Yamaha G22 A/E Manuals

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

Yamaha G22 A/E Service Manual

Yamaha G22 A/E Service Manual (309 pages)

Brand: Yamaha | Category: Golf Cars | Size: 23.05 MB
Table of contents
Symbol Identification6................................................................................................................................................................
Index7................................................................................................................................................................
General Information9................................................................................................................................................................
Safety Precautions11................................................................................................................................................................
Prepare For Emergencies11................................................................................................................................................................
Handle Fuel Safely11................................................................................................................................................................
Handle Batteries Safely11................................................................................................................................................................
Secure The Vehicle12................................................................................................................................................................
Recommended Jack Points12................................................................................................................................................................
Discharge The Speed Controller Capacitor12................................................................................................................................................................
Wear Protective Clothing13................................................................................................................................................................
General Service Information14................................................................................................................................................................
Serial Numbers14................................................................................................................................................................
Washing And Cleaning15................................................................................................................................................................
Correct Tools15................................................................................................................................................................
Tightening Torque15................................................................................................................................................................
All Replacement Parts16................................................................................................................................................................
Gaskets, Oil Seals And O-rings16................................................................................................................................................................
Lock Washers/plates And Cotter Pins16................................................................................................................................................................
Bearing And Oil Seals16................................................................................................................................................................
Circlips17................................................................................................................................................................
Disassembly And Assembly Suggestions17................................................................................................................................................................
Special Tools For Tune Up18................................................................................................................................................................
Special Tools For Engine Service18................................................................................................................................................................
Special Tools For Power Train19................................................................................................................................................................
Special Tools For Chassis Service20................................................................................................................................................................
Special Tools For Electrical Components21................................................................................................................................................................
Periodic Inspection And Adjustment23................................................................................................................................................................
Periodic Maintenance25................................................................................................................................................................
Inspection And Adjustment Engine For G22a28................................................................................................................................................................
Valve Clearance Adjustment28................................................................................................................................................................
Engine Oil Level Measurement30................................................................................................................................................................
Engine Oil Replacement30................................................................................................................................................................
Crankcase Breather Hose Inspection31................................................................................................................................................................
Air Filter Cleaning32................................................................................................................................................................
Compression Pressure Measurement33................................................................................................................................................................
Carburetor Adjustment35................................................................................................................................................................
Accelerator Stop Switch36................................................................................................................................................................
Inspection/accelerator Pedal Position Adjusting Bolt Height Adjustment36................................................................................................................................................................
Throttle Cable Adjustment36................................................................................................................................................................
Speed Limiter Adjustment38................................................................................................................................................................
Choke Cable Adjustment40................................................................................................................................................................
Fuel Pump Inspection40................................................................................................................................................................
Fuel Filter Inspection42................................................................................................................................................................
Fuel Hose Inspection42................................................................................................................................................................
Power Train43................................................................................................................................................................
Transmission Oil Level Measurement43................................................................................................................................................................
Transmission Oil Replacement44................................................................................................................................................................
Drive Belt Inspection For G22a45................................................................................................................................................................
Primary Sheave Lubrication For G22a46................................................................................................................................................................
Sheave Inspection46................................................................................................................................................................
Lubrication Secondary Sheave47................................................................................................................................................................
Shifting Cable Adjustment47................................................................................................................................................................
Chassis Brake Cable Inspection48................................................................................................................................................................
Chassis Parking Brake Adjustment49................................................................................................................................................................
Chassis Brake Shoe Lining Inspection49................................................................................................................................................................
Brake And Accelerator Pedals51................................................................................................................................................................
Steering Inspection52................................................................................................................................................................
Steering State Axial Play52................................................................................................................................................................
Steering Linkage Inspection53................................................................................................................................................................
Tie Rod End53................................................................................................................................................................
Wheel Alignment54................................................................................................................................................................
Toe-in54................................................................................................................................................................
Tire And Wheel Inspection56................................................................................................................................................................
Front Wheel Bearing Inspection56................................................................................................................................................................
Rear Axle Bearing Inspection57................................................................................................................................................................
Shock Absorber Inspection57................................................................................................................................................................
Electrical For G22a58................................................................................................................................................................
