Yamaha YUM2A Manuals

Manuals and User Guides for Yamaha YUM2A. We have 1 Yamaha YUM2A manual available for free PDF download: Service Manual

Yamaha YUM2A Service Manual (320 pages)

Brand: Yamaha | Category: Utility Vehicle | Size: 20.14 MB

Table of Contents

7
- General Information
  9
  - Identification
    10
    
    Utility Vehicle Serial Number
    10
    
    Engine Serial Number (Yum1A/Yum2A)
    10
    
    Traction Motor Serial Number (Yum2E)
    10
    
    Motor Control Unit Serial Number (Yum2E)
    10
  - Safety Precautions
    11
    
    Safety Lockout Procedure
    11
    
    Discharge the Motor Control Unit Capacitor
    11
    
    Recommended Jack Points
    11
  - Important Information
    12
    
    Preparation for Removal and Disassembly
    12
    
    Replacement Parts
    12
    
    Gaskets, Oil Seals and O-Rings
    12
    
    Lock Washers/Plates and Cotter Pins
    12
    
    Bearings and Oil Seals
    13
    
    Circlips
    13
    
    Rubber Parts
    13
  - Basic Service Information
    14
    
    Quick Fasteners
    14
    
    Electrical System
    15
  - Special Tools
    20
Specifications

23
Periodic Checks and Adjustments

71
Chassis

97
- General Chassis (1)
  
  100
  - Installing the Seats
    101
  - Removing the Seats
    101
- General Chassis (2)
  
  102
- General Chassis (3)
  
  102
  - Removing the Mudguard
    107
  - Installing the Mudguard
    107
- General Chassis (4)
  
  108
- General Chassis (5)
  
  108
  - Removing the Hood
    111
- General Chassis (6)
  
  112
  - Installing the Steering Wheel
    113
- General Chassis (7)
  
  114
- Front and Rear Wheels
  
  115
  - Remove the Wheels
    118
  - Checking the Wheels
    118
  - Checking the Wheel Hubs
    118
- Front and Rear Brakes
  
  119
  - Checking the Brakes
    121
  - Installing the Brakes
    121
- Pedal Assembly
  
  122
- Steering System
  
  128
  - Removing the Tie-Rod
    129
  - Checking the Steering Joint
    129
  - Checking the Tie-Rod Ends
    129
  - Installing the Steering System
    129
  - Lubricating the Steering Shaft
    130
- Front Suspension Components
  
  131
- Rear Suspension Components
  
  135
Engine (Yum1A/Yum2A)

139
- Engine Inspection
  
  140
  - Measuring the Compression Pressure
    140
- Engine Removal (1)
  
  141
- Engine Removal (2)
  
  141
  - Installing the Engine
    144
- Cylinder Head and Rocker Arms
  
  145
  - Removing the Cylinder Head
    147
  - Checking the Cylinder Head
    147
  - Checking the Rocker Arms and Rocker Arm Shafts
    148
  - Checking the Push Rods
    148
  - Installing the Cylinder Head
    148
- Valves and Valve Springs
  
  150
  - Removing the Valves
    151
  - Checking the Valves and Valve Guides
    151
  - Checking the Valve Seats
    153
  - Checking the Valve Springs
    154
  - Installing the Valves
    154
- Starter Generator
  
  156
  - Checking the Starter Generator
    158
  - Assembling the Starter Generator
    159
- Flywheel
  
  160
  - Removing the Flywheel
    161
  - Installing the Flywheel
    161
- Camshaft
  
  163
  - Removing the Crankcase Cover
    164
  - Checking the Camshaft
    164
  - Checking the Decompression System
    165
  - Checking the Valve Lifters
    165
  - Installing the Camshaft
    165
  - Installing the Crankcase Cover
    165
- Crankshaft and Piston
  
