YAMAHA SERVICE MANUAL
G9-AJ/EJ G9-AG/AH G9-EG/EH1 G9-EH2 G2-A1E .
L1T-19616-G9 -93
INDEX ~
GENERAL INFORMATION
GEN INFO
SPECIFICATIONS
SPEC
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PERIODIC INSPECTION AND ADJUSTMENT
1----
ENGINE OVERHAUL
1-----=
CARBURETION
INSP ADJ
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I---.,;f CARS
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POWER TRAIN
1---
CHASSIS
ICHAS~
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ELECTRICAL TROUBLESHOOTING
POWR TR
HEeD
I
CONTENTS CHAPTER 1. GENERAL INFORMATION CAR IDENTIFiCATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER (FOR G2-Al
1-1 1-1 1-1
IMPORTANT INFORMATION NO FLAME SOURCES WASHING AND CLEANING RIGHT TOOLS MAKING IT NEAT TIGHTENING TORQUE ALL REPLACEMENT PARTS GASKETS, OIL SEALS, AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLlPS _ NOTES ON DISASSEMBLY AND ASSEMBLY
1-2 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-4 1-4
SPECIAL TOOLS FOR TUNE UP FOR ENGINE SERVICE FOR POWER TRAIN FOR CHASSIS SERVICE FOR ELECTRICAL COMPONENTS
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1-5 1-5 1-5 1-6 1-7 1-8
CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS FOR G2-A. FOR G2-E ,
2-1 2-1 2-1
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MAINTENANCE SPECIFICATIONS ENGINE TRANSMISSION CHASSIS ELECTR ICAL.
_
GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS
2-2 2-2 2-7 2-9 2-12 2-17
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2-17
CABLE ROUTING (FOR G2-Al.
2-18
CABLE ROUTING (FOR G2-El
2-20
CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION
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3-1
PERIODIC MAINTENANCE TABLE FOR G2-A FOR G2-E JACK-UP FRONT SIDE REAR SIDE
3-1 3-1 3-4
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COWLING BODY SEAT COWLING OPENING REAR COWLING REMOVAL
3-6 3-6 3-6
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GEN INFO
SPEC
3-7 3-7 3-7
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ENGINE (FOR G2-A) VALVE CLEARANCE ADJUSTMENT ' ENGINE OIL LEVEL MEASUREMENT ENGINE OIL REPLACEMENT OIL DELIVERY HOSE INSPECTION __ AIR FILTER CLEANING _ " ENGINE BRACKET ADJUSTMENT _ COMPRESSION PRESSURE MEASUREMENT _ CARBURETOR ADJUSTMENT. _ _. _ _ THROTTLE CABLE ADJUSTMENT _ SPEED LIMITER ADJUSTMENT CHOKE CABLE ADJUSTMENT.. _ , FUEL PUMP INSPECTION _.. _ FUEL FILTER INSPECTION _ FUEL HOSE INSPECTION _ _
POWER TRAIN. _ TRANSMISSION 01 L LEVEL MEASUREMENT TRANSMISSION OIL REPLACEMENT DRIVE BELT INSPECTION (FOR G2-A) PRIMARY SHEAVE LUBRICATION (FOR G2-A) SHEAVE INSPECTION , SHIFTING CABLE ADJUSTMENT (FOR G2-A)
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3-8 3-8 3-10 3-10 3-11 " .3-12 3-13 3-13 3-15 3-15 3-17 " .3-18 3-19 3-21 3-21
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3-22 3-22 _.3-22 3-23 3-24 3-25 3-25
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ENG
CARB
f--_®I---,C!0 POWR TR
CHAS
ELEC
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i I
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CHASSIS BRAKE CABLE INSPECTION PARKING BRAKE ADJUSTMENT SHOE LINING INSPECTION , BRAKE AND ACCELERATOR PEDALS STEERING INSPECTION .. " STEERING LINKAGE INSPECTION WHEEL ALIGNMENT TIRE AND WHEEL INSPECTION
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3-26 3-26 3-27 3-27 3-29 3-30 . 3-33 3-33 3-34
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1----.;-
TRBL SHTG
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FRONT WHEEL BEARING INSPECTION REAR AXLE BEARING INSPECTION SHOCK ABSORBER INSPECTION
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ELECTRICAL (FOR G2-A) SPARK PLUG INSPECTION STARTER BELT INSPECTION _" BATTERY INSPECTION " BATTERY CHARGING ACCELERATOR STOP SWITCH ADJUSTMENT
ELECTRICAL (FOR G2-E) BATTERY CHARGING .. , BATTERY INSPECTION SPEED CONTROLLER INSPECTION SOLENOID RELAY INSPECTION TRACTION MOTOR INSPECTION CABLE ROUTING INSPECTION FUSE
