YAMAHASERVICEMANUAL
GI-AM3CAR
@YAMAHAGOLF
EXHAUST VALVE Fig. 1 1. Cylinder 2. Piston 3. Ring nut ass'y 4. Shaft View in direct~onof A 5. Butterfly exhaust valve 6. Exhaust plpe 7. Plug 8. Bear~ng 9. Gasket 10. Gasket cover 11. Lever 12. Locknut 13. Exhaust pipe spring 14. Speed limiter lever 15. Speed adjust screw 16. Rod ass'y 2 17. Connector comp. (crank) 18. Clamp 19. Rod ass'y 1 20. Return spring 21. Locknut 22. Locknut 23. Torsion spring 24. Throttle wire ass'y 25. Choke wire ass'y 26. Cl~p 27. Stopper Fig. 2
2. Setting the engine idle speed
With the V-belt removed, make sure the engine idles at 1,200 rlmin. (When the V-belt is mounted, the idling speed is 1,000 rlmin.) If not, make an idle speed adjustment by turning the throttle stop screw. While making this idle speed adjustment, the engine speed will not affect the opening of the butterfly valve (exhaust valve).
1. Setting the governor lever
A. ADJUSTMENTS View in direction of B Fig. 3 1. Locknut 6. Connector arm 11. Lever 2. Joint rod 7. Clamp 12. Butterfly valve 3. Speed adjust screw 8. Connector rod 2 13. Exhaust flange 4. Governor lever 9. Return spring 14. Exhaust pipe 5. Connecter rod 1 10. Shaft
Adjust the length of the joint rod 1 so when the accelerator pedal is fully depressed, and the governor lwer is turned counterclockwise, the carburetor thorttle valve just reaches the fully open position. (To adjust the joint rod length, loosen two locknuts, adjust the length, then tighten the locknuts.)
NOTE:Before adjusting, installed between remove the return spring connector rod 2 and the exhaust pipe.
3.
distance B = 20 - 25 mm (0.79 -0.98 in)
7.
4. Adjusting the throttle wire
3. Exhaust valve setting
After this operation, check the following points:Check whether both links and butterfly valve move smoothly. Check whether the links move beyond dead center, and become locked. Check for abnormal noise from the butterfly valve and related parts.
Adjust the throttle wire so when the accelerator pedal is fully depressed, the carburetor throttle just reaches fu II-open position.
1. Adjusting screw 2. Governor lever
Adjust the car speed by turning the adjusting screw in either direction. The maximum amount of adjustment is about 4.8 kmlh (* 3 Tighteningm.p.h.1 the adjust screw increases the speed; loosening it decreases the speed.
1. Butterfly valve Shaft Exhaust flange Engine (or Screw) Locknut pin
To facilitate checking the exhaust valve in the full-closed position, prepare a tool as shown in Fig. 4
Fig. 5
5. Governor adjustment
8. Stopper
2.
4.
5. Plate 6. Bolt
Adjust the length of connector rod so when the governor lever returns to the closed position, the butterfly valve in the exhaust port closes completely. (To adjust the length of connector rod 1, loosen two locknuts, and after adjusting, tighten the locknuts.)
To check that the exhaust valve is completely closed, remove the exhaust pipe. The valve
position can be checked by looking into the exhaust flange. As shown in Fig. 1, check the valve position. The screw head should face the exhaust pipe.
distance A = distance A' = 19 mm (0.75 in)
AfterNOTE:adjusting the throttle wire, install the return spring between connector rod 2, and the exhaust pipe.
Approx. 2,700 r/min at 19.2 kmlh (12 m.p.h.) on hard, level surface.
ENGINE
6. Rod assembly 2 adjustment
Adjust the rod ass'y 2 length by turning the shaft so that when the throttle valve is at a closed (idle) position (by pushing the speed limiter lever slightly), the exhaust valve is at a closed position as illustrated on the next page. Tighten the locknut, keeping the plastic ends at a 90" angle to each other.
Carb. throttle valve position at idling
GOOD
B. DISASSEMBLY AND ASSEMBLY
Standardfactory.eye-to
2. As illustrated, the bracket should be installed with the open end facing downward, and all joints should be installed squarely facing the ball so that movement is free throughout its operating range.
NOTE:
1. The link adjustment should be made only by adjusting the length of the joint rod and connector rod 1. It is unnecessary to adjust the length of connector rod 2 because it is already adjusted by the
In general, except when links are damaged or the joint is extremely worn, neither removal nor disassembly is necessary. When dismounting the engine from the chassis or reassembling links after replacing parts, the adjustments specified in D, above must be performed.