  167
  - Removing the Connecting Rod and Piston
    168
  - Checking the Cylinder and Piston
    168
  - Checking the Piston Rings
    169
  - Checking the Piston Pin
    170
  - Checking the Crankshaft and Connecting Rod
    170
  - Checking the Balancer
    171
  - Installing the Connecting Rod and Piston
    171
Fuel System (Yum1A/Yum2A)

175
- Fuel Tank
  
  176
  - Checking the Fuel Pump Body
    177
  - Installing the Fuel Pump
    177
  - Installing the Fuel Tank
    177
  - Removing the Fuel Pump
    177
  - Removing the Fuel Tank
    177
  - Checking the Fuel Pressure
    178
- Air Filter Case
  
  179
- Throttle Body
  
  180
  - Removing the Throttle Body
    181
  - Checking the Fuel Injector
    181
  - Checking the Throttle Body
    181
  - Checking the Intake Manifold
    181
  - Checking the Intake Manifold Joint
    181
  - Installing the Throttle Body
    181
Drive Train

183
- Primary and Secondary Sheave (Yum1A/Yum2A)
  
  187
  - Removing the Primary Sheave
    187
  - Removing the Secondary Sheave
    187
  - Checking the Primary Sheave
    188
  - Checking the Secondary Sheave
    188
  - Disassembling the Secondary Sheave
    188
  - Assembling the Primary Sheave
    189
  - Assembling the Secondary Sheave
    189
- Transmission (Yum1A/Yum2A)
  
  191
  - Disassembling the Transmission
    195
  - Checking the Transmission
    195
  - Assembling the Transmission
    195
  - Installing the Shift Cables
    195
- Transmission (Yum2E)
  
  197
  - Checking the Transmission
    199
- Traction Motor (Yum2E)
  
  200
  - Assembling the Traction Motor
    201
Electrical System

203
- Ignition System (Yum1A/Yum2A)
  
  206
  - Circuit Diagram
    206
  - Troubleshooting
    208
- Electric Starting System (Yum1A/Yum2A)
  
  210
  - Circuit Diagram
    210
  - Troubleshooting
    212
- Charging System (Yum1A/Yum2A)
  
  214
  - Circuit Diagram
    214
  - Troubleshooting
    216
- Charging System (Yum2E)
  
  218
  - Circuit Diagram
    218
  - Troubleshooting
    219
- Lighting System (Yum1A/Yum2A)
  
  220
  - Circuit Diagram
    220
  - Troubleshooting
    222
- Lighting System (Yum2E)
  
  224
  - Circuit Diagram
    224
  - Troubleshooting
    226
- Signaling System (Yum1A/Yum2A)
  
  228
  - Circuit Diagram
    228
  - Troubleshooting
    230
- Signaling System (Yum2E)
  
  234
  - Circuit Diagram
    234
  - Troubleshooting
    236
- Fuel Injection System (Yum1A/Yum2A)
  
  238
  - Circuit Diagram
    238
  - Reading Error Codes - Fuel Injection System
    240
- Fuel Pump System (Yum1A/Yum2A)
  
  244
  - Circuit Diagram
    244
  - Troubleshooting
    246
- Drive System (Yum2E)
  
  248
  - Circuit Diagram
    248
  - Troubleshooting
    250
- Electrical Components (Yum1A/Yum2A)
  
  252
  - Checking the Switches
    253
  - Adjusting the Headlight Beams
    255
  - Checking the Fuses
    255
  - Checking and Charging the Battery
    256
  - Checking the Relays
    258
  - Checking the Spark Plug Cap
    259
  - Checking the Ignition Coil
    259
  - Checking the Ignition Spark Gap
    259
  - Checking the Crankshaft Position Sensor
    260
  - Checking the Starter Generator Operation
    260
  - Checking the Voltage Regulator
    261
  - Checking the Fuel Sender
    261
  - Checking the Reverse Buzzer
    262
  - Checking the Engine Temperature Sensor
    262
  - Checking the Intake Air Pressure Sensor
    262
  - Checking the Intake Air Temperature Sensor
    263
  - Checking the Fuel Injector
    263
  - Checking the Oil Level Switch
    264
- Electrical Components (Yum2E)
  