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3-35 3-35 3-35 3-36 3-36 3-37 3-38 3-39 3-40
3-41 3-41 3-44 3-46 3-49 _.. 3-51 3-51 3-51
CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL PREPARATION FOR REMOVAL DRIVE BELT CARBURETOR , AIR CLEANER CASE LEAD AND HOSE MUFFLER ENGINE REMOVAL
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ENGINE DISASSEMBLY , STARTER-GENERATOR. AI R SHOUD CYLINDER HEAD , PRIMARY SHEAVE , .. , .. , FLYWHEEL (Cooling Fan) CRANKCASE COVER , , CAMSHAFT BALANCER SHAFT AND CRANKSHAFT , PISTON AND CONNECTING ROD ENGINE BRACKET INSPECTION AND PREPAIR CYLINDER HEAD " ., VALVE VALVE SEAT VALVE INSTALLATION
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4-1 4-1 4-2 4-2 4-2 4-3 4-3 4-3 4-4 4-4 4-4 4-5 4-6 4-7 , .4-7 4-8 4-8 4-8 4-9 4-9 4-9 4-11 4-12 4-16
ROCKER ARM, ROCKER ARM SHAFT AND ROCKER ARM SHAFT SUPPORT CAMSHAFT GEARS CYLINDER AND PISTON PISTON RING AND PISTON PIN CRANKSHAFT AND CONNECTING ROD
4-17 4-18 4-19 4-19 4-20 4-23
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ENGINE ASSEMBL Y AND ADJUSTMENT ENGINE BRACKET CRANKSHAFT, CAMSHAFT AND BALANCER SHAFT PISTON AND CONNECTING ROD CRANKCASE COVER FLYWHEEL " PRIMARY SHEAVE " CYLINDER HEAD AIR SHROUD STARTER-GENERATOR REMOUNTING ENGINE
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4-27 4-27 4-27 4-28 4-32 4-32 4-33 4-33 4-35 . 4-37 4-38
~ GEN INFO
SPEC
INSP
ADJ
ENG
CHAPTER 5.
CARBURET ION CARBURETOR SECTION ViEW REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION
5-1 5-2 5-4 5-4 5-5 5-6 5-7
FUEL PUMP OVERHAULING
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CARB
5-8 5-9
CHAS CHAPTER 6. POWER TRAIN (FOR G2-Al PRIMARY SHEAVE REMOVAL DiSASSEMBLy INSPECTION ASSEMBLY INSTALLATION SECONDARY SHEAVE DISASSEMBLY INSPECTION ASSEMBLY
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6-1 6-2 6-2 6-3 6-3 6-4 , .. 6-6 6-7 6-8 , 6-8
ELEC
TRBL SHTG
DRIVE V-BELT INSPECTION AND REPLACEMENT
6-10 6-10
TRANSMISSION REMOVAL DiSASSEMBLy INSPECTION ASSEMBLy INSTALLATION
6-12 6-12 6-13 6-14 6-15 6-16
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POWER TRAIN (FOR G2-E) TRANSMISSION REMOVAL DISASSEMBLY INSPECTION ASSEMBLY iNSTALLATION
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6-18 6-19 6-19 6-21 6-21 6-22
CHAPTER 7. CHASSIS
H" REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION
7-16 7-17 7-18 7-18 7-20 7-20
FRONT SUSPENSION AND KNUCKLE REMOVAL INSPECTION " INSTALLATION REAR SUSPENSION REMOVAL INSPECTION INSTALLATION
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7-23 7~4
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7-26 7-26 7-28 7-30 7-31 7-31
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CAB LES CABLE MAINTENANCE
7-32 7-32
CHAPTER 8. ELECTRICAL (FOR G2-Al 8-1
ELECTRICAL COMPONENTS
8-3
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IGNITION SYSTEM TROUBLESHOOTING
I--::G::-::E""'N:INFO
SPEC
INSP
G2-A CIRCUIT DIAGRAM
STARTING AND CHARGING SYSTEM TROUBLESHOOTING STARTER-GENERATOR .. " SOLENOID RELAy VOLTAGE REGULATOR
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8-5 8-7 8-15 8-22 8-25 8-27 8-29
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ENG
CARB
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8-35 8-37
1----
G2-E CIRCUIT DIAGRAM
8-43
CHAS
ELECTRICAL COMPONENTS
8-45
SIGNAL SYSTEM TROUBLESHOOTING
POWR TR
ELECTRICAL (FOR G2-El
STARTING AND RECHARGING SySTEM TROUBLESHOOTING G.E. TRACTION MOTOR HITACHI TRACTION MOTOR SPEED CONTROLLER SOLENOID RELAy CHARGING RECEPTACLE SIGNAL SYSTEM TROUBLESHOOTING
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8-47 8-49 _. 8-54 8-61 8-67 8-69 ·8-71 8-73 8-75
ELEC
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TRBL
SHTG
CHAPTER 9. TROUBLESHOOTING TROUBLESHOOTING CHART (FOR G2-A)
9-1
ENGINE (FOR G2-A)
9-2
SUSPENSION AND STEERING
9-3
ELECTRICAL (FOR G2-A)
9-4
STARTER-GENERATOR (FOR G2-A) ELECTRICAL (FOR G2-E) MOTOR (FOR G2-E)
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9-4 _.'