Check to see that when the throttle valve is fully open, the exhaust valve is also fully open.
eye distance of connector rod (2): 179 mm (7 in)
Bracket Joint
3. Do not apply grease to the contact surface of the joint.
J J24-00024 J24-0001011012,403mm(94.6 in)
Description:EnginetypeNumberofcylinderDisplacementBorexStrokeCompressionratioCoolingsystemStartingsystemIgnitionsystemLubricationsystemCylinderhead:Combustionchamber
Reversible, 2-stroke, Gasoline, 7-port piston reed valve Forward-inclined, Single 214 cm3 (13.06 cu.in) 68 x 59 mm (2.68 x 2.32 in) 5.7 : Forced1 air cooled Normal & Reversible starter generator C.D.I."Autolube" oil injection 31.3 cm3 (1.91 cu.in) Dome + Squish 0.6 mm (0.024 in)
Model:CodeFrameNo.I.D. No. & Starting NO. Engine I.D. No. & Starting No.
Dimensions:OveralllengthOverallwidthOverallheight (steering height)
Weight:Dryweight
340 kg (750 Ib) 19 kmlh (12 mph) 4,000 rlmin (25 kmlh) Appx. 800 rlmin 3,000 mm (118 in) 4,500 mm (177 in) at 19 kmlh (12 mph) 2 30"persons(57%grade) on pavement 20 kmlP at 19 km/h on pavement 4,500 km/P at 19 kmlh on pavement
1,140 mm (44.9 in) 1,180 mm (46.5 in) 295 mm (11.6 in) 428 mm (16.9 in) 1,550 mm (61.0 in) 900 mm (35.4 in) 900.mm (35.4 in)
Maximum speed Starter generator red zone Cranking Minimumspeedturning radius Braking distance Seating capacity Hill climbing ability Fuel consumption Oil consumption
6. Engine
Min. ground clearance 110 mm ( 4.3 in)Model.
volume (with spark plug)
ItemPerformance:Maximum loading limit
Compression chamber type Head gasket thickness
G1-AM3
Height of floor Height of seat from floor Wheel
A. General
Tread:baseFrontRear
Model
GI -AM3
SPECI FICATIONS
0.25- 0.75 rnm (0.010 - 0.030 in) 2.0 mm (0.079 in)
Piston pin outside diameter x Length
diameter
Crank bearing type (Left) Q'ty
x
x Q'ty Solid #6306shaftc3 (Nylon retainer) x 1 pc #6306 c3 (Nylon retainer) x 1 pc FPJSO 72 8 x 1 PC FPJ-30 48 8 x 1 PC
Crank bearing type (Right) x Q'ty
I Type I Needle bearing
TaperBoreMaterialsizelimitOutofround limit
Piston oversize
Cast iron sleeved aluminum 68 mm (2.677 in) 0.05 mm (0.0020 in) 0.01 mm (0.0004 in)
Small end bearing: Big end Crankshaft:bearing: I Needle bearing
Crankshaft assembly width (A)
Crankshaft deflection (0)
Connecting rod big end side clearnace (C)
Piston ring design (2nd)ll.D. mark
40 rnrn
Crankpin type
Ring end gap (installed)(Top)(2nd)
Crank pin outside x
Model
Piston:Piston skirt clearance (measuring point) Std.Max.
PistonPistonring:ring design (Top)/l.D. mark
Connecting rod small end deflection (P)Max.
0.030 - 0.035 mm (0.0012 - 0.0014 in) (10 mm (0.39 in) from piston skirt end) 0.1 mm (0.0039 in) 1st. 68.25 mm (2.687 in) 2nd. 68.50 mm (2.697 in) 418x 55 mm (40.709 x 2.165in)
Crank oil seal type (Left) x Q'ty
Length (1.57 in)x 2.1652:~~~~in)1 00'945-0.0005
Kevstonel" 0.2Keystone1"R"RN"-0.4rnrn(0.008 - 0.016 in)
Cylinder:Item
Crank oil seal type (Right)
GI-AM3
0.2 - 0.4 mm (0.008 - 0.016 in)
0.02 mm (0.008 in)
CLUTCH SIDE +O56 TE.05mm (2.20 -0.002 in)
Choke Carburetor:Freecable:playModelIMakerPINO.I.D.markVenturidiameter (Ven. T.)
