User Manuals: Yamaha G22 A Golf Cart

Manuals and User Guides for Yamaha G22 A Golf Cart. We have 1 Yamaha G22 A Golf Cart manual available for free PDF download: Service Manual

Yamaha G22 A Service Manual (309 pages)

Brand: Yamaha | Category: Golf Cars | Size: 23.05 MB

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

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals

User Manuals: Yamaha G22 A Golf Cart

Yamaha G22 A Service Manual (309 pages)

Table of Contents

Related Products

Yamaha Categories