Beams
Checking the Fuses
Checking and Charging the Battery
Checking the Relays
Checking the Spark Plug Cap
Checking the Ignition Coil
Checking the Ignition Spark Gap
Checking the Crankshaft Position Sensor
Checking the Starter Generator Operation
Checking the Voltage Regulator
Checking the Fuel Sender
Checking the Reverse Buzzer
Checking the Engine Temperature Sensor
Checking the Intake Air Pressure Sensor
Checking the Intake Air Temperature Sensor
Checking the Fuel Injector
Checking the Oil Level Switch
Electrical Components (Yum2E)
Checking the Switches
Adjusting the Headlight Beams
Checking the Fuses
Checking and Charging the Battery
Battery Charger (Yamaha Provided Charger)
Removing and Replacing the Battery
Checking the Relays
Checking the Reverse Buzzer
Checking the Throttle Position Sensor
Troubleshooting
Troubleshooting (Yum1A/Yum2A)
General Information
Starting Failures
Poor Medium-And-High-Speed Performance
Faulty Gear Shifting
Shift Lever Does Not Move
Faulty Drive Train Performance
Overheating
Poor Braking Performance
Faulty Shock Absorber Assembly
Unstable Handling
Faulty Lighting System
Diagnostic/Error Code Identification Chart (Yum1A/Yum2A)
Troubleshooting (Yum2E)
General Information
Poor Performance
Poor Braking Performance
Faulty Shock Absorber Assembly
Unstable Handling
Faulty Lighting System
Resetting Motor Control Unit (Mcu) (Yum2E)
Mcu Main Harness Coupler (Yum2E)
Pc Genius Diagnostic System (Yum2E)
Introduction
Pc Genius Diagnostic Tool
Connecting the Pc Genius
Diagnostic Mode
Troubleshooting Using Pc Genius
Fault Code Table
Pc Genius Golf Car Programming System (Yum2E)
Golf Car Programming Mode
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Download this manual
SERVICE MANUAL
UTILITY VEHICLE
YUM1A
YUM2A
YUM2E
LIT-19616-A0-37
J0F-F8197-E1
Table of
Contents
Previous
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Page
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Chapters
Table of Contents
7
Specifications
23
Periodic Checks and Adjustments
71
Chassis
97
Engine (Yum1A/Yum2A)
139
Fuel System (Yum1A/Yum2A)
175
Drive Train
183
Electrical System
203
Troubleshooting
285
Table of Contents
Troubleshooting
TROUBLESHOOTING
208
TROUBLESHOOTING
212
TROUBLESHOOTING
216
TROUBLESHOOTING
219
TROUBLESHOOTING
222
TROUBLESHOOTING
226
TROUBLESHOOTING
230
TROUBLESHOOTING
236
TROUBLESHOOTING
246
TROUBLESHOOTING
250
TROUBLESHOOTING
285
TROUBLESHOOTING (YUM1A/YUM2A)
286
TROUBLESHOOTING (YUM2E)
291
TROUBLESHOOTING USING PC GENIUS
296
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This manual is also suitable for:
Umx
Yum1a
Yum2a
Yum2e
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