J10-14417-00J10-14450-10"V"type0.3mm(0.012 in) 10.4 f 0.2 mm (0.409 f 0.0078 in)
Air cleaner:
-
Float height (F.H.)
Pilot air jet (P.A.J.)
GI -AM3
Throttle valve (Th.V.)
Pilot screw (P.S.)
Max. output (690 mmAg exhaust pipe 111)
Pilot jet (P.J.)
Intake reed valve:
By-pass (1 ) (B.P.-1)
Max. output (0 mmAg exhaust pipe Min.)
Mixing ratio
Element assembly PIN
-Model
Valve seat (V.S.)
Element cover PIN
(controlled by exhaust pressure)
0.50Pink - 0.55 mm (0.020 - 0.022 in) 1.80 - 1.85 mm (0.071 - 0.073 in) 111.9 x Approx.1/8421.Icm3/h at 3,250 rlmin Approx. 5.9 cm3/h at 3,250 r/min 150 : 1 at Max. Dower
Main jet (M.J.)
Type Color code
Main nozzle. (M.N.)
- Minimum stroke - Maximum stroke - Reduction ratio
Pilot outlet (P.O.)
Wet paper with element cover
By-pass (2) (B.P.-2)
Air jet (A.J.)
AtTyperest open limit Valve lift
Fuel FuelManufacturerITypePartpump:No.tank:FuelgradeFueltankcapacityFueltankpositionMaterialIColorGaugepositionLubricationsystem:Autolubepump-
1 mm (0.04 J2400J24-14101-00BV21-161MIKUNIin)416#97.541.22B#42.541.o#10041.040.8$0.741.11and318turnout18mm(0.7in)1,200rlminJ10-24410-02MIKUNIIDF-36(Diaphragm)Anygradegasoline25.5L(5.6Impgal,6.7USgal)FrontofleftrearwheelPolyethyleneIBlackSideoffillercapSeparatedlubricationYAMAHAAutomaticoilinjection system
Element type
Engine idling speed"
GI -AM3
C. Transmission Model
V-belt wear
DifferentialIReductionlimit gear: Secondary reduction system Secondary reduction ratio Differential type
OilItemtank:OilOiltank capacity Oil tank
MaterialIColorposition
Clutch engagement rlrnin Shift
Yamalube Golf Car oil or if not available, any two stroke oil that is B.I.A. certified for service T.C.W. 1.7 L (1.5 Imp qt, 1.8 US qt)
Secondarycodespring:PartNo.Outsidedia.xWire dia.
Top of left rear OnePolyethylene/Whitefenderhole(G0.85)orifice
GI-AM3
V-belt automatic centrifugal engagement 3.1 : 1-0.8: 1 1,500 rlrnin 3,600 42.990501rlmin-32557x3.2rnrn (1.69 x 0.126 in) 7.8 kg10.372 kglrnm 6.5182 rnm (2.95 in) Cr plated (Silver) 54.590501-45600x4.5rnrn (2.15 x 0.177 in) 6.371101 rnrn (3.98 in) Cr plated (Gold)
Forward 50 deglReverse 45 deg 231 mrn (9.09 in) 26 mrn (1.02 in) 31J17-46241-00x925rnrn (1.22 x 36.4 in) 27 rnm (1.06 in)
Primaryrlrninspring:PartsNo.Outsidedia. x Wire dia. Set IoadISpring rate No of turnslfree length Color
Helical gear 2.952 x 4.588 SPUR gear 4 pinion SAE 90 Gear oil1800 crn3 (27 02.)
Oil bath flyweight Screw with locknut 19 krnlh (12 rnph)
V-belt part No.