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9-5 _
9-7
CAR IDENTIFICATION
I~EF"bI~1
GENERAL INFORMATION CAR IDENTIFICATION FRAME SERIAL NUMBER The frame serial number CD is located on the rectangular pipe under the operator's seat. or on the right hand side of the rectangular pipe by the rear bumper.
Starting Serial Number:
G2·A
J38-000101 JA2-000101 J55-000101
G2-E
J41·000101 JE2-000101 J56-000101
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NOTE:
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The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.
ENGINE SERIAL NUMBER The engine serial number CD is located on the 1eft-hand side of crank case.
Starting Serial Number:
G2·A
J38·0001 01 JA2-000101 J55·000101
NOTE:
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Designs and specifications are subject to change without notice.
1-1
D
GEN IMPORTANT INFORMATION
~d~
INFO~
IMPORTANT INFORMATION NO FLAME SOURCES
1. Avoid any flame sources in the service shop.
WASHING AND CLEANING
1. Thoroughly clean the exterior of the car body and engine. While cleaning, take care to protect the electrical parts, such as relay switches, motor, resistors, controllers, etc., from high pressure water splashes.
RIGHT TOOLS 1. Be sure to use the right special tool for the
right part in order to protect the part from damage. Always use the right tool and the right instrument.
MAKING IT NEAT
1. Keep the removed parts separately in groups so that they will not be misplaced or confused.
TIGHTENING TORQUE
1. Be sure to keep to tightening torque specifications. When tightening bolts, nuts, and screws, start with a larger-diameter one and from an inner-positioned one to an
outer-positioned one in a criss-cross pattern. Refer to CHAPTER 2. "TIGHTENING TORQUE".
1-2
IMPORTANT INFORMATION
GEN INFO ~4
ALL REPLACEMENT PARTS 1_ We recommend you use Yamaha genuine
parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.¡
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] GASKETS, OIL SEALS, AND a-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All
gasket surfaces, oil seal lips, and O-rings must be cleaned.
LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates CD and cotter
pins must be replaced when they are removed. Lock tabls) should be bent along the bolt or nut tlatls) after the bolt or nut has been properly tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) CD and oil sealts) @ with their manufacturer's marks or numbers ! In other words, the facing outward. stamped letters must be on the side exposed to view.) When installing oil sealls), apply a light coating of light-weight lithium base grease to the seal lip(sl. Oil the bearings liberally when installing.
Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces, --+t-~"
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IMPORTANT INFORMATION
~ dr INFO~
GEN
CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD, make sure that the sharp-edged corner CV IS positioned opposite to the thrust ® it receives. See the sectional view.
® Shaft
3000(11
NOTES ON DISASSEMBLY AND ASSEMBLY 1. Parts should be cleaned and blown off with compressed air whenever they are disassembled.
2. Contact surfaces of moving parts should be oiled when they are assembled. Apply grease to the oil seal lips.
3. After assemb ling, make sure each of the moving parts operates normally.
1-4
SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool )Nill help prevent damage caused by the use of improper tools or improvised techniques.
