Table of Contents
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Chapters
Table of Contents
Troubleshooting
Related Manuals for Yamaha YUM2A
Summarization of Contents
General Information
Identification
Describes how to locate vehicle, engine, motor, and control unit serial numbers.
Safety Precautions
Outlines essential safety measures for maintenance and operation, including lockout procedures.
Important Information
Provides general guidelines for disassembly, parts, and cleaning procedures.
Basic Service Information
Covers handling of quick fasteners and electrical component procedures.
Special Tools
Lists necessary special tools and their part numbers for tune-ups and assembly.
Specifications
General Specifications
Details overall dimensions, weight, and performance metrics for the vehicle models.
Engine Specifications (YUM1A/YUM2A)
Provides detailed technical data for the engine, including dimensions and tolerances.
Chassis Specifications
Lists specifications related to the chassis, wheels, tires, brakes, and suspension.
Drive Train Specifications (YUM1A/YUM2A)
Details specifications for the primary/secondary sheave and transmission for YUM1A/YUM2A.
Electrical Specifications (YUM1A/YUM2A)
Outlines electrical system specifications including voltage, ignition, and battery details.
Tightening Torques
Specifies torque values for various fasteners and components across different systems.
Cable Routing
Illustrates the correct routing and securing of various cables and wires on the vehicle frame.
Periodic Checks and Adjustments
Periodic Maintenance
Presents maintenance charts detailing checks and adjustments based on time or mileage intervals.
Pre-Operation Checks
Covers essential checks performed before operating the vehicle, such as oil levels and tire pressure.
Monthly Checks
Details maintenance tasks to be performed on a monthly basis, including drive belt and shift lever checks.
6-Month Checks
Outlines maintenance tasks required every six months, such as air filter and spark plug checks.
Annual Checks
Lists maintenance procedures to be conducted annually, including oil changes and belt adjustments.
4-Year Checks
Specifies maintenance tasks to be performed every four years, such as valve clearance and transmission oil changes.
Chassis
General Chassis (1)
Details the procedure for removing and installing the vehicle seats.
General Chassis (2)
Covers the removal and disassembly of the cargo bed and tailgate components.
General Chassis (3)
Explains the process for removing rear and inner covers, including mudguards.
General Chassis (4)
Details the removal of front and side panels, including fender and dashboard components.
General Chassis (5)
Describes the removal of the floor mat and instrument panel assembly.
Front and Rear Wheels
Provides instructions for removing and checking the front and rear wheels and hubs.
Front and Rear Brakes
Details the procedure for removing and checking the front and rear brake assemblies.
Pedal Assembly
Covers the removal and assembly of the accelerator and brake pedal mechanisms.
Steering System
Explains the procedures for removing, checking, and installing steering system components.
Front Suspension Components
Details the removal and installation of front suspension parts like shock absorbers and lower arms.
Rear Suspension Components
Covers the removal and installation of rear suspension components, including shock absorbers and arms.
Engine (YUM1A/YUM2A)
Engine Inspection
Explains how to measure engine compression pressure and check valve clearance.
Engine Removal (1)
Details the steps for removing the muffler and exhaust pipe from the engine.
Engine Removal (2)
Covers disconnecting electrical connectors and removing the engine from the chassis.
Installing the Engine
Provides instructions for installing the engine back into the vehicle chassis.
Cylinder Head and Rocker Arms
Details procedures for removing, checking, and installing cylinder head and rocker arm components.
Valves and Valve Springs
Explains how to remove, check, and install valves, springs, and related components.
Starter Generator
Covers the removal, disassembly, checking, and assembly of the starter generator.
Flywheel
Provides instructions for removing and installing the flywheel, including necessary tools.
Camshaft
Details camshaft removal, inspection, and installation procedures, including related components.
Crankshaft and Piston
Explains the removal, checking, and installation of the crankshaft, piston, and connecting rod.