Spark Plug Inspection58................................................................................................................................................................
Starter Belt Inspection59................................................................................................................................................................
Starter Belt Adjustment59................................................................................................................................................................
Battery Inspection60................................................................................................................................................................
Battery Charging61................................................................................................................................................................
Electrical For G22e62................................................................................................................................................................
48v Charger Features63................................................................................................................................................................
48v Charger Operating Instructions63................................................................................................................................................................
Led Readings - Normal Charge Cycle63................................................................................................................................................................
Led Readings - Abnormal Charge Cycle64................................................................................................................................................................
Charge Receptacle Inspection68................................................................................................................................................................
Controller Connector Inspection68................................................................................................................................................................
Discharge Minutes Adjusted For Temperature71................................................................................................................................................................
Battery Discharge Chart72................................................................................................................................................................
Battery Discharge Testing72................................................................................................................................................................
Chassis73................................................................................................................................................................
Front And Rear Bumper Removal75................................................................................................................................................................
Front And Rear Bumper Installation75................................................................................................................................................................
Bumpers76................................................................................................................................................................
Seat Removal77................................................................................................................................................................
Seat Installation77................................................................................................................................................................
Seat78................................................................................................................................................................
Front Cowling Removal79................................................................................................................................................................
Front Storage Panel Removal79................................................................................................................................................................
Front Cowling Installation80................................................................................................................................................................
Front Cowling81................................................................................................................................................................
Rear Body Removal82................................................................................................................................................................
Rear Floor Cover Removal82................................................................................................................................................................
Rear Body Installation83................................................................................................................................................................
Rear Cowling For G22a84................................................................................................................................................................
Rear Cowling For G22e85................................................................................................................................................................
Front Wheel86................................................................................................................................................................
Front Wheel Removal87................................................................................................................................................................
Front Wheel Inspection88................................................................................................................................................................
Front Wheel Installation89................................................................................................................................................................
Rear Axle Wheel For G22a90................................................................................................................................................................
Rear Axle Wheel For G22a Removal91................................................................................................................................................................
Rear Axle Wheel For G22a Inspection91................................................................................................................................................................
Rear Axle Wheel For G22a Installation92................................................................................................................................................................
Rear Axle Wheel For G22e94................................................................................................................................................................
Rear Axle Wheel For G22e Removal95................................................................................................................................................................
Rear Axle Wheel For G22e Inspection95................................................................................................................................................................
Rear Axle Wheel For G22e Installation96................................................................................................................................................................
Brake98................................................................................................................................................................
Brake Pedal99................................................................................................................................................................
Brake Pedal Disassembly100................................................................................................................................................................
Brake Pedal Inspection101................................................................................................................................................................
Brake Pedal Assembly102................................................................................................................................................................
Accelerator Pedal For G22a105................................................................................................................................................................
Accelerator Pedal For G22e106................................................................................................................................................................
Steering System107................................................................................................................................................................
Steering System Removal108................................................................................................................................................................
Steering System Disassembly110................................................................................................................................................................
Steering System Inspection111................................................................................................................................................................
Steering System Assembly113................................................................................................................................................................
Steering System Adjust114................................................................................................................................................................
Steering System Installation115................................................................................................................................................................
Front Suspension117................................................................................................................................................................
Front Suspension Removal118................................................................................................................................................................
Front Suspension Inspection119................................................................................................................................................................
Front Suspension Installation121................................................................................................................................................................
Rear Arm Suspension For G22a122................................................................................................................................................................
Rear Arm Suspension For G22e123................................................................................................................................................................
Rear Arm Suspension Removal124................................................................................................................................................................
Rear Arm Suspension Inspection125................................................................................................................................................................
Rear Arm Suspension Installation125................................................................................................................................................................
Cable Maintenance126................................................................................................................................................................
Frame For G22a128................................................................................................................................................................
Frame For G22e129................................................................................................................................................................
Power Train For G22a133................................................................................................................................................................