  265
  - Checking the Switches
    266
  - Adjusting the Headlight Beams
    268
  - Checking the Fuses
    268
  - Checking and Charging the Battery
    268
  - Battery Charger (Yamaha Provided Charger)
    270
  - Removing and Replacing the Battery
    282
  - Checking the Relays
    282
  - Checking the Reverse Buzzer
    283
  - Checking the Throttle Position Sensor
    283
Troubleshooting

285
- Troubleshooting (Yum1A/Yum2A)
  
  286
  - General Information
    286
  - Starting Failures
    286
  - Poor Medium-And-High-Speed Performance
    286
  - Faulty Gear Shifting
    286
  - Shift Lever Does Not Move
    287
  - Faulty Drive Train Performance
    287
  - Overheating
    287
  - Poor Braking Performance
    287
  - Faulty Shock Absorber Assembly
    287
  - Unstable Handling
    287
  - Faulty Lighting System
    288
- Diagnostic/Error Code Identification Chart (Yum1A/Yum2A)
  
  289
- Troubleshooting (Yum2E)
  
  291
  - General Information
    291
  - Poor Performance
    291
  - Poor Braking Performance
    291
  - Faulty Shock Absorber Assembly
    291
  - Unstable Handling
    291
  - Faulty Lighting System
    291
  - Resetting Motor Control Unit (Mcu) (Yum2E)
    291
  - Mcu Main Harness Coupler (Yum2E)
    292
- Pc Genius Diagnostic System (Yum2E)
  
  293
  - Introduction
    293
  - Pc Genius Diagnostic Tool
    293
  - Connecting the Pc Genius
    293
  - Diagnostic Mode
    293
  - Troubleshooting Using Pc Genius
    296
  - Fault Code Table
    309
- Pc Genius Golf Car Programming System (Yum2E)
  
  311
  - Golf Car Programming Mode
    311

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Yamaha YUM2A Service Manual (320 pages)

Table of Contents

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Pre-Operation Checks

Monthly Checks

6-Month Checks

Annual Checks

4-Year Checks

Chassis

General Chassis (1)

General Chassis (2)

General Chassis (3)

General Chassis (4)

General Chassis (5)

General Chassis (6)

General Chassis (7)

Front and Rear Wheels

Front and Rear Brakes

Pedal Assembly

Steering System

Front Suspension Components

Rear Suspension Components

Engine (Yum1A/Yum2A)

Engine Inspection

Engine Removal (1)

Engine Removal (2)

Cylinder Head and Rocker Arms

Valves and Valve Springs

Starter Generator

Flywheel

Camshaft

Crankshaft and Piston

Fuel System (Yum1A/Yum2A)

Fuel Tank

Air Filter Case

Throttle Body

Drive Train

Primary and Secondary Sheave (Yum1A/Yum2A)

Transmission (Yum1A/Yum2A)

Transmission (Yum2E)

Traction Motor (Yum2E)

Electrical System

Ignition System (Yum1A/Yum2A)

Electric Starting System (Yum1A/Yum2A)

Charging System (Yum1A/Yum2A)

Charging System (Yum2E)

Lighting System (Yum1A/Yum2A)

Lighting System (Yum2E)

Signaling System (Yum1A/Yum2A)

Signaling System (Yum2E)

Fuel Injection System (Yum1A/Yum2A)

Fuel Pump System (Yum1A/Yum2A)

Drive System (Yum2E)

Electrical Components (Yum1A/Yum2A)

Electrical Components (Yum2E)

Troubleshooting

Troubleshooting (Yum1A/Yum2A)

Diagnostic/Error Code Identification Chart (Yum1A/Yum2A)

Troubleshooting (Yum2E)

Pc Genius Diagnostic System (Yum2E)

Pc Genius Golf Car Programming System (Yum2E)

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