Fuel System (YUM1A/YUM2A)
Fuel Tank
Covers the removal, installation, and checking of the fuel tank and its components.
Air Filter Case
Details the removal and checking procedures for the air filter case and its associated parts.
Throttle Body
Explains the removal, checking, and installation of the throttle body and intake manifold assembly.
Drive Train
Primary and Secondary Sheave (YUM1A/YUM2A)
Covers the removal, disassembly, checking, and assembly of the primary and secondary sheave systems.
Transmission (YUM1A/YUM2A)
Details the removal, disassembly, checking, and assembly of the transmission for YUM1A/YUM2A models.
Transmission (YUM2E)
Covers the removal and disassembly procedures for the transmission in YUM2E models.
Traction Motor (YUM2E)
Details the disassembly and assembly process for the traction motor in YUM2E models.
Electrical System
Ignition System (YUM1A/YUM2A)
Explains the ignition system circuit diagram and troubleshooting steps for YUM1A/YUM2A.
Electric Starting System (YUM1A/YUM2A)
Details the electric starting system circuit diagram and troubleshooting procedures.
Charging System (YUM1A/YUM2A)
Covers the charging system circuit diagram and troubleshooting for YUM1A/YUM2A.
Charging System (YUM2E)
Provides the circuit diagram and troubleshooting for the charging system in YUM2E models.
Lighting System (YUM1A/YUM2A)
Explains the lighting system circuit diagram and troubleshooting steps.
Lighting System (YUM2E)
Details the lighting system circuit diagram and troubleshooting for YUM2E models.
Signaling System (YUM1A/YUM2A)
Covers the signaling system circuit diagram and troubleshooting for YUM1A/YUM2A.
Signaling System (YUM2E)
Provides the signaling system circuit diagram and troubleshooting for YUM2E models.
Fuel Injection System (YUM1A/YUM2A)
Details the fuel injection system circuit diagram and error code reading procedures.
Fuel Pump System (YUM1A/YUM2A)
Explains the fuel pump system circuit diagram and troubleshooting.
Drive System (YUM2E)
Provides the drive system circuit diagram and troubleshooting for YUM2E models.
Electrical Components (YUM1A/YUM2A)
Details the location and checking procedures for various electrical components on YUM1A/YUM2A.
Electrical Components (YUM2E)
Lists electrical components and their checking procedures for YUM2E models.
Troubleshooting (YUM1A/YUM2A)
Starting Failures
Identifies common causes for engine starting failures related to various systems.
Faulty Drive Train Performance
Lists potential issues causing poor drive train performance or the vehicle not moving.
Poor Braking Performance
Covers common problems related to braking system performance and potential causes.
Unstable Handling
Addresses issues causing unstable handling, related to steering and suspension components.
Faulty Lighting System
Outlines potential causes for the headlight not illuminating.
Diagnostic/Error Code Identification Chart (YUM1A/YUM2A)
Provides a table correlating diagnostic codes with symptoms, causes, and engine start status.
Troubleshooting (YUM2E)
Poor Performance
Lists common causes for poor performance related to the traction motor and electrical system.
Faulty Shock Absorber Assembly
Identifies potential malfunctions within the shock absorber assemblies.
Unstable Handling
Covers potential issues causing unstable handling, related to steering and suspension components.
Faulty Lighting System
Outlines potential causes for the headlight not illuminating.
Resetting Motor Control Unit (MCU) (YUM2E)
Provides a procedure to reset the motor control unit to verify persistent problems.
PC Genius Diagnostic System (YUM2E)
Explains the PC Genius diagnostic system, its connection, and diagnostic modes.
Troubleshooting Using PC Genius
Details diagnostic codes and troubleshooting steps using the PC Genius tool.
Wiring Diagram
YUM1A/YUM2A Wiring Diagram
Presents the complete wiring diagram for YUM1A and YUM2A models, including component numbering.
YUM2E Wiring Diagram
Shows the wiring diagram for YUM2E models, illustrating component connections and color codes.
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