Primary Sheave133................................................................................................................................................................
Primary Sheave Removal134................................................................................................................................................................
Primary Sheave Disassembly135................................................................................................................................................................
Primary Sheave Inspection135................................................................................................................................................................
Primary Sheave Assembly136................................................................................................................................................................
Primary Sheave Installation137................................................................................................................................................................
Secondary Sheave138................................................................................................................................................................
Secondary Sheave Disassembly139................................................................................................................................................................
Secondary Sheave Inspection140................................................................................................................................................................
Secondary Sheave Assembly140................................................................................................................................................................
Drive V-belt Inspection And Replacement142................................................................................................................................................................
Transmission143................................................................................................................................................................
Transmission Removal144................................................................................................................................................................
Transmission Differential Disassembly146................................................................................................................................................................
Transmission Differential Inspection147................................................................................................................................................................
Transmission Disassembly147................................................................................................................................................................
Transmission Inspection149................................................................................................................................................................
Transmission Assembly150................................................................................................................................................................
Differential Assembly152................................................................................................................................................................
Differential Installation153................................................................................................................................................................
Power Train For G22e155................................................................................................................................................................
Power Train For G22e Transmission Removal156................................................................................................................................................................
Power Train For G22e Transmission Disassembly156................................................................................................................................................................
Power Train For G22e Transmission Inspection159................................................................................................................................................................
Power Train For G22e Transmission Assembly159................................................................................................................................................................
Power Train For G22e Transmission Installation160................................................................................................................................................................
Engine Overhaul161................................................................................................................................................................
Engine Removal163................................................................................................................................................................
Preparation For Removal163................................................................................................................................................................
Drive Belt164................................................................................................................................................................
Primary Clutch164................................................................................................................................................................
Air Cleaner Case164................................................................................................................................................................
Carburetor164................................................................................................................................................................
Wiring And Hose165................................................................................................................................................................
Starter Generator165................................................................................................................................................................
Muffler166................................................................................................................................................................
Engine Oil Drain167................................................................................................................................................................
Air Shroud167................................................................................................................................................................
Flywheel168................................................................................................................................................................
Cylinder Head169................................................................................................................................................................
Crankcase Cover169................................................................................................................................................................
Camshaft170................................................................................................................................................................
Balancer Shaft And Crankshaft170................................................................................................................................................................
Piston And Connecting Rod171................................................................................................................................................................
Oil Sender And Wire Guide Plate171................................................................................................................................................................
Bearings171................................................................................................................................................................
Cylinder Head Inspection And Repair172................................................................................................................................................................
Valve174................................................................................................................................................................
Valve Seat175................................................................................................................................................................
Valve Spring178................................................................................................................................................................
Valve Installation179................................................................................................................................................................
Rocker Arm180................................................................................................................................................................
Gears182................................................................................................................................................................
Cylinder And Piston182................................................................................................................................................................
Piston Ring And Pin183................................................................................................................................................................
Piston Ring Oversize184................................................................................................................................................................
Piston Pin185................................................................................................................................................................
Crankshaft Runout186................................................................................................................................................................
Crank Pin Outside Diameter186................................................................................................................................................................
Connecting Rod Oil Clearance186................................................................................................................................................................
Piston, Connecting Rod And Crankcase Cover188................................................................................................................................................................
Bearings Installation189................................................................................................................................................................
Piston And Connecting Rod Installation189................................................................................................................................................................
Crankshaft, Balancer Shaft And Camshaft191................................................................................................................................................................
Cylinder Head And Rocker Arm196................................................................................................................................................................
Ignition Unit198................................................................................................................................................................
Remounting Engine199................................................................................................................................................................
Carburetion203................................................................................................................................................................
Carburetor Section View206................................................................................................................................................................
Main Metering System206................................................................................................................................................................