FOR TUNE UP
1. Inductive Tachometer PIN YU-08036, 90890-03113 This tool is needed for detecting engine rpm.
2. Compression Gauge PIN YU-33223, 90890-03081 This gauge is used to measure the engine compression.
FOR ENGINE SERVICE
1. Heavy-Duty Universal Puller PIN YU-33270, 90890-01362 This tool is used to remove the flywheel.
2. Valve Spring Compressor PIN YM-04019, 90890-01253 This tool is needed to remove and install the valve assemblies.
1-5
SPECIAL TOOLS
GEN INFO ~
3. Valve Seat Cutter Set piN YM-91043 This tool is used to resurface the valve seat.
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litS 4. Valve Adjuster PIN YM¡08035, 90890-01311 This tool is used to adjust the valve clearance.
FOR POWER TRAIN
1. Primary Sheave Holder PIN YS-01880, 90890-01701 Th is tool is used to hold the primary sheave when removing or installing the primary sheave securing bolt.
2. Primary Sheave Puller PIN YG-01876, 90890-01876 This tool is used for removing the pnmary sheave.
3. Secondary Sheave Holder PIN YG-40103, 9089001705 This tool is used to compress the sheave spring when removing or installing the secondary sheave securing nut.
1-6
5. Plastigage@ Set "Green" PIN YU-3321 0 This gauge is needed to measure the clearance for the connecting rod bearing and the crank shaft bearing.
FOR CHASSIS SERVICE
1. Drift punch (6 mm) or Valv.e Guide Remover
PIN YM-04064, 90890-04064 This tool is used to remove the spring pins for steering knuckle.
2. Dial Gauge PIN YU-03097, 90890-03097 This tool is used to measure small movement or runout such as the rear axle deflection.
3. Cable Injector PIN ACC-llll0-43-15, 90890-70054 This tool is used to lubricate the throttle, shifter and brake cables.
1-7
GEN .,. dr SPECIAL TOOLS
INFO~
FOR ELECTRICAL COMPONENTS
1. Pocket Tester PIN YS-03112. 90890-03112 This instrument IS invaluable for checking the electrical system.
2. Hydrometer PIN Y U-03036, 90890-03036 This gauge is used to measure the specific gravity of battery electrolyte.
3. Low Reading Ohmmeter PIN YU-91 026, 90890-03064 This instrument is use to measure the low range resistance (Q - 1[1) of the electrical components.
4. Dynamic Spark Tester PIN. YM-34487, 90890-03144 This tester is necessary for checking the ignition system components.
1-8
GENERAL SPECIFICATIONS
SPECIFICATIONS GENERAL SPECIFICATIONS FOR G2-A
Model Code Number
Model
G2-A J38, JA2, J55 (For U.S.A. and Canada)
Frame Serial Number
J38-000101, JA2-000101, J55-000101
Engine Serial Number
J38-000101, JA2-000101, J55-000101
Dimensions:
Overall Length Overall Width Overall Height (Steering height) Height of Floor Height of Seat from Floor Wheelbase Tread: Front Rear Min. Ground Clearance Weight: Dry Weight (Without battery) Performance: Maximum Loading Limit Maximum Speed Starter Generator Red Zone Cranking Speed Minimum Turning Radius Braking Distance Seating Capacity Hill Climbing Ability
2,332 1,116 1,175 285 420 1,550
mm mm mm mm mm mm
(91.8 (43.9 (46.3 (10.2 (16.5 (61.0
in) in) in) in) in) in)
900 mm (35.4 in) 900 mm (35.4 in) 104 mm ( 4.1 in) 275 kg (606 Ib) 250 kg (550 Ib) 19 km/h (12 mph) 4,000 r/min Appx. 800 r/min 2,900 mm (114 in) 4,500 mm (177 in) at 19 km/h (12 mph) 2 persons 26° (50% grade) on pavement
FOR G2-E G2-E
Model Model Code Number Frame Serial Number
J41,JE2,J56 J41-000101, JE2-000101, J56-000101
Dimensions:
OveraII Length Overall Width Overall Height (Steering height) Height of Floor Height of Seat from Floor Wheelbase Tread: Front Rear Min. Ground Clearance
2,332 1,116 1,175 285 420 1,550
mm mm mm mm mm mm
(91.8 (43.9 (46.3 (10.2 (16.5 (61.0
in) in) in) in) in) in)
900 mm (35.4 in) 900 mm (35.4 in) 104 mm ( 4.1 in)
2-'