Jet TYsenser:pePipedia.1Material
-4
plate type with cleaner: Wire 4 6.35 mm (0.25 in)lStainless
Governor:LubricantlcapacityTYpeAdjustmentFactoryspeedsetting -
V-belt width and outer line length
Transmission:IternTYpePrimaryreduction ratio
No. of turnslfree length Color code
Model
Torque cam angle Sheave center to center distance Sheave offset
Axle type trailing arm (Unit swing) Coil springs with hydraulic shock absorbers (double action type) 2.1 kgfmm 240 mm (9.45 in)
ItemFrame:TypeMaterialColorFrontcowl:TypeMaterialColorRearcowl:TypeMaterialColorSeat:Seatcover
Vinyl chloride leather + Nylon lining Ivory
swingarm (independent suspension)
SteeringBumper:FrontRearsystem:TypeSteeringangle (L, HI (R, H)
G1-AM3
ColorMaterial
SteelUrethanewhitefoam+EVAendSteel+EVAendWormandpin1.4turn1.4turn3.0mSAE90Gearoil150cc(5.1oz)Singlewishbone10?5mm(0.394
Seat cushion Material
RearRearaxle:wheel axle type
FrontCasterCamberToe-inTypeaxle:Kingpin inclination
FrontCamberToe-insuspension:TypeSpringrateCoilspringfree length
Oil damper (Single actionftension only)
f 0.197 in) 0 deg 7 deg 3 Semi-floatingdeg split 0 mm (0 in) 0
Coil springs with hydraulic shock absorbers (Single action type) 3.6 185kgfmmmm(7.28 in)
Singledeg
Tubular steel (STKM) Yamaha Black
-
Damper type
D. Chassis
RearTypesuspension:SpringrateCoilspringfree length
Damper type
die shell type fiber galss (SMC) Fiber reinforced plastic (FRP) Ivory white
Oil damper (Double actionfBoth Comp & Tens) Model
Turning Lubricantradius CapacityType
Urethane(RIM)lvorywhiteMatchmetal
Ladder type pipe structure
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LeadingITrailing shoes (self-adjusting)
- 11Flywheel-
= Cranking speed approximately 800 rlmin
Primary winding resistance 1.0a + 15% at 20'~(68" F) (Orange - Black)
9 mm (0.35 in)/300 rlmin. 11 mm (0.43 in)/3.000 rlmin
Mechanical brake linkage to individual drum brakes on each rear wheel with self-adjusting brake shoe. Dual internal expanding shoe
18 x 8.50 - 8.0014 ply rating 0.8 kg/cm2 (12 psi)
magneto (C.D.I. type)
350a + 10% at 20' (68'~) (Brown - Black) Output (Min.) 40V AC @ Cranking speed*
Pulser coil resistance (Color code)
Brakes:ItemBrakeMethodsystemofoperationLiningthicknessStdIMin.Brakedruminsidedia.Linkageadjustment(Brake wire free play)
Secondary winding resistance 5.9ka ? 15 % at 20"~(68' F)
Parking brake TypeRelease timing (Free play of throttle wire end)
WheelTire: type Front (pattern) Rear Tire size FrontRear
Foot type; Parking brake with automatic release 0 - 0.5 mm (0 - 0.02 in)
Tubeless (Rib)
Charging coil resistance (Color code)
Lightly depress the accelerator pedal with your hand (The parking brake is not released.)
ModelIManufacturer
160 mm (6.30 in)
Tubeless (Block)
F3T35671lM ITSUBISHI
Ignition timimg Static B.T.D.C. 1.3 mm (0.051 in) by dial indicator
GI -AM3
18 x 8.50 - 8.0014 ply rating
Tire pressure FrontIRear Rim size FrontIRear
4 mm (0.157 in)/1.5 mm (0.06 in)
E. Electrical Model
4.5V14~+10%at20~~(68~~)(WhiteIRed-Black)AC@Crankingspeed*
0.1 - 0.5 mm (0.004 - 0.020 in)
7.00 - I - 8.00
Diode (Yes or No)(High tension code - Black) No
GI-AM3
Noise supGessor 5kQ 2 15% at 20"~(68" F)
OQQQOO
Spark SparkThreadTypeplug:&QuantitySparkpluggapsizeplugcap:TYpeNoisesuppressor resistance C.D.I.