Float System207................................................................................................................................................................
Electrical215................................................................................................................................................................
G22a Wiring Diagram217................................................................................................................................................................
Electrical Component Locations218................................................................................................................................................................
Electrical Components (engine)219................................................................................................................................................................
Ignition System220................................................................................................................................................................
Ignition System Components221................................................................................................................................................................
Troubleshooting222................................................................................................................................................................
The Starter Does Not Turn222................................................................................................................................................................
No Spark Or Wear Spark226................................................................................................................................................................
G22a Ignition System Troubleshooting228................................................................................................................................................................
Engine Will Not Run, No Spark228................................................................................................................................................................
The Battery Is Not Charged230................................................................................................................................................................
Starter-generator233................................................................................................................................................................
Solenoid Relay239................................................................................................................................................................
Voltage Regulator240................................................................................................................................................................
Generator Voltage Inspection240................................................................................................................................................................
Signal System (oil Warning/reverse Buzzer)242................................................................................................................................................................
Signal System Components243................................................................................................................................................................
The Oil Level Indicator Light Does Not Come On244................................................................................................................................................................
The Reverse Buzzer Does Not Operate247................................................................................................................................................................
G22e Wiring Diagram250................................................................................................................................................................
Electrical Components252................................................................................................................................................................
Traction Motor253................................................................................................................................................................
Traction Motor Removal254................................................................................................................................................................
Traction Motor Disassembly255................................................................................................................................................................
Tractor Motor Inspection And Testing257................................................................................................................................................................
Tractor Motor Assembly260................................................................................................................................................................
Tractor Motor Installation261................................................................................................................................................................
Motor Control Unit262................................................................................................................................................................
Electrical Troubleshooting267................................................................................................................................................................
Acceleration Becomes Rough, Uneven Or Jerky267................................................................................................................................................................
Visual Inspection267................................................................................................................................................................
Test Throttle Position Sensor267................................................................................................................................................................
Car Does Not Slow On Downhill Grade And/or Car Will Roll Away Without Slowing268................................................................................................................................................................
Speed Sensor Wire Harness Check268................................................................................................................................................................
Car Has No Reverse Warning Beeper269................................................................................................................................................................
Speed Sensor Test269................................................................................................................................................................
Speed Sensor Magnet Check269................................................................................................................................................................
Buzzer Wiring Check269................................................................................................................................................................
The Car's Top Speed Is Slower270................................................................................................................................................................
Ground Wire Check270................................................................................................................................................................
Check Brakes And Chassis270................................................................................................................................................................
Car Won't Run Either Direction, Solenoid Does Not Click271................................................................................................................................................................
Reset Controller271................................................................................................................................................................
Fuse Check271................................................................................................................................................................
Tow Switch Test272................................................................................................................................................................
Wire Check Solenoid To Tow Switch272................................................................................................................................................................
Controller Ground Wire Check272................................................................................................................................................................
Solenoid Ground Bypass272................................................................................................................................................................
Wire Check - Solenoid To Controller273................................................................................................................................................................
Solenoid Relay Bench Test273................................................................................................................................................................
Car Won't Run Either Direction, Solenoid Does Click274................................................................................................................................................................
Throttle Position Sensor Check274................................................................................................................................................................
Main Switch Check275................................................................................................................................................................
Accelerator Stop Switch Check275................................................................................................................................................................
Direction Switch Check276................................................................................................................................................................
Check Traction Motor276................................................................................................................................................................
Z-1 Diagnostic Tester278................................................................................................................................................................
Z-1 Harness Identification278................................................................................................................................................................
Operation Instructions280................................................................................................................................................................
Specifications285................................................................................................................................................................
General Specifications287................................................................................................................................................................
Engine Specifications288................................................................................................................................................................
Transmission Specifications291................................................................................................................................................................
Electrical Specifications293................................................................................................................................................................
Power Train Specifications295................................................................................................................................................................
Cable/wire Routing For G22a296................................................................................................................................................................
Table Of Contents309................................................................................................................................................................

Advertisement

Share and save

Advertisement