For U.S.A. and Canada I For Australia and JapanI Group 24 I N-50lFURUKAWA 12V-48 AH I 12V-50 AH 1.26 1I 1.26 - 1 15kg - I 4,500 cc I 6-314x10-114x9in 1 252~225xl65mm
Starter generator GSBI 07-02lHITACH I 0.614V-15A15,OOOkw rlmin 0.01 3Q * 20% at 20"~(68" F) (A1 - A2)
Model
NGK BP-6HS x 1 pc 0.6 - 0.7 rnrn (0.024 - 0.028 in) M14x P1.25
= Cranking speed approximately 800 rlmin
Tillil T107-23lHITACHtype I 14.8 + 0.5V
5Q + 10% at 20"~(68°F) (Red - Green) 0.006Q ? 20% at 20" C (68" F) (F1 - F2) J10-81111-1023rnrn(0.9in)/16 rnrn (0.63 in) 700 - 900 g (24.7 - 31.7 oz)/4 pcs. 41 + 0.1 rnrn (1.61 + 0.004 in) 0.7 rnrn (0.028 in)/41 pcs
YZ18 (J17-81950-00)/ASAHI DENS0 60ALess than 8V 11.8Q + 5% at 20"~(68"
ChargingMinimumModelIManufacturerunit:C.D.I.outputStartingISystern:TYpeModelIManufacturerStartingoutputChargingoutputArmaturecoilresistanceFieldcoilresistanceShuntcoil(Batterycharging)Seriescoil(Starting)BrushportnumberBurshlengthStdIMin.Springpressure/QrtyCommutatoroutsidedia.MicaundercutINo.ofslotVoltageregulator:TypeModel/ManufacturerRegulatedvoltage(Noload)VoltageregulatorCoregapYokegapPointgapVoltagecoilresistanceSoleniodrelay:
0.6 - 1.0 rnrn (0.0024 -- 0.04 in) 0.9 rnrn (0.035 in) 0.35 - 0.45 rnrn (0.014 - 0.01 8 in) 10.3!2 * 20% at 20°C (68°F)
F)II
Battery:Amperage(P/No.)/ManufacturerratingCutinvoltageWindingresistanceModelIManufacturerCapacity(Ratingminimum)SpecificgravityGrossweightElectrolytequantityDimension(WxHxT)Terminaldescription
F8T 02171/MITSUBISHI 4.OV @ Cranking speed*
- 12 -
Back
At your requirement 50160 Hz, 410 VA 6 - 12V 20A, 18 - 24V 10A 5% of AH ContinuousratingbeepS-121NIKKO600
Batterytern charger:
A.C. Input (House hold use) D.C. Out put Battery charge rating
10Al1pc plus one spare 10A/l pc plus one spare
G 1-AM3 l
PlusFuse:TYbuzzer:peModelIManufacturerFrequencyCurrentfuse:ArnperagelQ'tyMinumfuse:Amperage/Q1ty
2 100 Hz. Less than 0.08A
Use LoctiteB Use steadyTighteningLoctiteBUseloctitea
Cylinder head: FinalFirst
Part name
Secondary sheave x Input shaft
Tie rod x Ball joint
Thread size
Back plate ass'y x Rear axle housing
Cylinder x Exhaust pipe ring nut Carburetor x Joint
Transmission case 1 x Transmission case 2
Flywheel CrankcasemagnetoxEngine bracket
Front lower arm x Frame
Part to be tightened
Differential case x Ring gear Governor fork x Governor shaft
Traction motor terminal x Wire Relay terminal x Wire
PanClampPanBoltheadNutBolt&headPanheadBoltNutBoltPanhead
[Crankcase righrening sequence]
Transmission case x Rear arm Transmission case x Rear arm housing
Back lower support x Hinge
[Chassis]Tension rod x Front lower arm
[Engine]Spark
-
Pitman arm x Idler arm
Remarks
Tension rod x Frame
King pin x Steering knuckle
Rear arm comp. x Frame
CastleBolt nut
PanNutBoltBoltBoltheadBoltBoltBoltBoltNutNylonnutNylonnutBoltNutNutBoltNutNylonnutNutNut
Oil pump ass'y x Gear unit ass'y Fan x CDI magneto
10-3. TIGHTENING TORQUE
Crankcase left x Right
[Drive]Primary sheave cap x Engine
Steering gear housing x Steering cover
Steering adjusting bolt x Nut Wheel x Hub or drum
[Electrical]Batteryhold down x Battery
Airshroud cylinder 1 x 2
Airshroudplugx Cylinder head crankcase
L (liter) L mmHgkg/cm2kg/mm(liter) 519 (OF) - 32 1 Centigrade (OC)
(Nut) ("It) Nm 1 m-kg I ft-lb
INCH TO METRIC SYSTEM Multiplier Known ft-lbNmNIb 1 33.3 pa 0.03937 inHg Result 0.8802 L (liter) 1.057 Multiplier 0.10197 0.13826 0.10197 0.4535 Imp qt v Result mekgkg Imp oz 28.35 129.57 Centigrade ('c) 915 roc) t32 Fahrenheit (OF) ( Imp gal US psikIb/inUSImpgalqtqtN/mmPapainHg 4.545 3.785 1.136 3.785 0.10197 0.0178 0.0102 0.0703 0.0075 25.4 Fahrenheit (OF)
METRIC TO INCH SYSTEM
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
Generalspecificationstorque
Known L (liter)
-1
CONVERSION TABLES 9.807 Nrn 7.233 ft-Ib
I
GENERAL TORQUE SPECIFICATIONS
